Operational Excellence

Bonga FPSO: Shell CEO Award for Excellence

Shell Nigeria BONGA FPSO, Nigeria
May 2007 to August 2010
220k bbl/d
Production Capacity
95%+
Plant Availability
Zero
Safety Incidents
Zero
Operational Spills

The Challenge

First deep offshore FPSO (over 1,000m depth) in Shell with no local competency available. Required establishing world class operations and safety standards while developing local capability.

Strategic Solution

1

Developed, operationalized and regularly updated installation HSSE case

2

Reviewed Major Accident hazard barriers with individual accountable persons to confirm adequacy and ownership

3

Participated in selection, recruitment and performance appraisal of offshore personnel with training and mentoring

4

Prepared comprehensive operating manuals including procedures, work permit system, safety management, and emergency procedures

5

Delivered business results with zero incidents and no operational spills

6

Maintained flare limits of 0.5mmscf/d, effluent limits of 30ppm, water flood volume of over 250kbbl/d

7

Achieved plant availability of above 95% with full compliance to Asset Integrity targets

8

Ensured hydrates prevention with applicable inhibitors and operational practices for deep offshore operations

9

Implemented strict Permit to Work system with continuous effectiveness monitoring

10

Mentored and developed next generation of offshore leaders

Measurable Results

Recipient of Shell CEO Award for best production and HSSE performance in the group

Achieved full compliance to group Asset Integrity standard

Successfully ramped up 220k bbl/d FPSO to full capacity within 72 hours ahead of schedule after first statutory shutdown

Achieved Calculative status in Maintenance and Integrity Assurance standard, among first top seven assets in Shell group

Achieved EFFECTIVE status after external assessment by group Operations Excellence auditors

Zero operational spills and zero incidents throughout tenure

Consistently delivered agreed oil production targets with above 95% plant availability

Overall Impact

Shell CEO Award with zero incidents and industry leading performance on first deep offshore FPSO

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