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Microbiologically Influenced Corrosion (MIC) is a major concern in process industries, particularly in the Oil and Gas sector. It is estimated that 25-30% of corrosion related failures in pipelines and industrial equipment can be attributed to MIC. The cost of metallic corrosion has been estimated to range between 2-3% of the gross domestic product (GDP) in developed countries and MIC certainly accounts for a significant fraction of the total cost of corrosion amounting to billions of dollars due to unexpected shutdowns, equipment replacement, mitigation strategies, etc.
Microbiologically Influenced Corrosion (MIC) is a major concern in process industries, particularly in the Oil and Gas sector. MIC has been linked to numerous corrosion failures and it is estimated that 25-30% of corrosion related failures in pipelines and industrial equipment can be attributed to MIC, costing billions of dollars.Close examination of extensive sessile bacteria data, water chemistry and the corrosion damage morphologies observed on corresponding corrosion coupons in different oil field waters (brackish, recycled, produced, effluent) over a period of some 10 years, indicated that there was a distinct relationship between the bacteria type, water chemistry and the corrosion damage pattern. The water analysis data indicated that waters with different TDS levels, influences the species of viable bacteria that existed. Very high TDS waters (such as effluent waters) are not viable for SRB (sulfate reducing bacteria) but are viable for GAnB (general anaerobic bacteria) and anaerobic APB (acid producing bacteria). A mixed consortia of SRB/GAB/GAnB can co-exist in lower TDS waters (such as brackish waters). The localized corrosion damage morphology is dependent on the bacteria species that is present. It may be possible to develop a pictorial guideline for identifying MIC on the basis corrosion damage morphology as an aid to developing biocide treatments and the forensic analysis of corrosion failures .
Oil and gas wells represent a large capital investment. It is imperative that corrosion of well casings be controlled to prevent loss of oil and gas, environmental damage, and personnel hazards, and in order to ensure economical depletion of oil and gas reserve. Wells placed in external corrosive environment shall be protected by appropriate barriers such as additional cemented casing, cathodic protection and coating to assure well casing integrity.
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A holiday is defined as a pinhole or discontinuity in a coating lining. These discontinuities are frequently very small and not readily visible and create a pathway for oxygen and an electrolyte to cause deterioration of the underlying substrate. These defects will tend to reduce the life expectancy of a coating in service, particularly if the service is to include immersion, such as the lining of a tank or a pipe.
Corrosion is a ubiquitous phenomenon, which can have massive impacts on the functioning of industrial assets. The threat of corrosion is exacerbated in situations where regular corrosion inspections are difficult. The Virtual Corrosion Engineer (VCE) Project within Shell is intended to offer a solution to this problem by automatically assessing the corrosion rates and threat levels in assets due to a variety of corrosion mechanisms. The VCE system has been deployed in an asset progressively since 2019.