1
Managing Deep Water Operations
Operational Safety & Asset Integrity
Reliance Industries Ltd
OISD & API 17-18-Nov-14
Prem Verma
2
Safety Contact
33
Brief Introduction of KGD6
Concept, Design & Engineering
Construction & Commissioning
Operational Excellence
HSE, Quality & Compliance
Asset Integrity
Improvement Suggested
Innovation
Contents
4
KGD6
5
Development Facilities - Offshore
CRP
Manifold
Umbilical
Jumper
Pipelines
Wells &
XMT
6
Development Facilities – Onshore
Onshore
Terminal
Slug Catchers
GTG &
Heaters
GDU
MEG
Column
7
Onshore Terminal
Deep Water-
Offshore
Onshore Terminal
Multi support VesselROV
Operational Areas & Support
ROV – Doing Inspection
8
First Oil- 17th Sep’08
First Oil – 17th Sep-2008
First Gas – 1st Apr-2009
Central Control Centre at Onshore Terminal
9
Concept, Design & Engineering
10
Concept & Design – Project Phase
Design and selection of equipment and facilities guided by:
Proven Technology as far as possible
Use of Standard Equipment / Product
Simplicity in Design and Operation
Flexibility for integration of other known and future discoveries
Maximize reliability and availability
Safety in Operations
11
Engineering, Surveys and Studies
Conceptual Engineering and FEED (Aker Kvaerner) – Front end Engineering
& Design
Third party validations as part of FEED
Review of Subsea Pipeline Engineering (Dr. Andrew Palmer)
Review of Flow Assurance work (Scandpower)
Certification and verification works and HAZOP (DNV)
HAZID of Subsea System (DNV)
Review and validation of FEED (Bechtel)
Geotechnical investigations for all subsea structures locations
Geo-hazards Study incl. site specific earthquake study (NGI)
Geo-mechanics Study (Schlumberger) & Validation (Terralog) - Soil Stability
Hydrate Remediation Studies ( Paragon ) – Flow Assurance
Chemical selection and compatibility studies - IFE
Integrated Reliability, Availability & Maintainability (RAM) Analysis performed
by DNV (including subsea, pipelines, CRP & OT)
100 years of metrological data considered for the design
12
Construction & Commissioning
13
24X7 Excellent Management support & Integrated Team
Utility system commissioning at early stage proved to be
very useful
Timely support from Other Sites, Engineering, Vendors &
Consultants
Audit recommendations implemented before first gas
N2/ He Test & Bolt Tensioning – helped in better integrity of
pipelines
Excellent documentation on startup
Flawless Start Up – Key Points
Design and construction with proper safeguards
14
Audits during construction & commissioning:
DNV audits
Shell Global Solutions
Ward Associates
Aker Solutions Australia (ASA)
Internal Audits
Audit Management – Construction & Commissioning
Audit Status- Construction & Commissioning
External Audits
Audit
Shell 2008
Shell 2009
Ward 2008
Ward 2009
ASA
Internal Audits done by GMS, Becrel, Process Integrity Team
15
Operational Excellence
16
Operational Excellence
99.9 % uptime in operations
100% Safe Operation
100% Quality gas exported
100 % Statutory Compliance
Zero Security Incidents
16Benchmarking operations in Deep water field.
17
Processes /Systems in place
HSE MS / HEMP in place
SAP in place since start up of the plant
PM module in place & effective monitoring in progress
All documents uploaded in REIMS (1,00,000 approx)
All IT enabled systems in place
Laboratory : LIMS implemented
Business process- Technical Capitalization jobs completed
LMS is implemented
Abbreviations:-
HEMP- Hazards & Effects Management Process. HSE – Health Safety & Environment .
SAP- System Application & Products . PM-Plant Maintenance .
LIMS- Laboratory Information Management System . LMS- learning Management System
REIMS- Reliance Enterprise Information Management System
KGD6 Operations – Processes /systems
Effective use of processes and systems
18
Integrated Operation – Intelligent Field
From Deep Water Operations to Customers in Integrated manner along with RGTIL & Gas
Marketing
Coordinated interaction by O&M team on 24X7 basis with Subsurface, CS-1, RGTIL & Gas
Marketing
Intelligent Field Operations:
IP21 implemented for the 1st Time in Upstream Operations
Parameters are monitored 24X7- Every second
More than 60000 Tags Monitored
Parameters from Well Bottom Subsea, till delivery to Customers monitored
Well Opening/ Closing, Changing other parameters being Controlled from OT Central
Control Room
Various Processes & Systems used to integrate the data
Intelligent Field Creates Benchmarking in uninterrupted Operations
Seamless Integrated Operations result in Uninterrupted Operations
19
FPSO
FPSO Availability more than 99% from 2009-10
Proactive maintenance with planned shutdown
High Availability of Subsea Systems & Wells
Total 97 parcels offloaded successfully incident free in high seas
All Parcels sold with Nil Bottom Sediment & Water and RVP < 10 psi
Uninterrupted Operation of FPSO during cyclone “Thane” and “Neelam”
Produced water discharge into sea with Avg. Oil < 24 PPM against 40 PPM
Dhirubhai 1 is the leading FPSO in availability in the world
20
HSE and Quality
21
Health, Safety & Environment
100% Safe Operation. LTI Free operation of 2053 days at OT &CRP, 2029 days at FPSO
No Loss to Personnel & Property
HSE Management System adopted – Shell Global Solution
Environment : Over 2,00,000 saplings planted
IMS ISO 9001, 14001, OHSAS 18001 from April 2010 by M/s DNV, Recertified on Mar 2013
Pre & Post project environmental monitoring- Onshore by NEERI & Offshore by NIO
More than 20000 Mandays of HSE Training after First gas
HSE audit by Internal, External & regulatory authorities from time to time (GMS, M/s Marsh,
M/s Ace, M/s DNV, M/s SGS , M/s BP , OISD, Factory Inspector & APPCB)
One Reliance Best Practices are under implementation
Robust HSE Management System
22
Samples are analysed in inhouse Laboratory
Laboratory with all facilities inside the plant area is an added advantage
LIMS is used for sharing analysis report instantaneously
Corrective measures taken based on reports
Quality System
23
Asset Integrity
24
Integrity management is a complete life cycle process and needs to be
considered throughout all phases from concept to decommissioning
Decommissioning
Concept & Design
Operations &
Audits
Life Cycle
management
Asset Integrity Life cycle
Inspection,
Maintenance and
Review (IMR)
Change /
Repair
Construction ,
Commissioning &
Audits
25
Asset Integrity Management – Operations
OT SubseaCRP
Asset
Register
IM Process
Compliance
Resources
OrganogramCapability
AssuranceMSV / ROV
Softwares &
Tools
( Visual Works)
Internal/
External
Audits
Execution
Lessons
Learned
Processes,
Systems &
Doc. Control
Risk Register
& Risk
Assessment
FPSO
Management through SAP
26
O&M team much prior to commissioning (almost 2
years)
Participation in FAT & SAT, Handholding with Experts,
AKER, AGR etc.
OTS- Operator Training System to Panel Engineers
before first gas
PSS- Production simulator System - on & off-line, open
loop simulator
LMS – Learning Management System in place for
competency improvement
+500 SOP’s & SMP’s prepared prior to commissioning
+60% Employees received Behavioral training
Competency development for Contractor Employees
Number of Programmes
Before First Gas – 178 Nos
After First gas - 1826 Nos
Capability Building
Enhanced, Capable, Futuristic, Inspired & Motivated Personnel
0
5000
10000
15000
20000
25000
Before First gas After First gas
Training Imparted-Mandays
27
Resources – Sub sea team
CEO RIL E&P
Head
KGD6 Operations
Offshore Head
Subsea Maintenance Head
Lead Integrity
Engineer
Integrity Engineer
D1D3 Field
Integrity Engineer
MA Field
Integrity Support
Engineer
D1D3 Field
Specialist available to Lead
Integrity Engineer as requiredØ Subsea Controls
Ø Document Control
Ø Naval Architecture and Vessel
Motions
Ø Riser Specialists
Ø FEA Analyst
Ø Corrosion Specialist
Ø Offshore Inspection Support
Integrity Support
Engineer MA field
Lead Structural
Engineer
RIL Integrity Management Organization starts at top
level management and includes all levels of
management and support engineering as well as
additional call off support as required
One of the best teams in sub sea deep water industry
28
29
30
RIL has a full time MSV with ROV in the field to implement IM plan and
perform any remedial activities
ROV- Water Depth 3000 M
- Work Class 150HP ROV
MSV Crane- 91T @2500M
- With AHC
Resources– MSV & ROV
31
At KGD6, innovative approach takes AIM beyond routine inspection,
maintenance and repair.
100% uptime of subsea assets is maintained.
AIM program has helped KGD6 team to continue meeting one of the most
challenging life cycle management goals.
Subsea Inspections & Interventions
Si. No Activity Total
1 General inspections of subsea structures 80
2 SCM interventions 20
3 Subsea valve operations 70
4 Subsea pipelines inspection 70
5 Subsea installation, pre commissioning and
commissioning
40
Very sophisticated operation
32
Monitoring Programme
Key Performance Indicators
Sand/Erosion events
Corrosion events (RPCM)
Chemical Injection reconciliation
Fluid sampling (Laboratory testing) and trending
BOD compliance ( P&T, fluid composition,
chemical injection quality)
Testing
XMTs (system critical parameters, Valves, Guages
etc.,)
SSSV test
Top Side Facilities (CRP)
Regular Inspection / Audits
Maintenance of Riser
SSIV partial stroke testsFe Count trend
analysis
CI residual
measurements
Monitoring Programme
33
Digital Field from Well to Market
IM team reviewing day to day intervention and operational actions that may
have an impact on system integrity
Real time process surveillance using DCS, IP21 to give 24X7 access to
instrumentation and valve movements
Daily review all parameters, flow, pressure, pressure, sand, erosion
Surveillance
34
A key component of an effective IM program is inspection data management
Visual Works is a modular suite of applications to record, archive, review and
report digital video inspection data
Visual Works integrates with inspection packages to allow real time event
logging.
Data can be accessed from desktop PC’s
Resources Software & Tools- Visual works
ROV data management softwares found to be more very useful.
35
To Manage Permanent / Temporary
change in:
Plant
Equipment
Process or
Chemicals
Plant performance Improvement
Minor Modifications
Process control
Alarms Review
Trip settings
Changes updated in
P & ID’s
Isometrics
Alarms and Trips Set point Register
Master Line List
Control Narrative
Cause & Effect Matrix
Proposer - Proposal Initiation
Plant Manager – Justifications &
Recommendations
Head Instrumentation –
Review & Recommendations
Head Electrical – Review &
Recommendations
Head Mechanical – Review &
Recommendations
Team Formation for
Process Study & PHA
Team – Process Design Checks
Team – Process Hazard Analysis
Team – HAZOP Close-out &
Process Scheme Finalization
Plant HOD – Change Required?
YES
Proposal DroppedNO
Head CTS – Review &
Recommendations
HSEF HOD – Review &
Recommendations
ETS HOD – Approve?
Head O&M – Approve?
Site President – Approve?
Proposal Cleared for Execution
YES
YES
YES
NO
NO
NO
Management Commitment to comply Critical Processes
Management of Change ( MOC )
36
Scheduling, Monitoring & Review
KPIs are set at individual and department wise and periodical review of the same
Department KPIs are reviewed half-yearly by Site Head
Monthly Inter-Departmental & Department Review Meeting
Fortnight production schedule finalization – by VC with all stakeholders
Daily Operations & Maintenance review meetings and PTW meeting
Monthly Safety Committee meeting & Monthly Process Safety Meeting
Capturing the incidents/Near miss data through SHIEMS, conduct PSSR before restart
ReSOP system for improvement during maintenance/other non-routine field
KPI’s enhance the planning & monitoring process
37
KPI
Achievement
(Actual x
%Wt. / 100)
1Statutory Compliance - Safety Critical
Element Inspection
As
reported100% 2 100% 2.00
As per monthly reports Operations and
Integritty
2 Close out of Audit observations % 100% 2 100% 2.00No outstanding Audit finding, all finding
closed out in a timely manner
3 HSE Awareness - Competency % 100% 2 100% 2.00
Awareness of Safety Critical SOP's,
Emergency Response Plans, Permit to
Work. Sign off sheet for SS Panel and
Discipline Engineers.
4 Employee PME compliance
100% of
All
Subsea
Personn
el
20 2 100% 2.00no. o f personnel to complete PM E on time
divided by to tal personnel x 100
5 Risk Assessments for managing risk % 10 / year 2 100% 2.00Risk Assessments are done for managing
risk. No set numbers. But approximately
6SHEIMS Reporting and Closure including
Near misses%
<60 to
close out3 100% 3.00
All SHEIM S reports to be closed out in a
timely mannner.
7 HSE Observation for Subsea team No. 24 2 24 Nos 2.00SS team only to put in Stop Cards. Each SS
= 4.17%
8 Monthly Safety Meetings No. 12 2 12 Nos 2.001 Safety meeting per month - 3 per quarter =
25%. Each meeting = 8.33%
9 LTI Hrs 0 2 0 Hrs 2.00 0 = 25% per quarter
10 Production Loss / Asset Damage incident No. <4 2 0 2.00 <4 = 25% per quarter
11 ERP Mock Drill - Level 1 No. 6 2 5 1.67 1 Drill = 16.67%
12Internal Audits / Safety Walk at Operations
BaseNo. 6 2 6 2.00 1 Safety walk = 16.67%
14 Roxar WGFM re-calibration % 100 1 100% 1.00Call-o ff Issued 25%
M ob and resolving issues 75%
Report Issue 100%
15 Quarterly review of Alarm and trip settings No. 4 1 100% 1.001. Generation of four alarm and trip settings
review documents - 4*25%.
16 SCSSV Testing as per schedule % 12 2 100% 2.00M onthly Operations progress report. Each
report = 8.33%
17 Annual review of Operation's SOP's No's 28 1 1 0.9326 SOPs reviewed. Review of each SOP
each 2.5% * 40.
19 MEG Optimization/MEG Utilization % 10% 2 10% 2.00Annual Review of M EG Optimization (%
Reduction compared to previous year / m3
of water production)
20Reports on Flow Analysis by perfoming
Transient Simulations.No 4 2 4 2.00
Quarter review of :
1) M ultiphase Flow Analysis
2) Single phase Flow Analysis
3) Production Planning
21 Well performance analysis reporting No 16 2 16 2.00
M onthly reports on wells performance of
flowing wells.
Quarterly review/reports on:
1) Proposals for well re-starts, risk & rewards
2) Water studies.
22 Solid Transportation Study % 100% 2 100% 2.00Annual Review of the so lid transportation
study / OLGA modelling/path forward
SUBSEA MAINTENANCE
Actual
Value %
( Full
year)
R emarks
HSEF
Operations
Flow Assurance
U o M Limit No % Wt. Scope
38
46Controlled Copies-Print and get the
signatures done;upload in REIMS.% 100 1 100% 1.00
Document signed 60% REIM S Uploading
100%
47
BOM Items for SAP Codification-Enter all the
missing SAP tags of BOM Items in MMCS
for codification
% 100 1 100% 1.00
Codification Requested / Scope * 100 =80%
Scope - Total non-Sap Code item listed in
BOM submitted so far
48 Spares Management % 100 1 100% 1.00
Guideline set on how Spares are handled
20%, Work flow developed 50%, All
M in/M ax, M RP and Stock location for all
items given to SAP team 100%
49 SCM-RCA Regularization through SAP No.s 25 1 90% 0.90
Collect Aker SAP reports for all 25%;
Creation of job id and trigger o f RCA 50%,
Close out RCA 100%
50Transfer of Subsea Project documentation
not in REIMS into Sharepoint
No. /24
Well
reports
24 1 100% 1.00
Allow approx. 4% for every Well drilling report
and Hand over document x 24 well, plus 4%
on completion
51 Long term preservation of Spare Umbilicals - % 100 1 100% 1.00
Completion of N2 purging 50% Stools and
covers 60% Integrity Assessment report
100%
53 Tooling Anomaly Report closeouts % 100 1 99% 0.99 TAR's closed out/TAR's generated*100=
54 100% redundancy of all operational tooling % 100 1 100% 1.00 OC Inventory+SCM RT M onthly M onitoring
55 To keep to ROV Tools PM schedule % 98 1 95% 0.95M eeting C works PM schedule.
56 Annual Review of SMP's & SOP's No.s/90 90 1 100% 1.00
57 FCM CP rectification % 100 1 100% 1.00RCA Completion-50% and all units delivered
are installed 4 units 100% each
59 PRS Strategy + Engineering Study % 100 2 85% 1.70a) VQC/PR/VQM 15%
b) Scope of work 35%
c) TBE 75%
60 Development of BT Process for Subsea % 75 299% 1.98 Finalise the process 25%
Develop the process 50%
Ihanding over to BT Team 75%
61 TDF Completion % 100 2 98%1.96 1. Approval from BV - 25%
2. M echanical completion - 50%
3. FAT/SIT/Trial Completion - 100%
62 Develop KGD6 Subsea MDR % 100 2 100% 2.00
Aker-10%,Allseas-10%,Technip-
10%,Clampon-5%,Roxar-5%,cormmon-
5%,skoflo-5%,OC-10%,ASI-10%,FPSO-
10%,O&M -10%,M is-10%
63 Vibration Monitor installation % 100 2 40% 0.80
1. Preparation of Intervention procedure -
20%
2. Per Installation - 20% (Total 4 to be done)
Note- If any installation is drop weightage will
automatically divided in 80 %.
64 Making of Hydraulic Hoses on site % 100 1 25% 0.25Identification of equipment 25% SOW 50%
PR generation 100%
65 Completion of one yr storage pilot project % 100 2 100% 2.00N.of too ls sent for yr storage/No.of too ls
identified*100=
66 KHI feasibility study for D1D3 field (Lab Test) % 100 2 100% 2.00Completion by each Vendor 25% x 3,
Evaluation of Lab report by Vendors 25%
67 SCM Repair facility at Aker base % 100 1 75% 0.75Joint FR by ASI and RIL 75%
M anagement/OC Approval 100%
69 Training Complete Training Schedule
No. / 10
session
s
10 2 100% 2.0010 training sessions to be conducted 10%
each (Training Schedule to be developed)
100.0 90.99OVERALL KPI Achievement (%)
Subsea Base
Operations
Aker base
operations
New initiatives /
Innovations
39
Well barriers testing
XMT - Integrity Testing:
SCSSV Testing as per API 14B.
Allowable leak rate as per API 14H for the SCSSV Test is monitored
through pressure build-up.
4 Tests: AMV/AWV/XOV loop, PMV/PWV/XOV loop, PMV inflow, SCSSV
LOT are performed
Subsea Isolation Valves (SSIV)
24-inch Subsea Isolation Valves at CRP (6 off)
Partial Stroke Test every 12 months
Barrier testing is critical for safety of the assets
40
Corrosion Control – Design
Ø Internal Corrosion - Design Strategy
Pipeline Design includes 4-5mm corrosion allowance
Continuous Corrosion Inhibitor injection at all XMT
Criteria - limit corrosion metal loss to 0.1mm/year over life
Manifold Piping – Corrosion Resistant Alloys
Ø External Corrosion - Design Strategy
Coatings and Cathodic Protection
External Corrosion allowance (risers)
Pipeline Corrosion Control design
Risk assessments list pipeline corrosion as major threat
41
Monitoring – Internal Corrosion
Corrosion inhibitor dosing – reconciliation
CI residual monitoring.
RPCM – Provide continuous metal loss recording
Iron Counts - provides average metal loss trending
Corrosion Probes on CRP
Subsea UT testing
Monitoring - External Corrosion
General Visual Inspection
Cathodic Potential Measurement
Modified RIL NORSOK model
Modified NORSOK M 506 model and developed user-friendly
tool in excel environment
Corrosion Control – Monitoring
0.00000
0.10000
0.20000
0.30000
0.40000
0.50000
0.60000
0.0000
0.0200
0.0400
0.0600
0.0800
0.1000
0.1200
0.1400
0.1600
Au
g-0
9
Oct
-09
Dec
-09
Feb
-10
Ap
r-1
0
Jun
-10
Au
g-1
0
Oct
-10
Dec
-10
Feb
-11
Ap
r-1
1
Jun
-11
Au
g-1
1
Oct
-11
Dec
-11
Feb
-12
Ap
r-1
2
Jun
-12
Au
g-1
2
Oct
-12
Dec
-12
Feb
-13
Ap
r-1
3
Jun
-13
Au
g-1
3
Oct
-13
Dec
-13
Feb
-14
Ap
r-1
4
Cu
mu
lati
ve A
vera
ge
Met
al L
oss
(m
m)
Ave
rag
e C
orr
osi
on
Ra
te (
mm
py)
-C
alc
ula
ted
Mo
nth
ly
Metal Loss Based on Fe Count From Slug Catcher 1 and 2
Equiv. WT corrosin rate (mmpy) KPI - Ave. WT Loss Rate (mmpy)
Cumulative Average WT Loss KPI - Cumulative Ave. WT Loss (mm)
Performance measures are:1. Cumulative Average Metal Loss shall be below trend line of 0.1mmpy (shown here as broken red line)2. Monthly Average Corrosion Rate shall be below 0.1mmpy threshold (shown here as broken green line)
GTL 1 DWP to CRP Shut-In
CI injection moved from
GTL 2 DWP to CRP Shut-In
Effective monitoring and control of corrosion enhances the integrity of assets.
42
Erosion Monitoring and Control
Erosion Control - Design
Well completion design – Sand screens
Material selection
Process simulation (PSS) – maintain gas
velocity control
Sand and erosion monitors
Erosion Control - Monitoring
Solids production monitoring
Monthly reporting by instrument vendor
Monthly analysis by Integrity Team
Solids trending across system
Erosion monitoring
Monthly analysis by integrity team
Erosion control essential for good well integrity
43
Typical Findings and Issues
Ø Rigid Flow lines and Pipelines
CP readings good
Minimal Pipeline Free Spanning
Generally self buried without any apparent deviation since
installation.
Ø Umbilicals
Generally buried greater than 0.5D
Some instances of upheaval observed & found stable during
subsequent inspections
Ø XMTs
XMT CP readings good
Coating condition good
Some evidence of external hydrates forming
Good results enhance our confidence in operations
44
Typical Findings and Issues- cont
Ø Manifolds
Coating condition good, CP readings
Good
Debris Items – generally insignificant
No leaks
Ø SDAs
Coating condition good, CP readings
Good
Structure in good condition
Good results enhance the life of field
45
Riser Monitoring
Ø Jacket, Riser, J-tube GVI performed from (-)14m to
seabed
Ø Riser above water UTM program is in place.
Ø Topside piping erosion probe status is monitored.
Ø Topside Piping GVI performed
Performed coating Repairs
Flange protection mitigation is in place.
Ø Splash zone inspection.
Very important for structural safety of platform
46
Shallow water and Onshore pipelines
inspection
Shallow water pipelines GVI and CPFG
survey carried out.
Onshore Pipeline CP Survey performed
every three months and shows adequate
protection along onshore ROW.
UT survey performed on onshore pipelines
above ground piping once in two years.
-1300
-1250
-1200
-1150
-1100
-1050
-1000
-950
-900
Po
ten
tia
l, m
Vo
lts
GTL 1, 2 & 3 Landlines CP measurements - June 2014
P5 (24" GTL 2) TLP A- June 2014 P6 (24" GTL 1) TLP A- June 2014 P7 (24" GTL 3) TLP A- June 2014 P5 (24" GTL 2) TLP B- June 2014
P6 (24" GTL 1) TLP B- June 2014 P7 (24" GTL 3) TLP B- June 2014 Maximum Minimum
Shallow water and onshore pipelines pose high risk of third party damage
47
Audit Management - Operations
Audits during Steady State Operations:
2H offshore audit on Integrity management
Integrated Management System (IMS) by DNV
Offshore asset audit by OISD
Insurance survey audit by ACE & Marsh
Audit Status - Operations
External Audits
Audit
2H Offshore Integrity
IMS audit
OISD
Insurance Audit
3rd party Safety audit
BP Operations Audit ( 3rd party)
Internal Audits done by GMS
48
Improvement Suggested
49
Additional Consideration?
• Equipment Performance Data, Failure Frequency
• System Configurations
Reliability
• Maintenance Resource
• Manpower constraint
• Mobilization Delay
• Spares Constraints
Maintainability
• Equipment Up-time
• System Up-time
Availability
En
han
ced
Pro
du
cti
on
Up
-
tim
e
• Equipment Interchangeability
• Response Time
• Intervention Constraints
Operability
50
Ø Proven Technology to be employed
Ø Standardization
Identical Design for interfaces on IB/OB side, Standard Hot-stab design.
Allow interchangeability.
Ø True Redundancy
Back-up for all critical equipment which effects production
No interdependency between redundant system and ability to use them remotely.
Ø Isolations and Barriers
Double barrier where required ,
e.g. Double barrier for all break-out in production and hydraulic path to facilitate
safe intervention.
Ø Vent Network & Hydrate
Vent Network to facilitate individual well de-pressurization from both side of hydrate
plug.
Facility of chemical injection – HXT Connector / HXT Crown
Improvement Suggested
51
Innovation
52
Innovations
Ø Subsea
Emergency SDA MEG Bypass System developed – To mitigate the risk
SCM Change out in Manifold – Without affecting production
Tool Deployment Frame - Subsea Structure Designed & Mfg. in-house
Two More Patent Application from Subsea Intervention Team
Ø OT
Internal Packing Modification in MEG Reclamation Column- Improved Efficiency
Use of Solid Separation system for MEG sludge processing- Dr Muller Filter
Hopper Arrangement for Air Compressor Molecular sieve filling- Reduced dust Carryover
Optimization of chemical injection in MEG Pretreatment
Addition of Flocculants in MEG Pretreatment – Enhancing Solid Settling
Introduction of Sodium Salt – Divalent salt Precipitation
7 patents and one design application filed from KGD6
53
N
o Uptime %
April 09- Mar 10 99.92
Apr 10- Mar-11 100
Apr-11 -Mar 12 100
Apr-12 -Mar 13 99.93
Apr 13 to Mar
1499.8
Apr 14 to Till
date99.97
RIL- KGD6 D1-D3 Operations
PerformanceS
i
KGD6 - Bench Marking
KGD6 - Bench Marking
Setting a New Benchmark
54
Project Phase:
Ø Best Project Management Award from PMI India -2010
Ø Marico Innovation Award (KGD6 Project) – 2010
Ø Petrotech Award by MOPNG– Best Project Management (Joint Winner ) - 2010
Operations Phase:
Ø BSC 5 Star Award- Occupational Health & Safety System & Sword of Honour-2011
Ø BSC 4 Star Award for Environment Management System -2012
Ø BSC International Safety Award-2012
Ø OISD award :
• Best Platform award for CRP (2010-11)
• Best Rig for DWF (Deep Water Frontier ) (2010-11)
• Best Onshore Processing Plant (2011-12)
• Best FPSO DB-1 (2012-13)
Ø Economic Times –Indian manufacturing Excellence “Super Platinum” Award-2011
Ø Corporate Social Responsibility Company of the year- Asia Oil & Gas Awards 2013 by Oliver Kinross
Ø Ramakrishna Bajaj National Quality Award( RBNQA)- Certification of Merit - 2010
Ø Gold Medal from Red cross society presented by Hon’ble Governor of AP- 5th Consecutive Year in 2013
Ø 4 star rating EHS award in southern region by CII in 2014
Recognition & Awards
Excellence in excellence
55
Any questions?
56 56
Thank You
Thank you
57
Keep wells flowing
Flow-assurance actions to reduce pressure drop in pipeline
Surfactant injection in well B15 under progress in D1/D3 @ 400 Liters/day
Surfactant injection in well B11 under progress in D1/D3 @ 100 Liters/day.
For D26 wells, Well Fluid Samples are sent for analysis to NALCO INDIA to
identify right foaming agent. Draft report rcvd Sept2014 & comments sent.
Await response from NALCO.
12m3 of surfactant at site. Another 46 m3 ETA by Nov end.
Increase in B15
Gas rate
Gas rate increased from 0.78 MMscmd to 0.81 MMscmd
ABP
FTHP
Surfactant Injection rate
Increase in B11
Gas rate
58
Keep wells flowing
Monitoring & optimizing wells 24
x 7 basis & actions to control
water.
Monitoring DWPLEM pressure
and optimizing production by
choke adjustment/Surfactant
optimization/reducing CS 01
pressure. DWPLEM Pressure
51.54 Bara.
MA gas injection into GTL-1 at
DWPLEM. MA gas Injection
rate 0.88 MMscmd.
DWPLEM PRESSURE
CRP PRESSURE
Surfactant Effect
OT Press 34.5 Barg
Slugging stabilised
after MA gas injection
59
Flow in Deep-water Pipeline DWPLEM and CRP – Gravity vs Friction
DWPLEM to CRP loading Curve (∆P Vs Qg).(Qg 8.06 MMScmd DelP 10.0 bar)
Current
Point
Qg 7.3 MMscmd
Del P 10.67 Bar
on 12th Oct 2014
during FPSO
shut down (cyclone HUDHUD)