SPE 155232

Failure Analysis of An Onshore Pipeline in Petroleum Industry – A Case

Study
Maushumi Kakoti Talukdar, Abhay Kujur, S. Bhat & S.K. Sahota
Institute of Engineering & Ocean Technology
Oil and Natural Gas Corporation Ltd.
Panvel, Navi Mumbai-410221

Copyright 2012, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Oil and Gas India Conference and Exhibition held in Mumbai, India, 28–30 March 2012.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
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ABSTRACT
The premature failure of an onshore underground well fluid line led to a fatal fire incident. Though there
is no reduction in overall thickness localized internal corrosion were noticed at both 6 O’ clock and 12
O’ clock position. In some localized area near the weld there is heavy metal loss leading to formation of
holes at 6 O’ clock position
Results of various laboratory investigations confirm that the corrosion and premature failure of pipeline
sample was caused by localised corrosion attack. The calculation of flow regime confirms that the flow
is stratified and software analysis shows that deposition of water is throughout the whole length of the
pipeline thereby creating an ideal condition for deposition and growth of bacteria colony. Two different
corrosion mechanisms namely microbial induced corrosion and localized corrosion of chloride have
acted together and resulted in the severe attack at 6 O’ clock position. With MIC being the most
pronounced. The condensed water and acid gases have caused localized corrosion often called top line
corrosion at 12 O’ clock position. Therefore the flow condition, presence of high concentration of
chloride and bacterial activity has acted in synergy to cause this failure of the pipeline.
2 SPE 155232

INTRODUCTION:
A multiphase underground well fluid pipeline in India’s Southern onshore field was commissioned in
1997. Owned by Oil and Natural Gas Corporation Ltd. (ONGC) the 4 inch diameter, API 5L Gr A PSL-
1, 2.135 Km pipeline suffered 35 leakages after 2006. The partial pressure of carbon dioxide in the
flowing gas was 0.085 psi . In 2009 the line failed leading to a fatal fire accident. Though there is no
reduction in overall thickness, localized internal corrosion was noticed at both 6 O’ clock and 12 O’
clock positions of the pipeline. In some localized areas near the weld there is heavy metal loss leading to
formation of holes at 6 O’ clock position (Photograph-1&2). Around 60% thickness reduction was
observed near the holes.

Photograph 1&2: External and internal surface of the failed pipeline.

LABORATORY INVESTIGATIONS:

Laboratory investigations were carried out to identify the cause of premature failure. The details of the
studies are presented in this paper.
PIPELINE MATERIAL INTEGRITY STUDIES:
Elemental composition analysis of the pipeline specimen by spark spectroscopy showed that it complies
with API5L Gr.A PSL1 specifications. The microstructure was observed under an inverted metallurgical
microscope and found to have small colonies of pearlite in ferrite matrix typical of API 5 LX-A Gd
material. The Vickers hardness (HV) was 128 HV3. The yield strength, ultimate tensile strength and
percentage elongation of the pipe material were determined as per ASTM A370 and within the specified
parameters of API5L.X-Gd A (PSL-1) Carbon Steel. Thus the material met the specifications.
CORROSION PRODUCT ANALYSIS:
The scales on the internal surface of the pipeline and corrosion product scrapped out from the corroded
portion of the pipeline were analysed for their composition using chemical methods as well as Electron
Diffraction Spectra (EDS) analysis. It was found that scales are rich in carbonate and the corrosion
SPE 155232 3

product is mainly iron oxide with considerable amount of iron sulphide (Videla hector A. et al 2002) and
chloride.
PRODUCED WATER ANALYSIS:
The produced water sample collected from the pipeline was chemically analysed. Table 1 shows the
results.
Table 1: Results of Produced Water Analysis
Component Quantity
pH 6.5
Carbonate mg/ l Nil
Bicarbonate mg/ l 610
Sodium Chloride mg/ l 91,688
Calcium mg/ l 1880
Magnesium mg/ l 508

The results show that the chloride content is of very high order which favors pitting corrosion.
Though the calcium and magnesium are of high order thereby forming protective layer on the pipe
surface, but presence of high chloride concentration in the produced water, CO2 salting out effect is
predominant hence protective FeCO3 scale formation is not favored. High water cut has aggravated the
corrosion process.
MORPHOLOGY OF THE PITS:

The deep corrosion pit that perforated

the pipe wall thickness showed a
sloped wall typical of corrosion by
sulfate reducing bacteria (SRB). The
large pits have formed through
coalescence of small pits as shown in
Photograph-3

Photograph -3 Localised attack leading to formation of holes

a sloped wall as observed on the internal surface.
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Polished and etched transverse section when observed under inverted metallurgical microscope reveals
the propagation of corrosion into the
metal matrix (Photograph 4).

Scanning Electron Micoscope (SEM)

Photograph-4 Transverse section, 200X propagation of
corrosion into the metal matrix.
scanning on the corrosion pit reveals
sloped wall pit portion showing pits
typical of Microbial Induced Corrosion
(MIC) attack (Photograph- 5). Closely
spaced fatigue striations typical of
corrosion fatigue were also observed
(Photograph-6).

Photograph 5: SEM micrograph of as Photograph- 6: Closely spaced striations

received sample from sloped wall pit portion indicative of corrosion fatigue.
showing pits typical of MIC attack.

CORROSION RATE:
Corrosion rate studies were done with metal coupons fabricated from the failed pipe. These coupons
were wet ground to a surface finish of 400 grit and degreased with benzene, washed with distilled water,
acetone and dried in a vacuum dessicator. The surface area and weight of the coupon were measured.
The produced water was purged with carbon dioxide (CO2 )gas to remove the dissolved oxygen, if any.
Subsequently, coupon was exposed to simulated pipeline conditions in a high pressure high temperature
PARR Instruments Co. autoclave in continuous water wet conditions. Water sample collected from the
source point of the pipeline were used in the simulated pipeline operating conditions for immersion test
as per ASTM G31 -2004 guidelines. After the test, coupons were cleaned with water, rubbed against
filter paper and successively cleaned with Clark solution, water and acetone and dried in a vacuum
dessicator and weighed to determine the weight loss. From the observed weight loss, area of exposure
SPE 155232 5

and density of pipeline steel, the corrosion rates were calculated. Table 2 gives the result of corrosion
rate study.
Table 2: Corrosion rate in simulated test:

No. Test Particulars

1 Pipeline Coupon API5L.X-Gd A

2 Corrodent Produced Water

3 Line Pressure (Psi) 28.4

4 CO2 mole% 0.3

5 Partial pressure CO2 (psi) 0.085

6 Temperature (oC) 40

7 Uniform Corrosion rate 0.35 mm/yr

DISCUSSION:

Corrosion severity depends on partial pressure of CO2, H2S, water content and presence of chloride ions
in service condition. Among the various parameters, the acid gases like carbon dioxide and hydrogen
sulphide play a very important role with respect to their effect on corrosion severity on material of
construction. Table 3 classifies the severity of CO2 corrosion as per API rule of thumb

Table 3: CO2 corrosion severity:

CO2 partial pressure (psi) Severity Grade
<7 Non corrosive
7 to 15 Indicate corrosion
15 to 30 Severe corrosion
> 30 Very severe corrosion

Based on the partial pressure of CO2 alone (0.085 psi), the severity of the pipeline in the failed pipeline
would be considered non corrosive.

The produced water, however, has a very high quantity of sodium chloride which is of the
order of 91,688 ppm. Because of this high chloride content CO2 salting out effect is predominant hence
protective iron carbonate (FeCO3) scale formation is not favored. Moreover because of high water cut
(64%) this effect will be more pronounced.
6 SPE 155232

SIMPIG software was used to understand the flow of liquid inside and the water accumulation in
the pipeline. The flow was found to be segregated/ stratified resulting in water separation and there is
accumulation of water throughout the length of the pipeline.

Fig 1:Software output showing the accumulation of Fig 2:Software output showing the flow
water in the pipeline regime

RISK ASSESSMENT:
Based on the information gathered, the likelihood of the occurrence of MIC is evaluated for each contributing
factors in terms of a flow chart as depicted in Fig. 3 (Sooknah R. etal 2007). A ranking is made of the
susceptibility or extent of the potential for MIC to occur under the operating conditions. The ranking is from F =
0 (no susceptibility) to F = 10 (highest susceptibility or greatest potential for occurrence of MIC).
The chart reveals that for the failed line most of the parameter comes in the range F=10 indicated by the yellow
coloured boxes. Therefore the line is most susceptible to MIC.
SPE 155232 7

CONCLUSIONS AND RECOMMENDATIONS:

Results from various studies confirm that the corrosion and premature failure of pipeline at 6O’clock
was caused by localised corrosion attack and the condensed water and acid gases have caused localized
corrosion often called top line corrosion at 12 O’ clock position. At 6 O’ clock two different corrosion
mechanisms namely microbial induced corrosion and localized corrosion of chloride have acted together
(Scott P.J.B. et al 2007) and resulted in the severe attack and failure of the pipeline. However, the role of
bacteria appears to be the most pronounced. As the flow is stratified and there is deposition of water
throughout the whole length of the pipeline, well fluid is almost stagnant at places of low topography
creating a site ideal for the growth of microbes. Presence of significant amount of sulphide in the
corrosion product confirms the presence of SRB as there is no H2S in the flowing gas. Though presence
8 SPE 155232

of high concentration of carbonates of calcium and magnesium favours the formation of protective scale,
passivity breakdown and localised corrosion of carbon steel strongly depends on the presence of
aggressive anions like chloride. Therefore the flow condition, presence of very high concentration of
chloride and bacterial activity has acted in synergy to cause this failure of the pipeline.
It is always recommended to have periodic pigging of oil & gas pipelines to knock out hold up water or
deposits and corrosion products. In such scenario, it is economical to combine the pigging frequency
with that of the batch inhibitor treatment
It is recommended to give inhibitor dosing in batches as follows
1st batch treatment:
200 liters as neat inhibitor or as 1: 1 mix with crude oil.
2nd batch treatment, after 2 weeks:
20 liters neat inhibitor or as as 1: 1 mix with crude oil.
3rd batch treatment, after 1 month:
20 liters neat inhibitor or as as 1: 1 mix with crude oil.
4th batch treatment, after 3 months:
20 liters neat inhibitor or as as 1: 1 mix with crude oil.
To continue the batch treatment every 3 months with 20 liters neat inhibitor or as as 1: 1 mix with crude
oil.
SRB test should be carried out at both dispatch and receipt end once in a month. If found to be present it
is recommended to give biocide dosing. . To start with it is suggested to treat with Amine based biocide.
The Aldehyde based and Amine based biocides are to be used alternatively to prevent the development
of resistance by microbes.
ACKNOWLEDGEMENT:
The authors thankfully acknowledge Sh J.T. Mahavar Executive Director and Head of the Institute of
Engineering and Ocean Technology, ONGC for providing the opportunity and facilities to carry out
failure investigation and for granting permission to publish this article.
REFERENCES:
1. Videla Hector A, Swords Carolyn L. ,Edyvean Robert G.J., 2002. Corrosion Product and Biofilm
Interactions in the SRB Influenced Corrosion of Steel.. Paper no. 02557. Corrosion. NACE
International .
2. Scott P.J.B, Al- Hashem A. and Carew J. 2007, Experiments on MIC of Steel and FRP Downhole
Tubulars in West Kuwait Brines, paper no. 07113 NACE International Corrosion Conference and
expo
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3 Sooknah Reeta, Papavinasam Sankara, Revie R.winston and Romero Matilde De, 2007, Modelling
the Occurrence Of Microbiologically Influenced Corrosion, Paper No. 07515 Nace Corrosion
Conference.