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A 25?5 km long and 28 in. diameter underground pipeline used for transporting wet sour Arab Light
grade crude oil failed after 3 years of service. The pipeline was operated at 40% of permissible flow
velocity and capacity and protected under a corrosion inhibitor programme. The failure occurred
due to corrosion of the lower surface of the pipeline resulting in pinholes within a period of one month.
Eight corrosion damaged areas were detected over the entire length of the pipeline. Ultrasonic nondestructive inspection and close potential surveys were conducted on the failed pipeline. Various
sections of the corrosion products were metallurgically evaluated using scanning electron
microscopy coupled with energy dispersive X-ray spectroscopy. The corrosion product was
identified using photometric and potentiometric analysis combined with X-ray diffraction. Crude oil
and water samples obtained from the pipeline were also analysed. The material of the pipeline was
identified as AISI grade C1018. Ultrasound testing revealed localised pitting at failed locations, while
close potential surveys ruled out external corrosion. Experimental results indicated that the failure
was caused by extensive microbiologically induced corrosion at the internal surface of the pipeline.
Sulphate reducing bacteria present in the crude oil, along with below standard flow velocity of the
latter, is thought to be responsible for the observed microbiologically induced corrosion.
Replacement with a 20 in. diameter pipeline was suggested as a permanent solution to the
corrosion problem, whereas a number of short-term measures were also recommended.
Keywords: MIC, SRB, Corrosion, Pipeline, Sour, Crude
Introduction
Crude oil pipelines form a wide transportation network
that transfers the crude oil from one facility to another for
treatment. Damage induced by pipeline corrosion disrupts
the transport process, adds to direct cost and can also
result in unfavourable events, such as fires and explosions
that disturb the environments ecology. For these reasons,
it is essential to prevent, identify and remedy corrosion
related failures of transmission crude oil pipelines.
Microbiologically induced corrosion (MIC) refers
to corrosion caused by biological organisms. Micro
biologically induced corrosion can occur in any aqueous
environment and is a common problem in oil and gas
industry facilities due to the omnipresent nature of
microbes and corrosive by-products in the pipelines. The
sulphate reducing bacteria (SRB) present in the crude oil
form a specialised group of microbes that use sulphate as
the electron acceptor for their respiration and generate H2S
as a terminal product.1 The ubiquity of these bacteria leads
to a variety of imposing industrial, economic and
ecological effects due to their ability to generate large
4Fe?4Fe2z z8e{
8H2 O?8Hz z8OH{
8Hz z8e{ ?8Hads
Bacterial consumption
Corrosion products
2{
z4H2 O
SO2{
4 z8H?S
2
2z
Fe zS {?FeS
Overall reaction
3Fe(OH)2 zFeSz2OH{
568
4FezSO2{
4 z4H2 O?
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FezS2{ ?FeSz2e{
The presence of micro-organisms on a metal surface
often leads to highly localised changes in the concentration of the electrolyte constituents, pH and oxygen
concentration and can result in localised corrosion,
depending on the passive film formation and repairing
capabilities of the underlying alloy.2935 Sulphate
reducing bacteria are very important micro-organisms
from environmental and industrial standpoints. The
anaerobic corrosion of metals is enhanced by the
activities of SRB and is a universal industrial problem
where aqueous process fluids contact equipment.
Corrosion of steel by SRB has been known for many
years, and various mechanisms have been postulated.
The ratio of corroded Fe/iron sulphide is found to vary
from 0?1 : 1 to almost 50 : 1.36 The anaerobic corrosion
of Fe due to SRB is characterised by a coating on the
metal surface consisting of black compounds containing corrosion products. The nature of this black
corrosion product appears to be most important in
determining the corrosion mechanism.37
In the present study, the crude oil pipeline was
designed for 322 thousand barrels per day (Tbpd)
with a flow velocity of 1?58 m s1. In practice, the
pipeline was operated at a low flow velocity of 0?54
0?69 m s1, which is below the minimum velocity
required as per its design specifications for production
rate ranges between 110 to 140 Tbpd, which is
approximately 3545% of the expected production
rate. The pipeline had been monitored under corrosion inhibitor programme using Cortron AR505. The
chemical composition of the corrosion inhibitor is
listed in Table 1. The injection rate of corrosion
inhibitor used for crude oil at the leading end of the
pipeline was set during the start-up of the facility at
5% water cut and 21 ppm by volume treatment rate.
The required injection rate since the plant start-up
varied between 19?7 and 29?6 L/day, based on a crude
production rate of 100150 Tbpd. Actual consumption rate during service varied from 7?2 to 30. This
paper states the pipeline history and inspection
outlines, identifies the cause of failure and provides
Experimental
Close interval potential survey, instrument scraping and
manual ultrasonic scan were applied to the failed
pipeline to investigate the possible causes of the
pipelines corrosion damaged area. Various chemical
analyses were undertaken for the sour crude and its
formation water. Corrosion products were washed with
toluene at ambient temperature and then petroleum
ether to remove the adhered crude oil. The samples were
dried at room temperature under nitrogen gas at
atmospheric pressure. For cross-section analysis, a
sample was polished with Cooper Nicholson round
handle needle file 5 K9. A scanning electron microscope
(model JEOL JSM-6490LA) attached with an energy
dispersive X-ray spectrometer (model JEOL EX-54165
JMU) was used to metallurgically evaluate various
sections of failed pipeline for corrosion products.
Imaging was performed in secondary electron imaging
mode at an accelerating voltage of 20 kV.
A portion of the dried sample was ground to a powder
and analysed by X-ray diffraction (XRD) to determine
its chemical composition. The identification of the
crystalline phases was achieved using X-Pert
HighScore Plus programme. The semiquantification of
XRD data was done using the Rietveld method. A
further dried portion was digested in HCl. On the acid
digest portion, a photometric technique was used to
determine the sulphate content. Further portions of the
Amount, wt-%
110
110
110
110
110
110
110
,1
,1
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2 (a, b) Backscattered electron SEM image showing the morphology of the outer surface of the corrosion deposit formed
at the inner surface of the pipeline. (c) Corresponding EDX spectrum showing predominance of iron and sulfur within
the corrosion product
Microstructural characterisation
Typical morphology of the outer surface of the corrosion
deposit scraped from the internal surface of the failed
pipeline is shown at low magnifications in Fig. 2a and b.
The energy dispersive spectroscopy (EDS) spectrum
(Fig. 2c) obtained from this corrosion product showed
a predominant presence of Fe and S. The same location is
shown at a slightly higher magnification in Fig. 3a and b
570
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3 (a, b) Backscatter electron SEM image of the outer surface layer of the corrosion deposit showing iron sulde crystal
inside a cavity. (c) Corresponding EDX spectrum obtained from the crystal showing high Fe and S concentration
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4 (a) Backscattered SEM image of the outer surface of the deposit showing spherical morphology of iron sulde. (b)
Corresponding EDS spectrum obtained from the region shown in (a)
572
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5 (a, b) Backscattered SEM image of the outer surface of the deposit showing aky structure. (c) EDS spectrum
obtained from the akes show relatively high O peak along with predominant Fe and S
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6 Backscattered and X-ray mapping images for C, O, Fe and S taken from cross-section of corrosion deposit: inner surface shows enrichment in Fe and S
574
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7 (a) Backscattered SEM image of the inner surface of corrosion deposit illustrating the morphology of pyrite aggregate.
(b) EDS spectrum obtained from pyrite aggregate in Fig. 7a
.60
4160
Total
0
0
0
16
53
69
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Parameter
Hydrogen sulphide
(H2S), ppm
BS&W*, %
Sulphate reducing
bacteria, colonies cc21
Start of
pipeline
End of
pipeline
2982
1606
16.1
100
2.2
2.56103
576
sample
Parameter
Result
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of
Compound
Amount, wt-%
Greigite (Fe3S4)
Mackinawite (FeS)
Pyrrhotite (Fe7S8)
Pyrite (FeS2)
Magnetite (Fe3O4)
Lepidocrocite [FeO(OH)]
44
15
7
2
28
4
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Al-Jaroudi et al.
(a)
(b)
9 a X-ray diffraction pattern obtained from corrosion product of pipeline and b standard XRD patterns of identied compounds in corrosion product
Mode of failure
The morphology and phase constitution of corrosion
products as determined by XRD and SEM respectively
clearly showed the evidence for MIC within the failed
pipeline. The MIC was responsible for severe corrosion
inside the pipeline resulting in pinhole damage. The
cause of MIC is the presence of the SRB microorganisms. The presence of iron oxide in the form of
high oxidation state of Fe [Fe3O4 and FeO(OH)] and
high corrosivity of the water associated with crude oil
indicates chemical corrosion, where the source may be
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Cause of failure
Conclusion
Acknowledgements
The authors wish to acknowledge the support of Saudi
Aramco, Saudi Arabia. The second author appreciates
the support extended by the Center of Research
Excellence in Corrosion, Research Institute, King
Fahd University of Petroleum and Minerals.
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