SPE 78572
Microbial Monitoring to Minimise Corrosion and Formation Damage in the Oil Industry
I.Spark and K.Mutch Commercial Microbiology® Ltd
Copyright 2002, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the 10
th
Abu Dhabi International Petroleum
Exhibition and Conference, 13-16 October 2002.
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Abstract
It is accepted that sulphate reducing bacteria (SRB) and
certain general heterotrophic bacteria (GHB) can promote pit
corrosion of topside and downhole equipment and cause
formation damage in the reservoir including H2S souring. In
order to inhibit microbial growth and hence minimise these
damage mechanisms, it is necessary to impose a strict
microbial monitoring regime that can be used to optimise any
biocide treatments. There are two major considerations
relating to microbial monitoring which must be taken into
account which are planktonic microbes (those in suspension)
and sessile microbes (those attached as a biofilm). By
monitoring the numbers of SRB/GHB entering and leaving
each component of the topside process system it is possible to
determine whether each is under good microbial control. If
numbers are found to increase from inlet to outlet, then
biocide treatment at a suitable concentration, can be used to
treat the fouled components before pit corrosion or H2S
production becomes a serious problem within the component.
If the biocide treatment is not performed in time the system
downstream may also become contaminated. By carefully
monitoring each process system including injection water,
firewater, cooling medium, and production systems, it is
possible to extend the process equipment lifetime
considerably, resulting in a major saving in equipment
replacement and lost shut down time. This paper describes the
microbial monitoring techniques required to minimise
corrosion, biopolymer, insoluble metal sulphide and H2S
production both topside and downhole.
Introduction
The action of SRB in causing microbially influenced corrosion
of steal is well documented.1-6 If allowed to go unchecked in
oilfield process systems pit corrosion can result with
subsequent expensive equipment/pipework replacement being
necessary. In addition to SRB corrosion, the growth of GHB
can result in polymer precipitation and acid production which
can further aid the corrosion process and act as a substrate for
sessile biofilm development.7
In seawater injection systems SRB/GHB growth is most
evident within the deaerator towers and downstream into the
injection downhole tubulars. In production systems the
activity of SRB/GHB can occur both downhole in the
reservoir, production tubulars and topside in the separators and
downstream process equipment towards the export oil
pipeline.
Oil and water pipelines can also suffer SRB/GHB related
corrosion particularly in the six o’clock position where
abrasion of the sulphide layer can occur. This results from
particulates (sand, corrosion fragments) dragging along the
bottom of the pipeline exposing fresh metal to SRB pit
corrosion with a pronounced groove being developed.
In order for SRB to grow, sulphate together with a suitable
carbon source, usually volatile fatty acids such as acetate, are
necessary. The source of carbon in seawater injection systems
is normally from bacterial breakdown of algae and
zooplankton (copepods) which is greatest during bloom
periods in the local region. In the North Sea the algal and
copepod bloom occurs twice a year around the end of spring
and again in the autumn, with promoted SRB growth at these
times in response to the elevated carbon in the injection
topside equipment. The source of sulphate is present in the
seawater itself. The source of carbon in production systems is
mainly volatile fatty acids from the crude oil such as formate,
acetate, propionate and butyrate. The sulphate in the
production system originates from either the native formation
brine (connate water) or a mixture of seawater (from injection
seawater break-through ) and formation brine. The higher the
carbon and sulphate concentrations then the more likely a
system will support SRB growth and be more prone to suffer
microbially influenced corrosion.
The temperature of a process system dictates whether
SRB/GHB growth is mesophilic (greatest around 30ºC),
thermophilic (greatest around 60ºC) or hyperthermophilic
(greatest around 90ºC). In seawater injection process systems
the growth is predominately mesophilic, whereas in
production process systems growth can be a combination of
2 [I.Spark a
mesophilic, thermophilic and hyperthermophilic depending on
the temperature gradient throughout the system.
By careful SRB/GHB monitoring of each component of
the process system and chemical analysis of sulphide and
volatile fatty acid (VFA) concentrations of the process water,
optimised biocide treatments can be used to ensure minimal
growth thus lower corrosion, H2S and biopolymer production
rates. This will extend the life of the process equipment
resulting in significant cost savings in equipment replacement.
The major problems associated with SRB/GHB downhole in
the tubulars and reservoir rock formations are H2S, insoluble
metal sulphide precipitation and biopolymer production, the
latter can block pores with a loss in production or injection
rates. The microbial cells can also block pores. Adding
suitable biocides to the injection water can help mitigate
downhole microbial problems.
Microbial Monitoring Techniques
The online fluids are sampled into sterile 30ml plastic
universal tubes, filled to the brim, and sealed prior to
immediate inoculation into the relevant media. Online
samples are taken at the inlet and outlet of each major
component of the injection or production process system
equipment, so that cell numbers going in and out can be
monitored. The online fluid is inoculated into either API
Medium8 which is more suited for Middle East Fields or
Modified Postgate B Medium8 which is more suitable for the
North Sea (Figure 1) to determine planktonic SRB numbers.
The online fluids are also at the same time inoculated into
Phenol Red Dextrose Broth (PRD)8 which is designed for
general aerobic and facultative anaerobic acid-producing
heterotrophic bacteria (GHB)(Figure 2). The inoculated
media are incubated at + or -5ºC of the process system from
which the samples were taken. For the GHB the PRD media
is normally incubated for seven days and for the SRB a period
of 28days. After incubation the SRB and GHB are
enumerated using the triplicate most probable number (MPN)
method.9 It is advisable to repeat the analysis until a
background level of bacteria is determined for the system.
This is because individual sample points can be fouled,
particularly if long dead leg areas occur between the
equipment and sample point, which may yield artificially high
bacterial numbers. If much higher numbers of cells come out
of the system compared to what went in, then the component
is likely to be fouled and should immediately be treated with a
suitable biocide to minimise or prevent corrosion or H2S
production.
To monitor sessile SRB/GHB is more difficult and can
only be determined online from corrosion coupons, bioprobes
or online sidestream monitoring device (Figure 3). The main
problem with using corrosion coupons or bioprobes to
determine sessile SRB/GHB numbers is that they are often
only retrieved at three, six or twelve month intervals. This
long time period between retrievals may result in an active
biofilm being undetected with corrosion having already
occurred before corrective action can be applied. A more
efficient and easier system to use is the online sidestream
nd K.Mutch] SPE 78572
device. This device is non invasive to the system and biostuds
can be removed on a regular basis such as once a week or once
a month depending on the process system and how
microbiologically clean it is (Figure 2). The studs are each
placed in sterile seawater brine containing sand and agitated
for a few seconds to remove each biofilm. The resulting
liquid containing the biofilm cells is inoculated and incubated
as before and numbers enumerated using the triplicate MPN
technique remembering to take into account the dilution factor
of the volume of seawater/sand diluent and area of the coupon
or stud. In the case of corrosion coupons a known area of the
coupon is swabbed using sterile swabs and placed into a
known volume of sterile seawater/sand and agitated. The
liquid containing the biofilm cells is inoculated and incubated
in the same manner as the biostuds.
It is very important to monitor both sessile and planktonic
numbers since it is possible to have very low numbers of
planktonic cells but high numbers of sessile cells and vice
versa. These cell numbers are plotted on graphs versus time
and if numbers of cells start to increase the system has lost
microbial control and thus optimisation of a suitable biocide
treatment can be made immediately before significant
corrosion, formation damage or H2S production has taken
place.
In addition to the microbial monitoring, chemical analysis
of the online fluids should also be performed to quantify the
sulphide and VFA content of the fluids. For the sulphide
measurement a 29ml volume of online fluid should be added
to a 30ml borosilicate glass universal containing 1ml of 20%
Zinc Acetate solution to which 1 Sodium Hydroxide Pellet
should be added. The analysis should be performed using the
methylene blue technique10 and expressed as mg/litre soluble
sulphide. For the VFA analysis 30mls of online fluids should
be placed in a plastic universal and a Sodium Hydroxide pellet
added. Analysis should be carried out using a Dionex fitted
with an ion pack ICE-AS1 column and formate, acetate,
propionate and butyrate concentrations in ppm determined.
Results
The following outlines the data which is gathered from a
typical field in the Northern North Sea area and is summarised
in Table 1.
In the case of the water injection system it can be seen
from Table 1 that mesophilic SRB and GHB numbers increase
from the Deaerator Tower (DA) and downstream to the
Injection header indicating that the system is microbially
fouled and optimisation of the biocide treatment is necessary.
The biostuds taken from the sidestream device also show high
numbers indicating that a sessile biofilm has developed inside
the process system pipework and again should be biocide
treated. The sulphide levels increase downstream of the DA
Tower again confirming SRB activity and the need for biocide
treatment.
In the case of the production system it can be seen from
Table 1 that numbers of m-SRB and GHB increase through
the 1st stage separator indicating that this is microbially fouled.
This has resulted in systems downstream of this having higher
SPE 78572 [Microbial Monitoring to Minimise Corrosion and Formation Damage in the Oil Industry] 3

numbers of cells present when compared to the original fluids
coming up at the wellhead (Table 1). The sulphide levels have
also increased from the 1st stage separator downstream and
VFA concentrations show utilisation of formate and acetate
through the 1st stage separator and downstream of this
equipment. This indicates that the production system, and in
particular the 1st stage separator has lost microbial control and
a suitable optimised biocide treatment regime should be
initiated.
Conclusions
Based on the data gathered together in this study the following
conclusions are made:-
• By monitoring the online fluids which enter and leave
each piece of topside process equipment for planktonic
SRB/GHB it is possible to identify which are fouled by
bacteria and to optimise biocide treatment to prevent
significant corrosion, biopolymer, insoluble metal
sulphide and H2S from occurring.
• Utilising corrosion coupons, bioprobes or sidestream
biostuds, the sessile numbers of SRB/GHB can be
enumerated to determine whether or not a biofilm has
developed and whether biocide treatment is required to
prevent microbial damage mechanisms.
• By careful microbial monitoring the equipment lifetime
can be extended considerably by maintaining good
microbial control throughout the process system avoiding
early equipment replacement due to corrosion and H2S
production.
• By monitoring SRB/GHB numbers, VFA and sulphide
levels in produced water at the riser or production
manifold headers, it is possible to determine whether
downhole or reservoir souring to H2S, corrosion of
production tubulars and isoluble metal sulphide
precipitation have occurred.
• By monitoring SRB/GHB numbers, VFA and sulphide
levels in produced water at the injection header it is
possible to predict whether downhole growth of
SRB/GHB is likely with loss of injection due to corrosion
products, insoluble metal sulphide precipitation, and
biopolymer precipitation blockage of reservoir rock pores.
in the Corrosion of Steel,” Biochemical Biophysical
Research Communications, 221, p 414-421(1996).
3. Beech, I.B. et al.: “Direct Involvement of a Extracellular
Complex Produced by a Marine Sulphate Reducing
Bacterium in the Deterioration of Steel,” Geomicrobiology
Journal, 15, p119-132(1998).
4. Edyvean, R.G.J. et al.:”Microbially Influenced Corrosion-
Has Industry Learnt its Lesson,” Proceedings of Eurocorr
2000, Institute of Materials, ISBN1-86125-127-0.
5. Gubner, R. and Beech, I.B.:”Field and Laboratory Studies
of Marine Biocorrosion of Carbon Steel,” Proceedings of
the 2nd NACE Latin American Congress on Corrosion, 9-
13 Sept, Rio de Janeiro, Brazil, Paper LA 96175(1996).
6. Beech, I.B. et al.:”The Role of Surface Chemistry in SRB-
Influenced Corrosion of Steel,” International Journal of
Marine Biology and Oceanography, OEBALIA 13, p243-
249(1993).
7. Beech, I.B. et al.:”The Effect of Marine Pseudomonas
NCIMB 2021 Biofilm on AISI 316 Stainless Steel,”
Biofouling, 15, p 3-12.
8. “Standard Test Method-Field Monitoring of Bacterial
Growth in Oilfield Systems,” Nace Standard TMO194-94,
Item NO.21224(1994).
9. Harrigan, W.F.and McCance, M.E.:”Laboratory Methods
in Food and Dairy Microbiology,”Pub:Academic
Press(1976).
10.Garbar, N.:”Direct Spectrophotometric determination of
inorganic sulfide in biological materials and in other
complex mixtures,” Analytical Biochemistry, 43, p129-133

Acknowledgments
Thanks to Commercial Microbiology® Ltd for permission to
present this paper.

References

1. Videla, H.A., et al.: “The Role of Iron in SRB-Influenced

Corrosion of Mild Steel,” Corrosion 98, Paper 289, NACE,
Houston, Texas(1998).

2. Pereira, A. et al.: “Characterisation of Representative

Enzymes from a Sulphate-Reducing Bacterium Implicated
4 [I.Spark a nd K.Mutch] SPE 78572

Figure 1- SRB Media. This media is designed to turn a black

colour in the presence of SRB. There are twelve media bottles
per pack grouped in sets of three to undertake triplicate MPN
enumeration of cells.

Figure 3-Sidestream Biostud Monitoring Device. This device

is fitted vertically online to the process equipment with flow
rate being controlled by the two valves either end of the device
which should be 0.1-1 metre/sec or 1.5-15 cubic cms/sec. A
pressure guage measures the system pressure and the device is
rated to 3500 psi. Flow should be from bottom to top so fluid
remains inside if a shut down of the process system occurs.
Twenty four biostuds can be inserted simultaneously.
Figure 2- PRD Media. This phenol red dextrose media is
designed to turn from red (right bottles) to yellow (left bottles)
in the presence of acid producing GHB. There are twelve
media bottles per pack grouped in sets of three to undertake
triplicate MPN enumeration of cells.
 SPE 78572 [Microbial Monitoring to Minimise Corrosion and Formation Damage in the Oil Industry] 5

SAMPLE LOCATION mSRB tSRB mGHB tGHB mAPGHB tAPGHB sulphide VFA
cells per ml cells per ml cells per ml cells per ml cells per ml cells per ml mg / l (formate, acetate,
propionate, butyrate)
ppm
WATER INJECTION SYSTEM
Upstream of Deaerator < 0.3 x 100 N/A 0.6 x 100 N/A < 0.3 x 100 N/A N/A N/A
Tower
Downstream of 3.5 x 100 N/A 1.5 x 101 N/A 0.3 x 100 N/A 0.350 N/A
Deaerator Tower
Injection Header 3.0 x 101 N/A 1.1 x 102 N/A 0.9 x 100 N/A 0.450 N/A

Biostuds 4.5 x 102 N/A 6.5 x 103 N/A 1.5 x 102 N/A 1.50 N/A
cells per cm2 cells per cm2 cells per cm2 µg / cm2
PRODUCTION SYSTEM
Wellhead 1.1 x 101 < 0.3 x 100 2.0 x 102 < 0.3 x 100 1.4 x 101 < 0.3 x 100 0.450 80, 120, 20, <2

Inlet to 1st Stage 1.1 x 101 < 0.3 x 100 2.0 x 102 < 0.3 x 100 1.4 x 101 < 0.3 x 100 0.420 80, 120, 20, <2
Separator
Outlet to 1st Stage 3.0 x 104 1.1 x 101 2.5 x 105 3.5 x 101 2.0 x 102 4.5 x 100 0.995 60, 100, 10, < 2
Separator
Outlet to 2nd Stage 2.5 x 104 < 0.3 x 100 2.5 x 105 < 0.3 x 100 2.0 x 102 < 0.3 x 100 0.652 58, 97, 10, < 2
Separator
Inlet to Hydrocyclones 2.5 x 104 < 0.3 x 100 2.5 x 105 < 0.3 x 100 2.0 x 102 < 0.3 x 100 0.652 50, 85, 5, < 2

Outlet to Hydrocyclones 3.0 x 104 < 0.3 x 100 4.5 x 105 < 0.3 x 100 3.0 x 102 < 0.3 x 100 0.650 50, 85, 5, < 2

Export Oil Pipeline 3.0 x 101 < 0.3 x 100 2.5 x 102 < 0.3 x 100 1.4 x 101 < 0.3 x 100 0.550 80, 120, 20, <2

Corrosion Coupon ex 1st 2.0 x 103 1.5 x 101 4.5 x 104 2.0 x 102 0.7 x 103 < 0.3 x 100 1.35 µg / N/A
Stage Separator cm2
Corrosion Coupon ex 2nd 0.3 x 101 < 0.3 x 100 0.7 x 102 < 0.3 x 100 < 0.3 x 100 < 0.3 x 100 0.30 µg / N/A
Stage separator cm2

Table 1