KGD6 Deepwater Asset Integrity Management

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


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


Safety Contact–Non RIL Incident


KGD6 Deepwater


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


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


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


Control Centre


Onshore Terminal

First Gas on April 2009


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


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


Operational Excellence

Towards Excellence in Excellence

99.96% Uptime

100% Safe

100% Quality Gas

“0” Security incident


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


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.



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


Integrity Management Process


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


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


e KPI monitoring till 2nd Qtr of 2017 -18


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


Risk Assessments updated based on Asset Condition Status, following methodology of

DnV RP F116 thru FMEA

Risk Assessment Sheet


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


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


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

KGD6 Deepwater Asset Integrity Management

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