ANNTJAL REPORT

PRODUCTION GAS DEPARTMENT

OIL INDIA LIMITED
DULIAJAN

2012-2013
 ANNUALREPORT
2012-13
PRODUCTION GAS DEPARTMENT

1.0 INTRODUCTION:

The year 2012-13 was another eventful and memorable year for the department. The
highest ever natural gas production and sale of 2444 MMSCM and 1891 MMSCM
respectively were achieved from Assam and AP fields during the year. The above
achievement was not only due to continuous hard work of Production Gas Department,
but also continuous supports and guidance received from various Departments and the
Managements.

During the year the Department was also adjudged as the'Best Department' in overall
safety performance category in the internal safety inspection. This reflects the dedication
and commitment of the department towards upholding HSE standards. The Department
is proud to receive the above recognition.

This note presents vanous activities of the department during 2012-13.

2.0 TARGET AND ACHIEVEMENT. (ASSAM & AP):

Target Achievement o/oAQ€

Operational Parameters (MMSCM) (MMSCM) Achievement
Gas Production 2684 2444 91

Gas Sale 2159 1891 88

Shortfall in Production and Sale is mainly due to the following reasons:

i) BCPL supply did not resume though it was planned as1 15 MMSCM.
ii) BVFCL withdrew less gas during May 2012fot plant maintenance.
iii) NRL withdrawal was less during April-May 2012 for their plant problem.
iv) Frequent local problems/bundh etc.
v) Less than the desired production potential.

Gas production and sale for the previous 3 years were as under:

Production(M MSCM) Sale(MMSCM)

Year o/oAQa
Target Achievement ToaQe Target Achievement
2009-10 2290 2210 96.50 1790 1663 92.80
2010-11 2339 2195 93.84 1839 1656 90.09
2011-12 2338 2410 '100.50 1894 1875 98.98
3.0 GAS PRODUCTION AND DISPOSAL:

i) Production: Quantitv (SCM)

Associated Gas :1189020815

Associated Gas-well : 629028509
Non-Associated Gas '. 625816812
Total :2443866136

ii) Condensate production (from gas wells) .223891 Kl

(Condensate produced has been spiked with Crude oil)

iii) Disposal:
Utilization Quantitv (SCM)

Sale . 1890744028
lnternal IJtilization :338134755
LPG Extraction : 32883774

Sub Total (A) '.2261762557

Unavoidable losses:

Flare : 167135912
Other Loss : 2808675
Compression shnnkage . 12158992

Sub Total (B) : 182103579

Total (A+B) .2443866136

iv) Sale Breakuo Quantitv (SCM)

BVFCL 524518665
NEEPCO 502582022
roc (AoD) 95200492
APL 34670179
ASEB (NTPS) 238090917
ASEB (LTPS) 124619806
NRL 172212728
TEA GRIDS & OTHERS 19884921 I
Total .1890744028
4.0 GAS PRODUCTION POTENTIAL:

0.890 MMSCIVD gas production potential was built up as under:

a. Contribution from new well (6 Well) ' 510 MSCMD

b. Contribution from work over efforts (11 Nos.) : 380 MSCMD
c. Total gain : 890 MSCMD
(Note: Out of 6 drilling wells 3 were completed in 2011-12, but put on
production in 2012-13.)
d. During the year there was a decline of 0.250 MMSCN4D of associated gas from
3.400 MMSCMD as on 311312012 to 3.150 MMSCMD as on 31/3/2013.
e. The net gain in NA gas production potential was 0.450 MMSCMD from 3.400
l\4MSCMD to 3.850 MMSCMD.
f. Number of producing gas wells was 62 as on 3110312013 as against 52 as on
31t03t2012.
g 4 wells ceased to flow and 3 wells were abandoned temporarily for technical
and environmental problems.

5,0 OPERATION

Fields
i) BH P measurement job : 50 Nos
ii) Hole probing job :8'1 Nos
iii) OFPT job :01 No.
iv) Gravel Pack : 0'1 No

Compression Services
i) Compressor Running hours
a. Low Pressure Boosters (LPB) .2,44,917 Hts
b. Gas Lift Gas Compressors (GL) : 2,75,965 Hrs
ii) Compressor Availability
a. Average LPB Availability : 88.30 o/o

b. Average GL Availability .92.30 %

iii) Compressor Utilization
a. Average LPB Utilization '. 70.5O o/o

b. Average GL Utilization 83.00 %

vi) Total gas boosted : 488 MMSCM

vii)Total gas lift gas supplied : 458 MMSCM
viii)Monetization of flared gas through compression . 47.285 MMSCM
services (BOO)
3
6.0 MAINTENANGE JOB:
Fields
i) Gas distribution / gas lift line repairing : 36 Nos.

ii) Replacement of stolen wellhead fittings : 64 Nos.

Compression Serviees
i) Gas Engine major overhauling : 05 Nos

ii) Gas Engine Top Overhauling : 04 Nos

iii) Compressor Overhauling job : 07 Nos

iv) Air compressor overhauling . 10 Nos

v) lnspection of Gas Engines : 267 Nos

vi) lnspection of Gas Compressors : 35 Nos

vii) HOT Crane Testing : 19 Nos

viii)HOT Crane Servicing : 08 Nos

ix) Steam Cleaning of Aerial Cooler : 29 Nos

x) Overhauling of CAT engine through AMC : 04 Nos.

xi) Annual Servicing of Glycol Plants : 12 Nos

xii) Replacement of Reflux coil of Still Column : 02 Nos
(Glycol Regenerator)
xiii)Still column body puncture repair .02 Nos.

SCADA
i) Antenna & Battery Maintenance : 39 Nos.

ii) RTU, Power supply unit & Computer system :22 Nos.
iii) Subscriber Radio & Base Radio maintenance : 15 Nos
iv) Field lnstrument under preventrve maintenance : 530 nos.

v) Calibration of Custody Transfer meter . 213 Nos

7.0 KILOMETRAGE & OVERTIME

Vehicle Kilometraqe

Total Kilometrage during the year was 10,08,586 Km as against 9,43,327 Km in

2011-12.

Increase in Kilometrage is mainly due increase in field and project activities. lt

may be mentioned that 3 major projects (Gas Field Development Project, SCADA
Project and lnstallatron of 10 Gas Compressor Packages) are being executed
 under direct supervision of the Department. Similarly field activities have
increased for completion of increased number of wells during the year.

Overtime

Total Overtime during the year was 1 ,78,610 Hrs against I ,66,725 in 2O11-12.

lncrease in OT is mainly due to the following;

i) Decrease in manpower strength

ii) lncrease in field & project activities
iii) Continuous duty for more than 8 hour shift duty due to bundh / obstruction etc.
iv) Breakdown compressor maintenance job for otl winning purpose
v) Emergency field jobs like repairing of gas lines and well heads for safety
reasons
vi) Attending emergency fire calls, miscreant acts etc. beyond duty hours.

8.0 MAJOR DEVELOPMENTAL JOBS:

i) Replacement of damaged 30 psig & 250 psig lines from Joypur OCS to GCS
ii) NDT at GCS 1, 4, 6, 8, Kathalguri, Ushapur & Joypur.
iii) Construction of Noise barriers at GCS Ushapur & Langkasi.

v) Painting of vessels and piping at GCS - 1, 2, 4, 6, 7, Kathaloni, Dikom,

Jorajan, Nagajan and Joypur.

vi) Revamping / relaying of servo/fuel lines in GCS -5

vii)Revamping and re-use of old 600 psig KOV as fuel scrubber at GCS-6.
viii)Completion of Asset superscription at GCS-1, 2, 5, 6,7,8, Kathalani, Dikom ,

Joypur, Jorajan, Nagajan, Ushapur, Salmari and Kathalguri.

ix) Re-siting of 4 Nos. of water type bath heaters for gas well production
x) Re-siting of a LPB compressor to GCS 5
xi) Replacement of leaky 12" gas distribution line between GCSl and OCSl
xii) Gas line laying jobs:
Line spec. Total Lin€ Remarks
laid (Km)
50 mm Gas s NHK 603, NHK 360, NHK 369, NHK 444, NHK 145,
Input line JJN 47, BZL#OO1 , NHK 145, LOC HUQ,
100 mm t 3CS2, NHK297,BZL1
Artery line
100 mm, X46 24.5 \HK602, NHK 136, NHK2,,I6, NHK 141, NHK537,
Flowline \HK 531, NHK 367,MKM 43, NHK 145,
\HK597,600, LOC HUL, BZLOOl
100 mm, X60 29 \HK 561, NHK 581, JJN 047, JNG 02, MKM 43
Flowline
9.0 PROJEGTS:

9.1 Non-Associated Gas Field Development (NAGFD) Proiects:

i) Central Gas Gathering Station and Central Offtake Point, Madhuban

a) Construction job is in progress;- EDC : 30.09.2013

b) Progress as on 31/03/2013 :79.11o/o

ii) Field Gas Gathering Station, Chabua

a) Construction job rs in progress;- EDC : 30.09.2013)

b) Progress as on 31/03/2012 .7o.52o/o

iii) Construction of 6 nos. Pipelines betlveen CGGS & COP, Madhuban and LPG
Offtake Point

a) Construction job in progress;- EDC : 30/06/2013

b) Progress as on 31/03/2013 .94o/o

iv) Construction of 400 mm X 40 Km long line from BAGHJAN to CGGS'

Madhuban

a) 27 Km out of 37 Km pipeline has been laid as on 31/03/2013

b) 8 Km length of pipeline in Baghjan, Dighaltarang & Matapung water body to
be laid. Mobilization by contractor is in progress as on 31/3/2013.
c) EDC 3110812013 is subject to progress of land acquisition and other related
issues along the pipeline route.

v) Construction of 400 mm, 20 Km long Chabua-Madhuban pipeline : Completed

in all respects

vi) Survey of Existing and New Pipeline Route:

a) Detailed survey & NDT of gas lines completed.

b) Survey for crude oil lines (180 Km) & additional gas lines(70 Km) has been
started.

9.2 Expansion and Modemization of SCADA

The replacement of the existing SCADA with a new state-of-the-art SCADA

system is in progress

a) Progress as on 31/03/2012 :64.54!o.

b) EDC :30/09/2013

EDC is subject to smooth progress of works in the fields without obstruction from
' local and other interested parties.
r

9.3 Purchase and lnstallation of 10 Nos of Gas Compressor Packaoes:

5 out of '10 Natural Gas Engine driven Gas Compressor Packages were in final
siage of commissioning as on 31i03/2103 and is expected to be commissioned by
3OtO4t2O13. The expected commissioning of the remaining 5 packages is
30/06/20,13 which is again subject to gas engine exhaust silencers to be delivered
against original supply of sub-standard silencers.

1O-O TECHNOLOGYUPGRADATION

101
Adsorption Process:

water Vapour & Heavier

EOI floated for construction of a Pilot Plant fof removal of
Hydrocarbons (C5+) from natural gas by Adsorption Process. The project is taken
up under the guidance of llT, Guawhati after successful completion of LAB scale
study at the lnstitute.

10.2 Conversion of Maatronic to Altronic lqnition Svstem of Gas Enqines:

Four Nos. of Magtronic systems of Gas Engines have been converted into more
reliable and safe mode of Altronic lgnition System.

10.3
95 dioital lqnition svstem:

04 Nos_ of Altronic ignition system of Gas Engine were converted into the state-of-
the-art cPU-95 digital ignition system. The microprocessor based digital ignition
system has the capability of diagnostic, troubleshooting, trending, enhanced
energy supply to spark plugs and variable timing control. The advantage of this
system is that it has minimum mechanical failure as it does not have any
mechanical moving component. So maintenance down time is comparatively less.

10.4 lnstallation of 2.5T Air Hoist:

One No. 2.5T capacity air hoist was installed at Kathalguri GCS as a replacement
of the chain pulley system for lifting heavy equipment, facilitating easy and safer
movement of heavy equiPment.

11.0 COST SAVING MEASURES:

Activities that resulted in savings of costs are as under:

sl Cost Saved
Activity (Rs % Cost Saving
No.
Repairing of2 Nos of l4" damaged 1,00,000 14.00
1.
silencers of Gas Engine
Revival of 2 Nos of ELGI make 1,04,200 4.40
2.
oortable air compressors
12.0 FINANCIALPERFORMANCE:
a) Revenue earned from gas sale : 1082.97 Crore

b) Budgets

i) Expendrture
Capital Budget . 122.62 Ctorc
ii) Revenue BudgetExpeSditure '. 42.26 Crore
c) Audits (lnternal/Technical)

i) Assets
Physical Verification of : 99.06%
ii) items
SLoc verification of Non stock : 1 00%
iii) Technical Audit oflnstallations : 03 Nos
iv) Writing off Assets ( Gas Compressors) : 30 Nos

13.0 ENERGY UTILIZATION/CONSERVATION ETC:

13.1 Enerqv Conserved

i) 25000 SCMD of Gas monetized by laying a 100 mm NB line from Mechaki to

Doomdooma with effect from 30.03.2013.
ii) Saving of about 60 litre of diesel per day due to commissioning of three nos. of
50 KVA Gas Engine Driven Generating set in FGGS 336, Deohal and Kusijan.
iv) Saving of about 7900 litre of diesel by using gas pressure to load bowser at
FGS Deohal.

13.2 Enerov Generated:

i) AP)
Natural gas production (Assam & : 2443866136 SCM
ii) Condensate produced (Gas Wells) : 223891K|s

13.3 Enerqv Consumed:

i) MG20W40
Lube Oil, : 420180 Ltrs.
ii) 121
Lube Oil, S : 9625 Ltrs
iii) Diesel
High Speed : 32225 Ltrs
iv) Petrol : 30 Ltrs
v) Natural Gas (lntemal Use) : 338134755 SCM

13.4 Other Chemical Consumed

i) Methanol :4,720 Ltrs

ii) Triethylene Glycol : 39,375 Kg
14,0 HEALTH. SAFETY&ENVIRONMENT:

14.1 Accidents

o Minor, Major & Fatal : Nil

o Near Miss : 03 Nos.

14.2 OISD Recommendations:

. Total outstanding recommendations as on 3110312012 : 18Nos.

. Total recommendations implemented during the year : 06 Nos
o Total remaining recommendations as on 3110312013 :12 Nos.
14.3 DGMS Permission / Notifications etc
. 311312012
Outstanding application as on : 33 Nos-
. DGMS Permission / Application applied for : 05 Nos.
. DGMS Permission received : 04 Nos.
. DGMS Permission to be received as on 31/3/2013 : 34 Nos.
14.4 Awards:

i) During the internal safety inspections, the Production Gas Department was
awarded First Prize for best overall safety performance.
ii) Other awards received during the internal safety inspection are as under:

lnstallation Ptize lnstallation Manaoer

GCS-Moran 10 Dilip Kalita
GCS-Diqboi 2no Joqesh Deori
GCS-Kathaloni 3td Lakheswar Khanikar
GCS-Lanqkasi 3'd Purbaivoti Bordoloi

14.5 98o/o of the employees of the department have undergone periodic medical
examination during the year.

14.6 As a part of awareness towards environment protection, the department initiated

tree planting at the time of superannuation of the employees. This is also an effort
towards retaining the memories of the employee's contribution towards the
department and to the Company.

15.0 HUMAN RESOURCE:

15.1 Manpowerstrength-
The of the nt is as under:
Strength as on
Category Sanctioned
31t03t2013 31tO3t2012
Executive 43 46 41
Workmen 440 404 4't4
 Note : i) 04 ETs were absorbed in Grade B as Production Engineer.
ii) 01 executive superannuated.
iii) 02 executives were transferred from the department
iv) 03 executives posted at Digboi and Moran were not included in the
above strength in 2o11-12.
v) 08 work persons were superannuated.
vi) 02 work persons expired during the year

Department congratulates the executives absorbed in the department and

remains grateful to all the executives and work persons superannuated and
transferred for their contribution to the department as well as to the Company. The
Department also offers heartfelt condolence on the demise of its 02 beloved
employees.

15.2 Trainino:
. Work persons:

a) ln house training :169

b) ln Country training :16

. Executives:

a) ln house Training : 19
b) ln Country training .26
c) Overseastraining/Conference .11
16.0 ACKNOWLEDGEMENT:

The undersigned takes this opportunity to express his sincere appreciation and gratitude
to every member of the Department for their dedication and commitment, without which
the results achieved, would not have been possible. The department would also like to
record its sincere thanks to various departments for their valuable services towards
fulfilling the objectives of the department. The department also gratefully acknowledges
the continuous guidance and supports received from the Local and Corporate
Management.

The undersigned appreciates Shri H.N. Borah, DyCEPG (A&C) for compiling the report.

(Bipin Gogoi)
Head - Production Gas
Date : 30/04/2013

t0