Eni spa Engineering & Feasibility studies

Abu Rudeis

Technical Note for 14” and 7” Pipelines

00 MACO MACO MACO 05/04/2023

REV REASON FOR ISSUE PREPARED VERIFIED APPROVED DATE

This document is property of Eni spa

It shall neither be shown to Third Parties nor used for purposes other than those for which it has been sent.
 Eni spa – Engineering & Feasibility studies Pagina 2 di 11

INDICE

1. INTRODUCTION .................................................................................. 3
1.1 ABBREVIATION ............................................................................................... 3

2. CLAD 14” PIPELINE ............................................................................. 4

2.1 CORROSION THREATS RELATED TO HYDRAULIC PRESSURE TESTS ................. 4
2.2 CORROSION THREAT: MICROORGANISMS ...................................................... 4
2.3 CORROSION THREAT: OXYGEN ....................................................................... 5
2.4 SUGGESTED GOOD PRACTICES ....................................................................... 5
2.5 MICROBIOLOGICAL ASSESSMENT AND MONITORING ..................................... 6
2.6 CORROSION INHIBITOR INJECTION............................................................... 6
2.7 BASELINE ....................................................................................................... 7
2.8 PIGGING ACTIVITY ......................................................................................... 7

3. TUBING 7” PIPELINE GRE LINED ........................................................ 8

3.1 CORROSION THREATS RELATED TO HYDRAULIC PRESSURE TEST ................... 8
3.2 CORROSION THREAT: MICROORGANISMS ...................................................... 8
3.3 CORROSION THREAT: OXYGEN ....................................................................... 9
3.4 SUGGESTED GOOD PRACTICES ....................................................................... 9
3.5 MICROBIOLOGICAL ASSESSMENT AND MONITORING ................................... 10
3.6 CORROSION INHIBITOR INJECTION............................................................. 10
3.7 BASELINE ..................................................................................................... 11
 Eni spa – Engineering & Feasibility studies Pagina 3 di 11

1. INTRODUCTION
Two new pipelines will soon start conveying multiphase fluids from Abu Rudeis field.
The pipelines are respectively:
 a 14” 625-cladded pipe;
 a 7” carbon steel pipe GRE lined, made of production tubing.
To preserve the future integrity of the pipelines and ancillaries, best practices and some recommendations
are following reported for application during construction and commissioning phases.
The present technical note extensively focuses on best practices and treatment that have to be applied during
and after hydraulic pressure test.

1.1 ABBREVIATION

CI Corrosion Inhibitor
HYD Hydraulic pressure test
IDMS Inspection Data Management System
MIC Microbiologically Influenced Corrosion
OS Oxygen Scavenger
UT Ultrasound Testing
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2. CLAD 14” PIPELINE

Seawater is the liquid source selected for use in HYD operations.

2.1 CORROSION THREATS RELATED TO HYDRAULIC PRESSURE TESTS

Water quality is a major factor to be considered for hydrostatic tests. It is well known and documented that
corrosion and cracking problems result from improper water quality.
Microbiologically Influenced Corrosion (MIC) represents a common corrosion threat ascribable to the poor
quality of the selected source of water.
Although more resistant to MIC than carbon steel, also clad 625 pipes may be affected by pitting in presence
of microorganisms and stagnant conditions.
Therefore, to avoid future pipeline’s failures, MIC threat shall be addressed at a very early stage, i.e., before
start-up.
Oxygen is not usually a relevant direct cause of corrosion in clad 625 pipe; however, its presence combined
with certain microorganisms can cause the formation of mineral scales potentially causing localized attacks,
due to changing in corrosion potentials.

2.2 CORROSION THREAT: MICROORGANISMS

Seawater contains several microorganisms belonging to the Domains of Archaea and Bacteria. Some of them
are responsible for MIC.
Although not exhaustive, the Table below shows some microbial groups involved in MIC:

Due to the high microbial diversity hosted, the use of raw seawater for HYD exposes the pipeline to the risk
of MIC.
The sequence of the events leading to the risk of MIC can be summarized as follows:
 raw seawater introduced into the pipeline for the hydraulic test brings with it several planktonic
microbial cells;
 during the few hours (4-8 hrs) of hydrotesting the formation of the biofilm is unlikely; however, in
the post-HYD period the pipeline is at risk of biofilm formation. In fact, microorganisms under
stagnant conditions attach to the metal surface, forming the so called “biofilm”;
 if raw, or not properly treated, seawater is used, the development of a mature biofilm is rapid, taking
approximately a week; for filtered seawater it takes approximately a month;
 Eni spa – Engineering & Feasibility studies Pagina 5 di 11

 this means that if seawater is left inside the pipeline, under stagnant conditions, a mature biofilm
establishes in less than one month leading very likely to MIC;
 a mature biofilm growing on the internal surface of the pipeline represents the precondition for the
occurrence of MIC;
 MIC typically manifests in the production phase when the presence of produced water provides
additional nutrients to microorganisms and accelerates their activity. Very often, indeed, several
failures occur suddenly and simultaneously.
NOTE: Once established biofilms are hardly completely removed, therefore, preventing it is the primary suggested
option.

2.3 CORROSION THREAT: OXYGEN

O2 dissolved in seawater reacts, to some extent, with carbon steel items, if any, causing a certain amount of
corrosion and it is also consumed by the metabolism of aerobic microorganisms.
Unlike microorganisms that continue to grow over time, O2 once completely consumed, and not replaced, it
is no longer a corrosion problem.
To remove oxygen from the source water is a good practice to avoid any corrosion process. At this scope, an
Oxygen Scavenger (OS) is added to the water used for the hydrotest of the pipeline.

2.4 SUGGESTED GOOD PRACTICES

Since a not adequate HYD may cause MIC failures, the application of all available good practices is always
highly recommended, regardless the high or low susceptibility of the selected construction material to MIC.
Before HYD:
 collect seawater for HYD from the so called “safe zone”, i.e., about 15m below sea surface and 15m
above seabed, thus minimizing the concentration of microorganisms, solids, and dissolved oxygen.
In case of water depth less than 30m, it is to be preferred to collect seawater closer to the surface
and as far as possible from the seabed;
 filter seawater to a minimum specification of 50 microns (μm);
 treat filtered seawater with chemicals. Typically, chemicals blends, composed of biocide, oxygen
scavenger, corrosion inhibitor, and a dye are available for this purpose;
 the biocide is essential, the OS is recommended for the above reasons;
 corrosion inhibitors and dye are also usually added. A filming CI is usually applied;
 the application dosage of OS is standardized, so it is easily defined;
 bisulphites-based compounds are typically added to scavenge oxygen. The most usual dosage ratio
is from 8 to 10 ppm of OS to remove 1 ppm of oxygen;
 the type(s) of biocide and its(their) concentration (ppm) shall be carefully evaluated:
 Biocide type: it is recommended the selection of a commercial product combining both fast-
reacting and long-persistent ingredients;
 Biocide concentration: it must be defined based on the duration of post-hydrotest wet parking.
NOTE: some active ingredients of the most common types of biocides are not compatible with bisulphites-based oxygen
scavenger. In the event the two chemicals react with each other, the biocidal effect may be insufficient for microbial
 Eni spa – Engineering & Feasibility studies Pagina 6 di 11

killing. Unless a combo chemical is used, in order to avoid insufficient microbial control, different treatment options
may be applied, depending on the available equipment and tools, i.e.:
 add OS first, allow it enough time to react, and then add the biocide.
 if the reaction time is insufficient, the dose of the biocide shall be increased to compensate for
the loss of effectiveness.
After HYD
 drain the seawater used for the hydraulic test from the pipeline. Drainage must be complete to
remove even water pockets1 in which microorganisms can remain undisturbed;
NOTE: to reduce the likelihood of corrosion occurrence, it is suggested to carry out hydrotest immediately before
commissioning, avoiding wet parking.
If seawater is not displaced after HYD, and the post-hydrotest lasts more than expected MIC may become a
serious threat.

2.5 MICROBIOLOGICAL ASSESSMENT AND MONITORING

When the pipeline turns in operation the microbiological monitoring of fluids (water) or, if present, corrosion
coupon (surface swab) is highly recommended to assess the need of additional biocide treatments.
Microbial monitoring must be carried out by means of proper methodologies.
Following, the three methodologies selected by Eni for MIC assessment are reported and briefly described:

 ATP for assessing microbial activity. The measurements must be carried out in the field in accordance
with Eni Std 28937E00;
 qPCR to quantify total amount of microorganisms, both bacteria and archaea;
 NGS to identify the microorganisms’ genera and species and verify if MIC communities are present.
The combination of the three methodologies is aimed to provide the baseline for assessing the contamination
condition. Once baseline has been clarified, the analytical protocol for follow-up monitoring is defined, based
on the severity of the MIC threat.
qPCR and NGS are quite sensitive analysis requiring skilled technicians to be carried out.

2.6 CORROSION INHIBITOR INJECTION

After the commissioning of the pipeline, it is highly recommended to start injection of corrosion inhibitor
only if carbon steel items will be installed (e.g., Riser).
The Service Company shall be consulted to specify the corrosion inhibitor which eventually will be lab tested
as part of the SoW by Eni HQs.
It is important to start the injection with a clean, uncorroded surface to get a good protective layer.
If corrosion inhibitor is injected, routine analysis of residual corrosion inhibitor shall be performed to monitor
the residual at the end of the pipeline.

1
The project confirmed that drying will not be performed. Additionally, since production will start immediately after
HYD, preservation is not necessary.
 Eni spa – Engineering & Feasibility studies Pagina 7 di 11

2.7 BASELINE

It is suggested to perform UT measurements in accessible locations of the pipeline made in carbon steel (i.e.,
non cladded items). The readings shall be recorded in the IDMS and compared to future measurements in
order to assess the corrosion rate being experienced.
The UT measurements should be performed before the start-up, or not later than the first month since the
production is commenced.
It is also recommended to analyse the production water against iron count (Fe+); the iron ions analysis shall
be routinely carried out on weekly basis with the aim to detect anomalies and increase of corrosion in the
carbon steel facilities upstream of the cladded pipeline.
It is also recommended to perform an ILI baseline inspection prior to pipeline start up but not later than
specified in Eni Std 20415.ENG.INT.PRG.

2.8 PIGGING ACTIVITY

After de-watering and gauging, bi-directional pigs, with or without brushes, shall be used. Pigging Service
Company may propose alternative pigs with evidence of suitability with CRA material.
Metal brush pigs shall generally not be used as iron inclusions can initiate pitting corrosion on the CRA
pipelines by disrupting the passive layer on the CRA material.
In order to limit the risk of MIC during normal operations, it’s recommended to run cleaning pigs on monthly
basis unless a MIC study being carried out by Eni HQs will return a low risk of MIC.
As per design the line will not be piggable for a while, it’s therefore recommended to install pigging facilities
not later than 8÷10 months after start-up.
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3. TUBING 7” PIPELINE GRE LINED

Seawater is the liquid source selected for use in HYD operations. The project confirmed that seawater after
HYD will be displaced and routed to the Petreco onshore plant.

The following sections are aimed to limit the corrosion threats to the carbon steel items and plant facilities;
GRE is considered immune to MIC, Oxygen and CO2 corrosion.

3.1 CORROSION THREATS RELATED TO HYDRAULIC PRESSURE TEST

Water quality is a major factor to be considered for carbon steel item (i.e., riser) during hydrostatic tests as
well as for the onshore plant carbon steel facilities.
Most relevant corrosion threats for hydrotested carbon steel pipelines are oxygen corrosion and
Microbiologically Influenced Corrosion (MIC).
Oxygen and microorganisms are, indeed, contaminants of the seawater used as a source of water for the
pressure test.
Oxygen can be easily controlled by the treatment of water with Oxygen Scavenger (OS); otherwise, to control
microorganisms’ activity could be challenging.
For this reason, MIC threat shall be addressed at a very early stage with a preventative approach.

3.2 CORROSION THREAT: MICROORGANISMS

Seawater, as all water sources coming from a natural environment, contains several microorganisms,
belonging to the Domains of Archaea and Bacteria. Some of them are responsible for MIC.
Although not exhaustive, the Table below shows some microbial groups involved in MIC:

Due to the presence and high diversity of microorganisms hosted, the use of raw seawater for HYD exposes
the carbon steel sections to the risk of MIC.
The sequence of the events leading to the risk of MIC can be summarized as follows:
 raw seawater introduced into the pipeline for the hydraulic test brings with it several planktonic
microbial cells;
 during the few hours (4-8 hrs) of hydrotesting the formation of the biofilm is unlikely; however, in
the post-HYD period the pipeline is at risk of biofilm formation. In fact, microorganisms under
stagnant conditions attach to the metal surface, forming the so called “biofilm”;
 Eni spa – Engineering & Feasibility studies Pagina 9 di 11

 if raw, or not properly treated, seawater is used the development of a mature biofilm is rapid, taking
approximately a week; for filtered seawater it takes approximately a month;
 this means that if seawater is left inside the pipeline, under stagnant conditions, a mature biofilm
establishes in less than one month leading very likely to MIC;
 a mature biofilm stratified on the internal surface of pipeline represents the precondition for MIC
occurrence;
 MIC typically manifests in the production phase when the presence of produced water provides
additional nutrients to microorganisms and accelerates their activity. Very often, indeed, several
failures occur suddenly and simultaneously.
NOTE: Once established biofilms are hardly completely removed, therefore, preventing it is the primary suggested
option.

3.3 CORROSION THREAT: OXYGEN

O2 dissolved in seawater reacts, to some extent, with metal causing a certain amount of corrosion and it is
also consumed by the metabolism of aerobic microorganisms.
Unlike microorganisms that continue to grow over time, O2 once completely consumed, and not replaced, it
is no longer a corrosion problem.
To remove oxygen from the source water is a good practice to avoid any corrosion process. At this scope, an
Oxygen Scavenger (OS) is added to the water used for the hydrotest of the pipeline.

3.4 SUGGESTED GOOD PRACTICES

Since a not adequate HYD may cause MIC failures, the application of all available good practices is always highly
recommended, especially for carbon steel pipelines.
Before HYD:
 collect seawater for HYD from the so called “safe zone”, i.e., about 15m below sea surface and 15m
above seabed, thus minimizing the concentration of microorganisms, solids, and dissolved oxygen.
In case of water depth less than 30m, it is to be preferred to collect seawater closer to the surface
and as far as possible from the seabed;
 filter seawater to a minimum specification of 50 microns (μm);
 treat filtered seawater with chemicals. Typically, chemicals blends, composed of biocide, oxygen
scavenger, corrosion inhibitor, and a dye are available for this purpose;
 the biocide is essential, the OS is recommended for the above reasons;
 corrosion inhibitors and dye are also usually added. A filming CI is usually applied;
 the application dosage of OS is standardized, so it is easily defined;
 bisulphites-based compounds are typically added to scavenge oxygen. The most usual dosage ratio
is from 8 to 10 ppm of OS to remove 1 ppm of oxygen;
 the type(s) of biocide and its(their) concentration (ppm) shall be carefully evaluated:
 Biocide type: it is recommended the selection of a commercial product combining both fast-
reacting and long-persistent ingredients;
 Biocide concentration: it must be defined based on the duration of post-hydrotest wet parking.
 Eni spa – Engineering & Feasibility studies Pagina 10 di 11

NOTE: some active ingredients of the most common types of biocides are not compatible with bisulphites-
based oxygen scavenger. In case of the two chemicals react with each other, the biocidal effect may be
insufficient for microbial killing. Unless a combo chemical is used, in order to avoid insufficient microbial
control, different treatment options may be applied, depending on the available equipment and tools, i.e.:
 add OS first, allow it enough time to react, and then add the biocide.
 if the reaction time is insufficient, the dose of the biocide shall be increased to compensate for
the loss of effectiveness.
After HYD
 drain the seawater used for the hydraulic test from the pipeline. Drainage must be complete to
remove even water pockets in which microorganisms can remain undisturbed;
 dry thoroughly the pipeline, to remove water accumulated in the low points (water pockets)
 put the pipe under preservation until commissioning, e.g., using high quality nitrogen.
NOTE: to reduce the likelihood of corrosion occurrence, it is suggested to carry out hydrotest immediately
before commissioning, avoiding wet parking.
If seawater is not displaced after HYD, and the post-hydrotest lasts more than expected MIC may become a
serious threat.

3.5 MICROBIOLOGICAL ASSESSMENT AND MONITORING

When the pipeline turns in operation the microbiological monitoring of fluids (water) or, if present, corrosion
coupon (surface swab) is highly recommended to assess the need of additional biocide treatments.
Microbial monitoring must be carried out by means of proper methodologies.
Following, the three methodologies selected by Eni for MIC assessment are reported and briefly described:
 ATP for assessing microbial activity. The measurements must be carried out in the field in accordance
with Eni Std 28937E00;
 qPCR to quantify total amount of microorganisms, both bacteria and archaea;
 NGS to identify the microorganisms’ genera and species and verify if MIC communities are present.
The combination of the three methodologies is aimed to provide the baseline for assessing the contamination
condition. Once baseline has been clarified, the analytical protocol for follow-up monitoring is defined, based
on the severity of the MIC threat.
qPCR and NGS are quite sensitive analysis requiring skilled technicians to be carried out.

3.6 CORROSION INHIBITOR INJECTION

After the commissioning of the pipeline, it is highly recommended to start injection of corrosion inhibitor to
protect any carbon steel section of the pipeline.
The Service Company shall be consulted to specify the corrosion inhibitor which eventually will be lab tested
as part of the SoW by Eni HQs.
It is important to start the injection with a clean, uncorroded surface to get a good protective layer.
 Eni spa – Engineering & Feasibility studies Pagina 11 di 11

3.7 BASELINE

It is suggested to perform UT measurements in accessible locations of the pipeline made in carbon steel. The
readings shall be recorded in the IDMS and compared to future measurements in order to assess the
corrosion rate being experienced.
The UT measurements before the start-up or not later than the first month since the production is
commenced.
It is also recommended to analyse the production water against iron count (Fe+); the iron ions analysis shall
be routinely carried out on weekly basis with the aim to detect anomalies and increase of corrosion in the
carbon steel facilities upstream of the GRE lined pipeline.