Optimization of Microbial Control Program & Integrity Augmentation– Transformation of Core Processes in Upstream Industry

Ensuring the integrity of crude oil network is of paramount importance for maintaining operational efficiency and minimizing environmental impact. Control of microbiologically induced corrosion (MIC) is critically essential for energy producers since MIC can progress at aggressive localized rates, leading to unpredictable and premature failures that result in loss of primary containment and disruptions in production. This paper details the MIC optimization program at ADNOC's largest oil- producing field, which ensured the network's integrity and resulted in a substantial OPEX saving of 81%, amounting to over 3 million USD/Year. Microbial induced corrosion control through biocide application is always considered as a safe way to augment the integrity of network. Like many other operators, we deployed a rotational biocide scheme in batch treatments to avoid creating biocide resistant microbial population. This case study presents a comprehensive, analytical approach using extensive field data to evaluate the optimization of required biocide dosage in our crude oil network. Implementation of MIC optimization program was implemented after careful review of below: MIC Damage Mechanism and Control MIC Risk Assessment Results for the crude oil network. Biocide Optimization Strategy. Biocide Optimization Roadmap and Recommendations Through assessment of the crude oil network was performed and bench marked with world leading energy producers. From wellhead to export network, all the crude oil network was divided into categories based on the following parameters: Temperature, Nutrients and H2S. Flow / velocity regime. Bacterial monitoring (cells / ml) Cumulative score, benchmarked with world leading Oil Producers. Based on the calculated bench marking score cards, the whole network was divided in two categories: RiskNetworkNo RiskWellhead pipe network and transfer lines to Stations.Temperature 60 - 100 CHigh salinity >250,000 mg/LH2S >0.2 barSulfates 20- 300 mg/LVelocity >3 m/secBacterial monitoring no more than 100 cells/ml.High RiskCrude Oil Export NetworkTemperature < 60 CLow salinity ∼60,000 mg/LNo H2S.Sulfates 20 - 300 mg/LVelocity 1-2 m/sec.Bacterial monitoring > more than 1000 cells/ml. Based on evaluation, MIC treatment was optimized and stopped for wellhead and transfer lines to station network with immediate effect, resulting in saving of more than 2407 drums / year equal to 2 MMUSD/ Year. Biocide treatment for export network was optimized from 500 ppm to 300 ppm and from batch treatment of 5 hrs to 3 years, which resulted in optimization of 1490 drums equivalent to 1.05 MMUSD/ Year. This novel implementation shows that the integrity of the crude oil network can be effectively maintained with an optimized MIC treatment plan. The bench marking and evaluation criteria presented in this paper can be utilized by other oil and gas producers to effectively manage MIC treatment plan and optimize OPEX significantly. Moving forward, the integration of these optimized treatment plans will serve as a benchmark for future operations, inspiring other producers to adopt similar strategies. This commitment to sustainability and operational excellence ensures that we continue to protect our valuable resources and environment for future generations.