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)