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OISD Work shop 4 – 5th Dec ’17, New Delhi. 1
KGD6 Deepwater
Asset Integrity Management
Surya Prakasa Rao. K
Siva Sankara Rao. B Reliance Industries Limited
OISD Work shop 4 – 5th Dec ’17, New Delhi. 2
DISCLAIMER
Any statement, opinion, prediction, comment, or observation made in this presentation/publication are those of the presenter/author only and in no condition should be construed necessarily representing the policy and intent of Reliance Industries Ltd. (RIL).
The information presented herein are of the presenter/author’s own and in no way RIL attracts any liability for any inconsistency or irregularity in terms of the accuracy completeness, veracity, or truth of the content of the presentation/publication. In addition, RIL shall not be liable for any copyright infringement and misrepresentation for the presented content as the content is presumed in good faith to be a creation of presenter’s/author’s own mind.
The scope of this presentation/publication is strictly for knowledge sharing purposes and not necessarily to provide any advice or recommendation to the audience/readers. Any endorsement, recommendation, suggestion, or advice made by the presenter/author shall be in his personal capacity and not in professional capacity as an employee of RIL. Any person acting on such endorsement, recommendation, suggestion, or advice will himself/herself be responsible for any injury/damage
OISD Work shop 4 – 5th Dec ’17, New Delhi. 3
Safety Contact–Non RIL Incident
OISD Work shop 4 – 5th Dec ’17, New Delhi. 4
KGD6 Deepwater
Asset Integrity Management
Safety Contact
Description of KGD6
Resources and Operational Excellence
Integrity Management Plan
Internal Corrosion Monitoring and Direct Assessment
External Corrosion Monitoring
CRP Risers and Jacket Inspection
Recognitions and Awards
OISD Work shop 4 – 5th Dec ’17, New Delhi. 5
Introduction to KGD6
• Oil production commenced on September 17, 2008; Flawless Deepwater Oil Field
Development in less than 2 years from Discovery.
• Gas production commenced on 1st April 2009; one of the Fastest Deepwater Gas Field
Development – Less than 6 years from First Discovery
OISD Work shop 4 – 5th Dec ’17, New Delhi. 6
Drilling and Completion of Development Wells
Subsea XMTs & Long offsets up to a water depth of 1200m
6 Subsea Manifolds (With a provision of 6 wells)
Deepwater Pipe Line End Manifold (DW PLEM) at 588m
8”/10” flow lines from Wells to Manifolds
16”/18” Deepwater infield pipelines from Manifolds to DWPLEM
2 x 24” Gas trunk lines from DW PLEM to CRP
Control & Riser Platform (CRP) at 100m
3 x 24” Export pipelines from CRP to OT
3 x 6” MEG lines from OT to UDH for hydrate inhibition
Subsea Control System & Umbilical's
Block Valve Station (BVS) at Land Fall Point (LFP)
Development Facilities - Offshore
OISD Work shop 4 – 5th Dec ’17, New Delhi. 7
Control Centre
OISD Work shop 4 – 5th Dec ’17, New Delhi. 8
Onshore Terminal
First Gas on April 2009
OISD Work shop 4 – 5th Dec ’17, New Delhi. 9
Resources – Specialized team
CEO RIL E&P
Head
KGD6 Operations
Offshore Head
Subsea Maintenance Head
Sr. Lead Integrity
Engineer
Lead Inttegrity
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
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 deep water industry
OISD Work shop 4 – 5th Dec ’17, New Delhi. 10
Intelligent Field
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 Processess & Systems used to integrate the data
Intelligent Field Creates Benchmarking in uninterrupted Operations
Intelligent Field – RIL KGD6
OISD Work shop 4 – 5th Dec ’17, New Delhi. 11
Operational Excellence
Towards Excellence in Excellence
99.96% Uptime
100% Safe
100% Quality Gas
“0” Security incident
OISD Work shop 4 – 5th Dec ’17, New Delhi. 12
Resources MSV & ROV
RIL has a full time MSV with two work class ROV’s in the field to implement
IM plan and perform any remedial activities
OISD Work shop 4 – 5th Dec ’17, New Delhi. 13
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 useful.
OISD Work shop 4 – 5th Dec ’17, New Delhi. 14
Asset Integrity Management
Vision: Perform the integrity management by implementation of industry best
practices in all opportunities
Objective: Comply with all relevant statutory and regulatory requirements. Detect
possible system degradation at a sufficiently early stage to allow remedial actions
OISD Work shop 4 – 5th Dec ’17, New Delhi. 15
Integrity Management Process
OISD Work shop 4 – 5th Dec ’17, New Delhi. 16
IMP – Integrity Management Plan
Risk based “IMP - Integrity Management plan”
Followed DNV RP F116 “Integrity Management of Subsea Marine Pipeline
Systems”`
Subsea network is divided into 149 Assets and Eight threat groups
IM Cycle : Baseline survey and Second cycle were completed. Third cycle in
progress
External corrosion monitoring through GVI (General Visual Inspection), CPFG
( Cathodic Protection Field Gradient) for Subsea pipelines.
Internal corrosion monitoring through In house NORSOK M506 by taking
inputs from flowing fluid rates, compositions and monitoring of RPCMs,
Corrosion coupons, Probes and Lab Analysis
OISD Work shop 4 – 5th Dec ’17, New Delhi. 17
IMP - Compliance to OISD/API/DNV
Standards/Codes followed
All activities are complied, as per PNG rules 2008: Ex: Petroleum and natural gas rules 2008 - Safety in offshore operations
OISD-STD-138 Inspection of cross country pipelines Onshore
OISD-STD-139 Inspection of Pipelines Offshore
OISD-STD-188 Corrosion monitoring of Onshore & Offshore pipelines
DNV-OS-F101-Submarine Pipeline System
API RP 14 E Recommended Practice for Design and Installation of Offshore Production
Platform Piping Systems
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids
ASME B31.8 Gas Transmission And Distribution Piping Systems
API- Spec 6A, API- Spec 6D or equivalent for pipe line valve
API- Spec 6A or equivalent for pipe flanges and flanged fittings
API 17 J Specification for Un-bonded Flexible Pipe
API 2RD Design of Risers for Floating Production Systems (FPSs) and TLPs
NACE SP0110 Wet Gas Internal Corrosion Direct Assessment Methodology for Pipelines-
2010
As a Best Practice we also follow, std.- “DNV-RP-F206” & “DNV-RP-F116
OISD Work shop 4 – 5th Dec ’17, New Delhi. 18
e KPI monitoring till 2nd Qtr of 2017 -18
OISD Work shop 4 – 5th Dec ’17, New Delhi. 19
Risk Based Inspection Methodology
Change in Approach to determine any change in Inspection Interval from the baseline
Equipment Condition Status – implying ”Confidence”
Rate of failure - implying a time based ”Development” of anomaly to
failure
Inspection Frequency is as per IM Plan and driven through SAP
RBI - Risk Based Inspection
OISD Work shop 4 – 5th Dec ’17, New Delhi. 20
Risk Assessments updated based on Asset Condition Status, following methodology of
DnV RP F116 thru FMEA
Risk Assessment Sheet
OISD Work shop 4 – 5th Dec ’17, New Delhi. 21
Pipeline Design includes 4-5 mm corrosion allowance
Critical pipelines are facilitated for internal inspection
QA/QC during fabrication and installation using third party inspectors
Corrosion assessment and Corrosion inhibitor selection studies
Ring Pair Corrosion Monitors (RPCMs) installed in 11 discrete locations
Erosion and Sand monitors installed on all XMTs
ER probes at above water locations Ex: Platform and Onshore
Internal Corrosion Control - Design
OISD Work shop 4 – 5th Dec ’17, New Delhi. 22
Chemical composition
Basis of Design Compliance for chemical composition
Monitoring of H2S, CO2, O2, Water and pH content in received fluids
Reported in BI Monthly reports
RPCM - Ring Pair Corrosion Monitors
Continuous metal loss data availability at 11 discrete locations
Metal loss of 8 sectors on each ring is monitored
Data is available online in DCS
Metal loss rate over the periods is compared
Internal Corrosion Control - Monitoring
OISD Work shop 4 – 5th Dec ’17, New Delhi. 23
CI injection
CI injection and inhibition philosophy
CI injection requirement is calculated daily and injection rate is adjusted
Measurement of CI Residuals at OT to ensure chemical injection is active
throughout system
System audit by NALCO periodically
Internal Corrosion Control - Monitoring