The third project in this series is a Hazardous Waste Incinerator System designed for Reliance Industries’ oil and gas drilling site called KGD6 on the east coast of India at the Bay of Bengal.  The KG-D6 block lies in the Krishna-Godavari basin and has a total reserve of 14,000 bcf of gas and 140 million barrels of oil. The investment in the project is approximately $6bn.  It covers an area of 8,100km² and lies in water depths between 700m (2,297ft) and 1,700m (5,577ft).

Aker Kvaerner was awarded the overall contract for project engineering which included the incinerator package.  Bechtel were the project expeditors for the project.

We were short-listed for the incinerator package along with two other manufacturers. We were pre-qualified by the customer after evaluation by Aker. The waste to be handled was hydrocarbon condensate which had quite a high calorific value along with other hazardous wastes.  Offshore petroleum drilling waste comprises drilling fluids and drill solid cuttings. Drilling fluids consist of remnants of drill mud. Drilling muds comprise base fluid and various solid and liquid additives to allow for a good drilling performance. The major components of drill muds are liquid such as water, oil, or other organic fluid and a weighting material typically bentonite and barite.  As the waste harms the environment, the composition and possible environmental impact of the waste produced from the offshore drilling is hazardous and it has to be disposed of only by incineration.

The incinerator has thus to handle both liquid and solid wastes and has to be fitted with air pollution control equipment, auto loading, PLC control panel for automatic operation. All the electricals, instruments, CEMS and panel have to be explosion proof, suitable for hazardous area Zone 2.  The contract was awarded to us against stiff competition from other manufacturers. What tilted the order in our favour was our track record and the certifications we had.

Time was of prime importance here as the inauguration of the drilling operation was already scheduled and we had to supply and install the system in time for the inauguration. We had to work hard to meet the deadline. From the customer’s side, an expeditor visited us from Bombay every 15 days and not only made sure we fulfilled the commitment regarding the progress of work as per project schedule, but put pressure on us to improve upon the date.

The fabrication of the main system with APC, stack and skid was no problem, but we faced a challenges with regard to the electricals, particularly the control panel. The deliveries quoted were unacceptable. The explosion proof manufacturer in Chennai, Baliga Lighting had another big ongoing project with Reliance, Jamnagar, but they were still accommodating with respect to our requirements. Baliga produced the equipment as per schedule, which was quality-wise very good.

The completion of the work at our shops did not end the project. There were 3 inspecting teams which visited us to do FAT. This included Aker Kvaerner, Bechtel and BVQI.  The inspection was successful and they accepted the system offered and gave us permission to despatch.  Though transport was in Haat’s scope, when the trailers and trucks were loaded and ready to go, Reliance sent their own escorts to accompany the vehicles to the end site.  They ensured there was no transshipment or unnecessary stoppage en route. The equipment reached the site safe and sound.

Our installation and commissioning team went to the site subsequently and completed the work to the customer’s satisfaction.

The system is in operation since the year 2009 and we keep providing service and spares. We are happy and so is the customer that the life of the incinerator meets their requirements.

The specifications of supply in this project were so stringent, that we had to adopt new methods and procedures as required by the client and this is what resulted in a good life and performance for the equipment.