annual report 2012-13: field engineering dept. · pdf filethe merger of erstwhile mechanical...

ANNUAL REPORT 2012-13: FIELD ENGINEERING DEPT.

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PREAMBLE:

Field Engineering Department came into existence in April, 2004. Consequent upon the merger of erstwhile Mechanical Engineering and General Engineering departments, Field Engineering was born. The officers of the department are mostly from mechanical engineering discipline. The department provides crucial engineering support to the organization’s main activity: the process of finding, producing, storage and transportation of oil and gas. Activities of the department include maintenance of critical production equipment across OIL’s operational fields, rendering workshop services to Drilling, Production and other departments through Central Workshop and ICE (Internal Combustion Engine) Workshop, operation & maintenance of Water Works stations at FHQ as well as in remote production installations including EPA & Moran, maintenance and overhauling of crude oil storage tanks at CTF and other miscellaneous but critical technical support services.

OBJECTIVES:

• Ensuring 100% availability of mechanical equipment, 24x7, pertaining to production process:

CODPs, water injection pump-sets, bowser loading pump-sets, generating sets, fire fighting pump-sets, WSS equipment etc.

• Servicing and maintenances of major equipment pertaining to drilling & workover processes:

Draw-works, engines, rig pumps, draw works, rotary tables, work-over engines, transmissions etc.

• Laying of effluent lines, provisioning of source water in the fields.

• Providing uninterrupted industrial water, potable water and low pressure gas supply to all installations, housing areas and various social organizations.

• Install and maintain fire-fighting infrastructure at different installations

including fire pump sets, pressurized ring mains, foam pouring systems etc.

• Maintenance of crude oil storage facilities at Central Tank Farm.


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SOME HIGHLIGHTS OF DEPARTMENTAL ACHIEVEMENTS DURING THE YEAR

� Field Engineering Department fulfilled its basic responsibility of providing 100% service

to the organization in production of oil and gas. Not a single KL of production was lost

due to want of our equipment or services.

� A dynamometer for load testing of IC engines was commissioned in the ICE Workshop.

This is the only equipment of its kind in this part of the country and can test engines of

capacity ranging from 10 to 100 HP.

� The bottom plate (annular portion) of crude oil storage tank 9A, of 10,278 KL capacity, at

CTF was replaced (first of its kind job in OIL) after thorough cleaning of the tank. Job was

completed on 31/03/2013 and tank handed over to Production next day.

� The department generated 4.2 MW of electrical power during the year with an installed

capacity of 7.2 MW.

� 6 numbers of draw-works, besides many other major equipment were overhauled and

serviced in CWS.

� Over 12 million gallons of potable water per day (12.05 MGD) was produced and

distributed across different installations. The department organized ‘Water Awareness

Week-2013’ coinciding with international World Water day on 22nd march 2013.

� 50 kilometres of effluent lines were laid across various locations to carry effluents.

� 90 IC engines (including 4 Caterpillar engines and 35 Cummins engines) were overhauled

in ICE Workshop.


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SECTIONS OF FIELD ENGG DEPARTMENT:

To achieve the above goals, the department has been divided into six sections: 1) Central Workshop (CWS)

2) Water Supply and Injection (WS&I) 3) ICE Shop & Well Stimulation Services (ICE-S &WSS)

4) ICE Field & Water Injection (ICE-F & WI) 5) Project & Tank Farm (Project & TF)

6) Planning & Administration (P&A) TARGETS AND ACHIEVEMENTS OF SECTIONS 1) CENTRAL WORKSHOP: Central Workshop (CWS) under Field Engineering department at Field Head Quarter, Duliajan was commissioned in 1962. CWS is responsible for overhauling, reclamation & maintenance of major oil field equipment used in our drilling, work-over and production processes. CWS also provides miscellaneous workshop services including machining, welding amd fitting jobs to all internal and some external customers. The focus is on quality and reliability. CWS has been accredited ISO 9001:2008 certificate on 09/03/2010. Surveillance Audit of the same was completed on 17.02.2012.

During the year, CWS has undertaken repair and fabrication jobs from the making of tiny nuts & bolts to repair/reclamation of mechanical spares, overhauling of the various types of oilfield equipment including heavy oilfield of the equipment.

Achievements of CWS

a) Number of job Notifications /service demands received : 2282 b) Number of completed jobs /service demand met : 2307 c) Number jobs /service demand cancelled by the indenter :25 d) % of completed job/ service demand met :100 %

e) CWS earned revenue of about Rs 12 lakhs during the year by providing workshop service to M/S NEWSCO, who is providing horizontal drilling service to Drilling Dept.


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Some of the major /core jobs done during the year:

Equipment with installation/ locations Quantity

Draw works(S-6 Rig :1+1=2,S-1 Rig :1,BHEL-D Rig:1,Nat 110MA:1,S-7 Rig:1]

6

Workover Outfit(Cardwell-B:1) 1

Rotary Counter Shaft [S-2 Rig:1] 1

Traveling Blocks [NAT110 M-B:1] 1

Crown Blocks [NAT110 MA:1,Spare Unit:1] 2

Rotary Swivels [ID No-24:1,ID No-25:1 ,ID No-33:1,ID No-38:1]

4

Rotary Tables [ ID No-2:1,ID No-36:1,ID No-38:1,ID No-39:1,ID No-40:1]

5

Drum Shaft /Transmission shafts Assy [Spare Unit:1,S6Rig:1,S2 Rig:1]

3

Compound Transmission Units (BHEL-C:1,Cardwell-C:1) 2

Gear Box of BHEL-A 1

Fabrication of Cementing Tank as per Design of Drilling Deptt(Cementing Section)

1

Compund Drive[cardwell-B:1] 1

Stabbing Board Outfit RG-A 1

BOP Test Bench/Drilling Equipment Section. 1

Triplex Plunger pump 8

Major Overhauling of Rig Pump[MP-2 /A1700 PTof S8 Rig:1,A1400PT/MP:1]

2

Truck mounted Coil Tubing Unit OIL 3509/Chasis Repair and modification job.

1

Apart from above broad list, CWS has also carried out the following vital jobs: 1. Rethreading of 6 ½” Dia NC-46(4”IF) Drill pipes as per API specifications. 2. Rethreading/Fabrication of Drill Subs, Cross-over subs of various sizes as per the requirement of Drilling Deptt.

3. Float collars with 9 5/8” Dia. casing joints as per design of Cementing section of Drilling Department

4. Rethreading of various sizes of NEWSCO EMDC Drill Pipes as per the approved legacy.

5. Outstation technical services to department like Production, Electrical and Drilling Departments of OIL.


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2) WATER SUPPLY AND WATER INJECTION:

Water supply and injection section is functionally responsible for: 1) Maintaining uninterrupted supply of potable water to the OIL Township at Field Headquarters, Industrial area premises and some of the adjoining field installations (CBUS, nearby OCS/GCS Complexes etc) on a 24x7 basis, achieved through round the clock operation and maintenance of two Water Treatment Plants at Tipling (New-4MGD & Old 1.5MGD), Two floating Pontoons at Dihing riverside and the entire water distribution network inclusive of the strategically located storage facilities.

2) Operation and maintenance of satellite water supply stations for various production installations e.g EPS, QPS, OCS, GCS, FGS, MUD PLANTS through Shallow Tube Wells, Deep Tube Wells, Submersible pumpsets etc.

3) Maintenance of Drenching pumps including fire fighting/protection network of all the production installations and also Duliajan and Moran Township.

4) Management of the effluent disposal networks for the evacuation of effluents from Drilling & Work Over locations as well as from collection areas within the OIL Township (BX+, OIL Hospital, LPG Premises etc), a very sensitive service having serious environmental and human concern.

5) Distribution network of low pressure gas in Duliajan & Moran township & industrial area

6) Supply of water for water injection purpose including the maintenance is also a primary job of this section

Achievement of Water Supply and Water Injection Section 1) Total water produced/ distributed by Field Engg. Dept. = 12.054 MGD

The breakup is as follows:

• Quantity of water supplied to Duliajan Housing area, South Bank and

Moran: 7.126 MGD.

• Water supplied for various Satellite water supply stations: Total 79 pump

sets in 29 satellite water-supply & 8 Water Injection Stations.


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• Water for W/I station is catered by DTWs: 26 Nos. in 8 installations and

the terminal rate achieved on 31.03.2013: 2.27 MGD.

2) Total 50 Km length of effluent lines laid at various drilling locations to keep the

environment free from pollution.

3) Total 50 nos. of shallow tube wells sunk to provide source water at various

drilling/workover and production locations.

4) Distribution of low pressure gas @ 78050 scum/day (approx.) to Housing,

industrial area & other consumers in Duliajan.

5) 4MGD WTP is already ISO 9001 certified. This year the ambit of ISO

certification is to be extended to Integrated Management System with both ISO

9001 and ISO 14001 certification. Contracts for both certification body as well

as consultancy have been formulated and certification is expected to be

completed by May 2013 .

6) In some DTW setups for Water Injection Stations, the existing Vertical turbine

pumps are being replaced by Submersible Pumps being more efficient and

needing lesser maintenance.

7) At a few Satellite Water Supply Setups at Production Installations the existing

EMD Reciprocating Type Source water pump sets are being replaced by EMD

Submersible pump sets, which besides being more efficient consume lesser

power due to their lower ratings.

8) Automatic Online Iron Removal Filter setups have been installed in Barekuri,

Baghjan, Bhekulajan, Balijan and Jorajan.

9) Mechanized drilling & Sinking of 10 nos DTWs were completed.

3) ICE SHOP & WSS: ICE shop & WSS of Field Engineering Department is primarily responsible for major overhauling of all IC engines pertaining to all departments in general and Drilling & Production (Oil) Departments in particular including the maintenance support services to WSS section.


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Summary of achievements of ICE shop & WSS during 2011-12:

Numbers of engines overhauled:-

Caterpillar: 4 Nos. Cummins: 35 Nos Others: 50 Nos Beside these, the following important jobs were also carried out:

� Repairing of air compressors and various pumps.

� Supported field & other areas by supplying Diesel Acoustic Generating Sets

� Repairing of CAT Engines at Drilling well sites as per job requirement.

� Repairing of CUMMINS Engines at Work-over well sites as per job requirement.

� Maintained 28 nos. of Road Rollers operating in the field area.

� Extended welding & cutting services to different Departments with deployment

of 60 Nos. of Brand New welding & cutting sets.

� Maintenance of some critical equipments in Central Tank Farm, Electrical power house, LPG Plant, Well-logging Dept., OIL Hospital, 4MGD Water Treatment Plant, Pontoon etc.

Fuel Section repaired/serviced the following equipment/items:-

� Fuel injectors: 665 Nos. � Fuel pump : 228 Nos. � Turbocharger: 28 Nos. � Governor Actuator: 46 No. � Allison Transmission: 03 No. � Torque converter: 01 No.

Magneto Section Repaired/serviced the following equipment/accessories:-

� Self starter: 178 Nos. � Alternator: 85 Nos. � Dynamo : 11 Nos. � Altronic : 111 Nos. � Wiring Harness: 20 nos.

Beside these, ICE-Shop section extended services to different well sites, NIA, WSS, work-over rigs, OCSs etc scattered all over in our oil fields.


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Following major jobs were also carried out / in progress:

• Continuous improvement and monitoring of house keeping, safety and general environment of the New ICE SHOP is being carried out.

• Construction of New ICE Go-down is in progress.

• Dynamometer for engine load testing has been successfully commissioned at New

ICE Shop.

• One no. 250 KVA emergency standby genset has been successfully

commissioned at R&D Building.

• Commissioning of one no. 500 kva emergency standby at OIL Hospital is in

progress.

• One no. of Washing Pump has been commissioned at Transport yard.

The maintenance of the following units of WSS have been carried out during the year

2012-13:

� Coiled Tubing Unit (CTU) : 03 Nos.


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� Nitrogen Pumping Unit (NPU) : 04 Nos.

� Fluid pumping Unit (FPU) : 02 Nos.

� Hot Oil Circulating Unit (HOCU) : 03 Nos.

(02 nos. commissioned during the year)

� Emergency Well Killing Setup (EWKS) : 01 No.

4) ICE FIELD & WATER INJECTION: The ICE (Field & WI) section of Field Engineering department primarily provides support services and maintains equipment of operation departments like Prod. (Oil) and Prod. (Gas). Hence the targets of ICE (Field & WI) section are linked with the overall targets of these departments as below:

• Ensuring no loss in production of crude oil due to non availability of equipment like CODPs, Bowser loading pump-sets, generating sets etc.

• Ensuring no loss in natural gas production due to non availability of vital equipment like generating sets.

• Ensuring that the Water Injection target for the financial year is achieved through maximum capacity utilization of surface facilities like WI pumps, engines and transmission systems.

• Installation and commissioning of new equipment as well as relocating equipment as per operational demand within stipulated time frame.

• Ensuring 100% availability of equipment, minimizing maintenance cost, planning of spares and consumables etc.

Achievements of ICE-Fields & Water Injection are as follows: No loss of crude oil production has been reported due to breakdown / non- availability of equipment maintained by ICE-Field section of Field Engg. Deptt. This status could be maintained by providing quality back up services in spite of following constraints:

- To maintain vast diversity of equipment - Scattered orientation of field installations - An ever increasing ratio of equipment

CRUDE OIL DISPATCHED THROUGH BOWSER LOADING/CRUDE OIL

DISPATCH PUMPS : 4506659 KLs


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• Back up maintenance services to Production-Gas installations for their equipment and provide support services to all the departments for mobilization of in house resources at the time of crisis.

• Power supply is maintained to all Production Oil & Gas installations with 86 no. gensets as follows:

POWER GENERATION IN VARIOUS FIELD INSTALLATIONS : 4.2MW

WITH THE INSTALLED CAPACITY OF 7.2 MW

• Maintained 100% availability of equipment to Production-oil department towards achieving terminal rate of water injection (i.e. 9589 KLPD) through maximum capacity utilization of surface facilities.

• Detailed analysis has been carried out on critical field equipment scattered in our field area and action has been initiated for replacement of those equipment which has already crossed the period beyond economic maintenance.

• All equipment marked for installation and commissioning were installed, commissioned and put into operation well within the stipulated time.

Sl. No.

Equipment Quantity Location/Installation

1. 250KVA GG Set 2 Makum OCS 2. 125KVA GG Set 1 FGGS Kuchijan 2 3. 50KVA GG Set 1 FGGS 336 4. 50KVA GG Set 1 FGGS 285 5. 50KVA GG Set 1 FGGS Kuchijan 2 6. 250KVA GG Set 2 Bhogpara OCS 7. 50KVA GG Set 2 Bhogpara SRP 12 8. 50KVA GG Set 1 WHS Balimara 1 9. 50 KVA GG Set 2 NKF EPS 10. 125KVA GG Set 1 HJC EPS 11. 30KVA DG Set 2 WHS TAI 12. 30KVA DG Set 1 WHS DGD 13. 63 KVA DG Set 1 Seismic Survey Camp

(Baruah Camp) 14. Cummins Gas Engine 1 Tiniali SRP 11 15. Gas Engine Driven

CODP 1 Makum OCS

16. Gas Engine Driven CODP

1 Hatiali EPS


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Installations Completed:

• EEfforts were made at all levels to improve the availability & reliability of critical equipment in field installations. During the financial year around 216 engines, 68 pumps, 23 gearboxes were periodically inspected and 02 engines were top overhauled at site. This has resulted improved reliability of equipment.

5) PROJECT & TANK FARM:

Project & Tank Farm Maintenance section of Field Engineering department deals with

the following jobs;

• Various project jobs under Production-Oil, Production-Gas, Production Project &

other departments of Naharkatia, Moran, Digboi & Manabhum Fields like

Administration, Chemical, G&R, L&D etc.

• Maintenance of Central Tank Farm (CTF), Duliajan.

• Operation & Maintenance of Flow Improver Chemical dosing set up for Branch &

Main line crude oil.

• Other special projects of the department like Disposal of COC Plant Duliajan &

Moran etc.


1 Bhogpara EPS

Sl. No.

Equipment

Quantity

Location/Installation


2 New Bhogpara OCS.


1 EPS Chabua -3


1 Kumchai EPS


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Summary of achievements of Project Section:

The following are the major jobs carried out during the financial year 2012-13

1. Dikom DBUS:

• Laying of 150 mm (6") dia fire water drenching line for connection of drenching fire fighting system at Dikom DBUS as per OISD 189: 100% job completed successfully.

2. Deohal FGS-285:

• Construction of drenching pump house including construction of pump foundation: 100% job completed.

• Construction of 400 KL RCC overground static water storage tank: Site approved. Contract awarded. Job yet to be started by contractor.

• Laying of 200mm (8") dia fire water drenching line for fire fighting system as per OISD 189: Contract awarded. Job will be started after getting 8” dia line pipe for which order has been placed with due delivery date as 31.04.2013.

• Installation and commissioning of new Drenching Pump units: Drenching Pump units placed at site. Commissioning will be taken up after completion of RCC tank & laying of fire water drenching line.

3. New Bhogpara OCS:

• Laying of 200mm (8”) dia fire water drenching line for fire fighting line: 100% job completed.

• Construction of Drenching pump house including construction of pump foundation: 100% job completed.

• Construction of foundation and installation Job of 2 nos. 22.5KL capacity IR Filter: 100% job Completed.

• Construction, installation and commissioning of 46.80 KL P.S. overhead water tank with staging: 100% job Completed.

• Construction of 800 KL RCC over ground static water storage tank: Job in progress.

• Sinking of 2 (two) no’s of shallow tube well, Installation & commissioning of 2 no’s of 5 HP Submersible pump units and 2 no’s of IR filter units along with Air compressor units: 100% job Completed.

• Installation and commissioning of new Drenching Pump units at: Drenching pump units installed at site. Commissioning is scheduled in April’2013.

4. Balijan QPS:



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• Construction of 400 KL RCC over ground static water storage tank: Site approved. Contract awarded. Job is in progress.



5. Bekhulajan QPS:


• Construction of 400 KL RCC over ground static water storage tank: Site approved. Contract to be awarded by civil dept.



6. Hatiali FGS:

• Laying of 200mm (8") dia fire water drenching line for fire fighting system as per OISD 189: 100% job completed.

• Construction of drenching pump house including construction of pump foundation at Hatiali FGS: Job not yet started due to non availability of site.

7. OCS-2:


8. OCS-3:


9. Bhagjan EPS:

• Construction of 650 KL RCC over ground static water storage tank at Contract awarded. Job is in progress.

• Construction of one no. drenching pump foundation inside the existing drenching pump house at Bhagjan EPS: 100% job completed.

• Laying of water filling line & fabrication and laying of new suction/delivery manifold lines: Job in progress.


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• Installation and commissioning of new Drenching Pump unit: Drenching Pump unit placed at site. Commissioning will be taken up after completion of RCC tank & laying of new suction/delivery manifolds & hook up of same to existing fire water drenching line.

10. OIL Hospital:

• Installation of two numbers De-Watering pumps: Both pumps have been commissioned successfully and working satisfactorily.

11. New TDX B’lows:

• Laying of water & Gas lines for: The job is in progress as per schedule.

12. 1000 KL RCC overhead water tank near Tingri area:

• Construction of 1000 KL RCC overhead water tank near Tingri area for potable water supply in that area: Contract awarded. Job is in progress.

13. 1000 KL RCC overhead water tank near St.Xavier School area:

• Construction of 1000 KL RCC overhead water tank near St.Xavier School area for potable water supply: Site approval obtained. Process of obtaining budget for re-routing of Electrical O/H HT line is in progress. Contract awarded. Job will be taken up immediately after electrical re-routing.

14. Laying of 150mm (6") dia fire water drenching line for fighting system at 5(five)

different production installations (Balijan/Bekhulajan/Hatiali/DIAN/HJC) as per OISD 189: Contract awarded. Job will be started immediately after obtaining site approval & pipe availability.

The achievements of Flow improver set-up at COCP, Duliajan are as follows:

Treatment of crude oil with flow improver chemicals were carried out at Duliajan for

uninterrupted transportation of the crude oil through Main Trunk Pipe Line &

Digboi Branch Line.

• Quantity of crude oil treated for Main line with flow Improver chemical during

the year @ 100 ppm= 677.62 MT.

• Total Flow Improver consumed for treating Main Line Crude Oil during the

financial year was 71,747 Kgs.

• Quantity of crude oil treated for Branch line with flow Improver chemicals

during the year @ 150 ppm was 443.8 MT.


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• Total Flow Improver consumed for treating Branch Line Crude Oil during the

financial year was 70,411 Kgs.

• Total Quantity of crude oil treated for Main and Branch line with flow Improver

chemical during the year = 1121.42 MT.

• Total Flow Improver consumed for treating Main & Branch Line Crude Oil

during the financial year was 1,42,158 Kgs.

The achievements in Maintenance of Central Tank Farm, Duliajan are as follows:

(i) Tank No. 9A of CTF, Duliajan:

• Major Overhauling job: Crude Oil Storage Tank No.9A at Central Tank

Farm, Duliajan is among the largest storage tanks available with a capacity

of 10,278 Kls. The said tank is about 40 years old. About 2223 KLS of crude

oil left in the tank was pumped out and around 320 MT tank bottom sludge

was removed by manual cleaning & scrapping.

• Health Check up of Tank bottom & shell plate: After proper cleaning, the

tank bottom & shell plates were inspected for thickness by Ultrasonic

Thickness & Pit Gauging (NDT) and found that the thickness of annular

portion of the bottom plate was reduced to an extent of 60% due to corrosion.

• Replacement of annular portion of bottom Plate: Since the condition of

annular portion of bottom plate was found to be damaged badly, the same were

replaced by new plate of 12mm thickness. This job involved cutting of tank shell

from bottom plate and jacking up of complete shell to a height of 40 mm which

was first of its kind for such a large crude oil storage tank in OIL history.


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Tank shell of Tank-9A being lifted after cutting of bottom plate

• Replacement of Steam Coil:

As the steam coils were found badly damaged i.e. punctured in many places,

the same (around 1000 meter) were replaced by new 4” dia steam coils.

• Radiographic & Hydraulic testing of Steam Coils & Tank:

The newly replaced steam coil joints by were tested by Die penetration test,

X-ray (NDT) & Hydraulic testing at 35 Kg/Sq.cm for 24 Hrs and found

satisfactory.

The old & newly replaced bottom plate joints & Shell-bottom plate joints were

tested by Die penetration, Vacuum box, Liquid Penetration and Ultrasonic

Flaw detection testing.

The whole tank was hydraulically tested by static water for about 3 days and

observed no leakage.

• Calibration of Tank by Dept. of Legal Metrology, Govt. of India:

After completion of all jobs the tank was inspected by personnel from Dept. of

Legal Metrology, Govt. of India and certification has been issued by them for

calibration of the tank.

• Certification of Tank by Competent Person of Petroleum and Explosives

Safety Organisation(PESO), Govt. of India:


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The competent person of Petroleum and Explosives Safety Organisation

(PESO), Govt. of India had visited during and after completion of job and

issued certification that the said jobs were carried out in accordance with all

rules & regulations pertaining to crude oil Tank.

• Replacement of Damaged Foam Line:

The damaged portion of the foam lines around the tank were replaced by new

foam lines. The same were tested hydraulically and found satisfactory.

• Re-routing of 16” dia crude oil delivery line:

The 16” dia crude oil delivery line of the tank was passing through COC

Plant. Since disposal of COC Plant is in process, the said 16” dia crude oil

delivery line was cut and re-routed.

• Testing of Drenching water ring line & Foam poring system:

All the fire water drenching lines, water monitors and foam pouring systems

were checked with the help of Fire Service and found satisfactory.

• Fitting of Earthing lines & measurement of earthing resistance:

All the earthing lines of the tank were fitted and tested for earthing resistance

with the help of Electrical dept. personnel and found to be well with in limits.

• Finally the tank was handed over to Production Oil dept on 01.04.2013, well

with in scheduled date.

(ii) All fire fighting arrangement like drenching system, foam pouring system etc. of

CTF Duliajan has been maintained as per statutory requirements.

Disposal of shut-down COC Plants at Duliajan & Moran:

After necessary approval from competent authority, the following jobs were

carried out;

(a) A preliminary hazard identification job was carried out jointly by a internal multi-disciplinary team consisting of representatives from S&E, Electrical, Civil, and FE departments.


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(b) During the hazard identification, it has been surfaced that a 16” dia crude oil pipe line in Duliajan and a 10” dia crude oil line at Moran are passing through the plants, which are to be re-routed prior to dismantling the plants.

(c) It is important to note that electrical power to Tank Farm equipment, Pump Stations etc is presently routed through the COC plants at Duliajan and Moran and we have been cautioned by Head-Electrical that without eliminating this hazard (making arrangements for alternate power supply) it will not be possible to take up any dismantling activity.

(d) The re-routing job of 16” dia crude oil delivery pipe line of Tank no.9A, CTF, Duliajan which was passing through the COC plant was completed.

(e) After continuous persuasion, Electrical department has assessed the technical requirement for electrical isolation of both the COC Plants at Duliajan & Moran and forwarded us a budgetary estimate to carry out the job vide letter no. Elect/1695/32 dated 22.10.2012.

(f) Obtained site approval for placement of mobile skid mounted power supply panel from Planning department vide their letter no.PLN/2-4/9(F/E)-1366 dated 19.11.2012.

(g) Accordingly, a proposal was put up to competent authority for approval of the required budget for electrical isolation job vides our letter no. FE/A.2.1/2074/2012 dated 17.11.2012 and obtained approval for the same on 04.12.2012. After obtaining the approval of competent authority, Appropriation Request (AR) for budget has been raised on 09.01.2013, the same was vetted by Electrical dept. on 16.01.2013. Budget approval obtained for Duliajan COC Plant & Budget for Moran COC Plant is in process.

(h) Obtained budget from competent authority for engaging two Independent Govt. approved Value Assessor for assessment of Floor Price of both the COC Plants at Duliajan & Moran.

(i) Scope of Work, BEC/BRC, and Equipment list of both the COC Plants at Duliajan & Moran (including old plant) with other special conditions were prepared and PR raised for engagement of Independent Govt. approved valuers for assessment of the floor price of COC Plants at Duliajan & Moran on 18.08.2012. Further a reply to the query of contracts

department was sent on 05.11.2012.


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(j) Accordingly, tender no.DCO8010P13 on 21.11.2012 was floated for engagement of Independent Govt. approved valuers for assessment of the floor price of COC Plants at Duliajan & Moran with Bid closing date as 18.12.2012.

(k) The offers (02 nos) received against above Tender no.DCO8010P13 for engagement of Independent Govt. approved valuers for assessment of the floor price of COC Plants at Duliajan & Moran was sent to us for technical scrutiny vide letter No. H-C/TS/PV/268/2012 dtd. 19.12.20112. Technical scrutiny of the same has been completed and award of contract after necessary approval by contracts dept. is in progress.

7) PLANNING & ADMINISTRATION:

This section is responsible for general administration, Capital as well as Revenue budgeting, disciplinary proceeding /welfare, processing of timesheet related to work persons. Processing of various allowances for executives / work persons as well as maintaining various records. The section also looks after the ERP related issues particularly in the areas of Plant Maintenance (PM), Materials Management (MM), Project system (PS) and Human Resources (HR) to improve ERP-SAP system usage in the department. Training of executives as well as work persons are also looked after by this section. Various reports required by the management and others are generated by this section like Annual Report, Energy Conservation measures, Score Card, TNI Matrix, training plans, Capital Works in Progress, Budget review, Storage Location status, Contracts status, Material suitability report status etc. This section of Field Engg Dept. monitors the overall overtime status monthly basis and information of increase and decrease trend of OT hours to be circulated among the other sections of the department to control and manage the trend. This section arranges all departmental meetings, various presentations etc. Management of all manpower issues (including additional manpower requirement) are carried out by this section of Field Engg Dept.


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HR RELATED ISSUES: MAN POWER POSITION, JOINING & SEPARATION,

TRAINING PROMOTIONS ETC:

MANPOWER:

The manpower strength at the year-end stood at: a. Executives: 31 (including one ET) b. Employees: 422

c. Superannuation: 17 d. New employee joined: 32

TRAINING:

Executives In-house programmes: 37 In-country : 19

Overseas : 6 Employees In-country : 8 Overseas : 2 MVT & other in-house trainings : 92 Apprenticeship Training to ITI, Diploma holders : 48 In addition, the department provided Summer Training to 87 students of various Engineering institutions and 4 contractor persons were also provided training.

PROMOTIONS:

• 4 executives of the department were promoted from Grade E (Level-1) to Grade F (Level-2)

• There was 1 promotion from employee to executive category (Grade A)

• 28 employees were promoted to respective higher grades among the employees’ category.

TRANSFERS:

During the following movement of executives took place in the department:

• Shri S Ahmed, Dy CE moved to Inspection Cell of Calcutta Branch Office.

• Shri G G Rasu, SE, moved from Rajasthan Project to Duliajan


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• Shri A Dam, Dy. CE moved from Calcutta Branch Office to Duliajan

• Shri P P Dutta, Dy. CE moved from Duliajan to Corporate Office, Noida on

promotion as Chief Manager -BD

• Shri Anurag Gupta, Dy CE moved to Contracts Department on promotion as

Chief Manager –Contracts.

PASSING AWAY The year 2012-2013 has been a difficult year for the department as we lost 6 valuable members of the team to that inevitable truth of life: death.

• Shri S E Mothilal, Chief Engineer, passed away on 29 December 2012 at Delhi.

• Shri Jiba Kanta Gogoi, 98173 of Central Workshop passed away on 25.07.2012.

• Shri Jiban Das, 95129 of Moran, FE passed away on 20.02.2013.

• Shri Rithi Ranjan Das, 98690 of COCP passed away on 30.10.2012.

• Shri Kishore Sonar, 103794 of WS/WI passed away on 02.03.2013.

• Shrimati Bonani Ghosh, 102040 of COCP passed away on 12.03.2013. PRESENTATION OF PAPERS AT SEMINARS/ CONFERENCES

• Shri T B Chakraborty, GM(E) & Shri Anurag Gupta, Dy. CE –FE, presented a paper on ‘Energy and Transport Sector Policy’ at the 6th

International Conference on Energy Sustainability organised by American Society of Mechanical Engineers (ASME)USA at San Diego California (23rd to 26th July 2012).

• Shri R Bhowmik, CE-FE presented a paper on ‘Challenges in reducing

accidents in Equipment’ organized by DGMS at Guwahati on 5th November 2012.


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NEW PROJECTS, & COMMISSIONING OF NEW INFRA STRUCTURE/EQUIPMENT:

(A) Measures adopted by Central Work Shop for facility upgradation:

i) Expansion of Heavy Fitting Shop: A Contract for CWS Expansion has been

awarded to M/s Lloyd Insulation (India) Ltd, Kolkata. EDC: Aug’2013.

Inauguration of workshop expansion project by GM(Engg)

ii) Enhancing the level of illumination in CWS:

For improvement of illumination within CWS shop Floor ,Electrical Dept has initiated

the for procurement and installation of equipment for enhancement of illumination

vide PR No-1407688 dt 17.02.2013 .Material waiting delivery and installation at site.

iii) Horizontal Hydraulic Press for Fitting Shop:

Procurement of 300Ton Horizontal Hydraulic Press,job in progress.

iv). New 20 Ton EOT overhead Crane: A new 20 Ton EOT Overhead crane is being

commission at Central Workshop.

v) TIG Welding Machine for CWS :

The TIG welding machine has been procured & commissioned at WSS. A team of

Welders and Work shop Engineer is being work out to undertakes the welding jobs of


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the coil tubes repairing of CTUs of WSS of Production Department from August’2013

after expiry of existing contract.

B) Augmentation of 4MGD WTP and river bed survey: Future project include

augmentation of 4MGD WTP and river bed survey for Water Security & Sustainability

of OIL Township for the next 30 years is in initiation stage.

ADOPTION OF STATE-OF-THE- ART TECHNOLOGIES, INNOVATIONS AND

PERFORMANCE OF EXCELLENCE WITH RESULTANT BENEFITS ATTAINED

THERE FROM:

During the year the following new equipment / technology were introduced: 1. Auomatic Iron Removal Filter setups are being installed in Barekuri, Baghjan, Bhekulajan, Balijan and Jorajan.

2. Dynamometer for load testing of engines, has been successfully commissioned

at New ICE Shop during this year. Quality of maintenance works related to

various engines has been immensely improved since the introduction of

Dynamometer.

ACHIEVEMENTS AND RECORDS, BREAKTHROUGH ACHIEVED AND MILESTONES

CROSSED:

Job Achievements:

1. CWS has been accredited ISO 9001:2008 certificate on 09/03/2010.

Recirtification audit duly carried out and Recirtification of the same is being

received from the Accredited authority.Certicate validity:- 08th March’2013 to 7th

March’2014.


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2. CWS has bagged 2nd Prize in the Inter organization Safety Competition as well

as Internal Safety Competition among all Workshops.

3. CWS generated revenue additional revenues by carrying out jobs(Rethreading

of drill pipes and Drill collars of M/s Newso Drilling Services Ltd.).

4. NTU Unit was brought to CWS for cracked main member of chasis.The resting

table of the CTU Assy was modified and placed in the given chasis.The unit

delivered after repairing and working successfully.

5. The cracked chasis of Truck mounted cementing unit of Drilling department

were successfully repaired at Central Workshop with minimum shutdown time

of the equipment.

6. All the plug/socket within CWS shop floor has been replaced with Industrial

Type Electrical devices.

7. This year the ambit of ISO certification for 4 MGD WTP is to be extended to

Integrated Management System with both ISO 9001 and ISO 14001 certification.

Contracts for both certification body as well as consultancy have been

formulated and certification is expected to be completed by May 2013.

8. Since inception, Water supply at Manabhum Base Camp was sourced from a

pond and water supply to Kumchai EPS was sourced from a rivulet Jetu, both of

the sources are polluted due to indiscriminate use by local inhabitants/ oil

contamination. Potable water for Kumchai EPS was transferred from

Manabhum Base Camp every day. OIL had tried several times earlier in vain to

source ground-water in the past by drilling borewell but failed due to gravel-

packed formation of the substructures. This year with the initiative of OIL and in


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collaboration of Public Health Engineering Department, Changlang district,

Arunachal Pradesh Two nos. borewell and pumps were installed at each of the

two locations for sourcing clean and potable water.

9. WSS- Field Engg. Section is actively involved in commissioning of 02 nos. of New

Hot Oil Circulation Units with latest technology during the year.

10. Installation of Solar Powered lighting systems at Nagajan Security Camp, Well – 279 Security Camp and Sabitri Tea Estate Road Intersection for Security Department.

The systems include: (a) At Nagajan Security Camp:

(i) 21 nos LED Based Indoor Luminaries and 09 nos DC Stand fans powered by 10 nos 70 Wp solar modules. (ii) 04 nos Dusk to down auto cut LED based area lighting system powered by 35 Wp SPV module each.

(b) At Well – 279 Security Camp: (i) 08 nos LED Based Indoor Luminaries and 04 nos DC stand Fans powered by 06 nos 70 Wp solar modules. (ii) 03 nos Dusk to down auto cut LED based area lighting system powered by 35 Wp SPV module each.

(c) At Sabitri Tea Estate Road Intersection: (i) 02 nos Dusk to down auto cut LED based area lighting system powered by 35 Wp SPV module each. The above systems are complete with necessary solar charge controllers and auto switch “on-off” (for area lighting systems) facility. NB: The system was designed and procured by Engineers of Field Engg. Department and procured and installed by ICE – F&WI sections.

COST SAVING MEASURES ADOPTED:

1. Replacement of DED Gensets with Gas Engine Driven Gensets at EPS – HJC: Two (02) Nos Diesel Engine Driven generating sets were used for captive power generation at EPS –HJC. Each set was run for 12 hours a day. By doing the replacement of Two (02) Nos Diesel Engine Driven generating sets with Gas Engine Driven Gensets at EPS – HJC following savings has been achieved:


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Both the sets were used for captive power generation at EPS –HJC. Each set was run for 12 hours a day. Approximate daily diesel consumption for running of the two sets = 250 Liters. Thus the replacement the Diesel Engine driven sets with Gas Engine Driven sets has resulted in cost savings to the tune of Rs. 12500/- per day.

2. Installation of Solar Powered lighting systems Well – 279 Security Camp: For lighting of the Well – 279 Security Camp, Diesel Engine driven generating sets of minimum 15 KVA rating was installed. Considering average 08 running hours per day, approximate daily diesel consumption = 30 Liters.

Thus installation of Solar powered lighting system at Well – 279 Security Camp has resulted in cost savings to the tune of Rs. 1500/- per day. Moreover the solar powered systems are environment friendly and needs very less maintenance effort as compared to conventional diesel engine driven generating sets.

ENERGY CONSERVATION MEASURES ADOPTED AND RESULTANT SAVINGS IN

TERMS OF ENERGY AND MONEY:

1. Cost saving in KUMCHAI as a result of installation of Electrical Motor Driven

borewell pumps AT Kumchai EPS for Supply of Water.

Avg. Running/day in Hrs of Diesel Engine driven pump- 01 no = 4Hrs

Avg. Diesel Consumption for Diesel Engine- 01 no (Ruston 6YDA)-01 no/Hr = 8L

Total avg. Diesel Consumption for Diesel Engine -01 no/ Day = 32L

Cost of diesel consumption per day = 32 x Rs. 42 = Rs. 1344

Cost of diesel consumption per annum per pump = Rs.4,90,560

Total Cost saving per annum for water supply pump at Kumchai Water Supply

Station: = Rs.4,90,560


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Mud Plant-7 Total Cost saving per annum for three pumps at three different Mud Plants is 2943360 Rupees. Future Plan towards conservation of energy and utilization of alternate (non-conventional) sources of energy: i) To replace 7 (seven) nos of Diesel Engine Generating sets with Gas Engine

Driven Generating sets ii) Introduction of water turbine in our field on a pilot project basis for electricity

generation. Details of energy saving can be determined only after final project report is obtained

ENVIRONMENTAL PROTECTION AND POLLUTION CONTROL MEASURES

UNDERTAKEN:

Field engineering department took utmost importance in protecting the surrounding

environment and controlling pollution in its all spheres of activities and adopted the

following practices:

• By laying 50 km x 100 mm NB pipelines; excess effluent was successfully transferred

from various drilling locations to nearby effluent pits to avoid pollution.

• Oil trapping of used lube oil from ICE-Shop floor was carried out.

• Installation of Solar Powered lighting systems Well – 279 Security Camp:

For lighting of the Well – 279 Security Camp, Diesel Engine driven generating

sets of minimum 15 KVA rating had to installed and run.

WATER AWARENESS WEEK:

With the initiative of Field Engg. Dept., Oil India Limited observed “WATER

AWARENESS WEEK-2013” (WAW-2013) from 22nd March 2013, which is globally

observed as the World Water Day as per United Nations Resolution. OIL’s endeavor is

highlighted in United Nations Conference on Environment & Development (UNCED)

list. Awareness Drive under WAW 2013 was carried out in FHQ, Digboi, Moran and

Manabhum.


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ACKNOWLEDGEMENT: All achievements of the department have been as a result of the team work, sincere devotion and honest hard work put in by all members of the Field Engineering Team. Guidance from RCE & GM (Engineering), the assistance received from various departments, and support from OIL Management towards fulfilling our objectives are gratefully acknowledged. Field Engineering Department pledges to leave no stone unturned to provide all support that our main processes require in order to realize our vision of making Oil India ‘the fastest growing energy company with the highest profitability’.

(A. K. Nandi) Head- Field Engineering

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