Rajiv Nischal is head of the Institute of Production Engineering and Ocean Technology (IPEOT) at India's Oil and Natural Gas Corporation (ONGC). A chemical engineer from the National Institute of Technology Rourkela with a master’s degree in financial management from the Jamnalal Bajaj Institute of Management Studies, he brings over 36 years of experience across ONGC and ONGC Videsh.
His roles have spanned operations, engineering, planning, project management, and international business, including serving as country manager for ONGC Videsh Myanmar, overseeing $1 billion in assets. He has worked across key ONGC assets and the corporate office, engaging with major stakeholders.
Md Imitaz (MI): Could you please share what makes IPEOT so significant within ONGC’s operational and strategic landscape? In your role, what are some of the key challenges you typically face, and how do you go about tackling them?
Rajiv Nischal (RN): IPEOT was formed by merging IOGPT [Institute of Oil & Gas Production Technology] and IEOT [Institute of Engineering and Ocean Technology] and is ONGC’s multidisciplinary center of excellence supporting onshore, shallow-water, and deepwater operations. With expertise across the entire production chain—from wellbore to consumer supply point—IPEOT focuses on well completions, performance analysis, stimulation, artificial lift, process engineering, flow assurance, field development, offshore structures, and more.
In 2024–2025, IPEOT conducted 365 technical studies (averaging one per day), aiding ONGC work centers in production enhancement, surface facilities optimization, material failure analysis, offshore structural assessments, field development plans, feasibility reports, and compliance studies. Additionally, IPEOT officers contributed to 52 multidisciplinary teams across assets, basins, and services, delivering tailored technical solutions.
These initiatives not only boosted production but also solidified IPEOT’s position as ONGC’s primary innovation hub. The institute earned several prestigious accolades, including the 2025 Golden Peacock Award, 2024 Asian Oil & Gas Award, and three Greentech Environment Awards for emission reduction, eco-friendly product, and innovative technology.
As head of IPEOT, I recognize challenges like translating lab-scale innovations into field-ready solutions. This involves rigorous piloting, diagnostics, specification framing and scaling up. We demonstrated success with polylactic acid-based formulations for water shutoff and single-phase retarded acid for limestone stimulation. Balancing immediate field needs with long-term R&D is achieved through parallel workstreams. We address tech adoption resistance via targeted engagement and combat data fragmentation through centralized digital systems like offshore geotechnical databases and AI-based regulatory tools. Continuous upskilling and collaboration ensure IPEOT drives ONGC’s technological leadership and energy self-reliance.
MI: Given the growing importance of deepwater fields in sustaining future hydrocarbon supply and ensuring energy security, how do you see their role evolving in the broader landscape of exploration and production (E&P)? Do you believe deepwater developments will remain a strategic priority globally? Additionally, how prepared is ONGC in terms of technical readiness, capability development, and institutional expertise to unlock the full potential of its deepwater assets?
RN: As conventional reserves decline, deepwater fields are becoming vital for sustaining global hydrocarbon supply and energy security. With rising demand and technological advancements, deepwater developments remain a strategic priority, especially in regions like Africa, Brazil, the Gulf of Mexico, and India.
In 2024, ONGC achieved a major milestone with the commissioning of Cluster-2A in the KG-DWN-98/2 Block (Eastern Offshore), comprising the M (India’s first deepwater oil field), A, and P fields. Linked to an FPSO [floating production, storage, and offloading vessel] via a complex subsea pipeline network, the project added over 35,000 BOPD and 1.2 MMcf/D of gas to ONGC’s output, showcasing its deepwater capabilities.
Cluster-2A presented flow assurance challenges due to high wax content, long subsea tiebacks, and low seabed temperatures. IPEOT played a key role, providing inputs across field development and flow assurance from concept to commissioning.
The project strengthened ONGC’s deepwater expertise, fostered cross-functional collaboration, and offered experience to younger engineers—preparing them for future projects like Clusters I & III and the Mahanadi Basin.
MI: The oil and gas industry is increasingly adopting green chemistry principles to minimize its environmental impact. Can you describe your experience with green chemical solutions in the oil and gas industry and how you've contributed to reducing environmental impact through their implementation?
RN: As the world moves toward a cleaner energy future, IPEOT embraced green chemistry, rethinking the solvents used in oilfield operations. This journey began as a scientific inquiry and evolved into a mission to replace petroleum-based solvents with safer, sustainable alternatives.
Conventional aromatic hydrocarbon solvents, though effective for wax and asphaltene removal, pose risks due to low flash points, toxicity, and high volatile organic compound emissions. To address these concerns, IPEOT launched a multiphase research initiative by screening literature and candidate compounds to identify green solvent families suitable for field use.
We focused on naturally derived compounds such as terpenes, phenolic lipids, and fatty acid esters sourced from renewable feedstocks and agro-industrial by-products. These solvents exhibit high flash points (>180°C), low vapor pressure, and strong solvency for heavy organics. Laboratory evaluations showed performance on par with or better than traditional solvents while eliminating flammability and toxicity concerns.
Field tests confirmed enhanced flow, reduced dosage, and improved safety. Environmentally, replacing aromatic solvents could cut CO₂-equivalent emissions by over 3,200 MT annually, advancing ONGC’s decarbonization goals.
This led to a modular green solvent platform for upstream applications, symbolizing a shift where performance and sustainability go hand in hand.
MI: In what ways is IPEOT developing simulation models powered with artificial intelligence (AI) and machine learning (ML) to enhance process optimization, predictive maintenance, and real-time decision support in oil and gas operations?
RN: IPEOT is driving ONGC’s digital transformation through advanced AI/ML-powered simulation models focused on process optimization, predictive maintenance, and real-time decision support. A key initiative is the upcoming Production Operation Control Center (POCC), which will integrate intelligent systems for real-time surveillance, anomaly detection, failure forecasting, and production workflow optimization across onshore and offshore assets.
IPEOT is also developing an AI-driven well stimulation adviser that analyzes historical data, reservoir characteristics, and operational constraints to recommend optimal designs, improving efficiency, and reducing costs. Additionally, intelligent tools for designing well stimulation and water shutoff treatments are being created, incorporating rock/fluid interactions and production trends for precise, data-backed decisions.
To enhance sensor reliability offshore, AI-based simulators are being built to detect and correct sensor faults in real-time control systems. An AI-powered pipeline leak detection system, tailored for offshore trunklines, uses pressure, flow, and acoustic data to quickly identify and locate leaks, minimizing environmental risk.
These AI/ML innovations are enhancing operational efficiency, resilience, and decision-making advancing ONGC’s journey toward intelligent, future-ready operations.
MI: With major E&P companies establishing digital command centers for real-time data visualization and operational insights, could you elaborate on ONGC's initiatives toward developing a digital operational control center and the key objectives behind it?
RN: ONGC is undertaking digital transformation with the establishment of its POCC at IPEOT, Panvel, India. Envisioned as the central nervous system of ONGC’s production operations, this center will drive data-based decision-making, boost efficiency, and provide real-time visibility across assets.
The POCC integrates data from ONGC’s fields to enable centralized, real-time monitoring of production parameters, well and equipment performance. It ensures rapid response to anomalies, improves reliability, and enables timely interventions. Powered by AI, ML, and cloud technologies, it supports predictive diagnostics, root-cause analysis, and failure forecasting to minimize downtime and extend asset life.
A core feature is optimization of artificial lift systems through digital twins, automated workflows, and real-time modeling for continuous performance tuning. The POCC also connects with ONGC’s digital ecosystem, including field instrumentation, enterprise resource planning systems, and future automation.
Aligned with ONGC’s Energy Strategy 2040, the POCC enhances operational control, reduces environmental impact, and improves safety via early warning and remote monitoring systems.
MI: Considering that ONGC has been engaged in offshore operations since 1976, a substantial number of its offshore platforms have surpassed their original design life. How does the organization systematically address the challenges related to maintaining structural integrity, ensuring operational safety, and extending the service life of these aging offshore platforms?
RN: ONGC has adopted a structured, multidisciplinary approach to ensure the integrity and safe operation of its aging offshore platforms, with IPEOT serving as the nodal agency for Structural Integrity Assessments and Life Extension Studies (LES).
Periodic underwater inspections, typically every 5 years, provide essential data on platform substructures including jacket members, braces, weld joints, and marine growth. IPEOT’s structural engineering team analyzes this data to assess degradation, corrosion, fatigue, or damage.
For platforms nearing or exceeding their design life, detailed LES are conducted using advanced analyses such as design-level in-place, linear and nonlinear ultimate strength, and deterministic fatigue analysis. These determine structural capacity under extreme loads and estimate remaining fatigue life of critical joints. Based on findings, mitigation measures like load reduction and structural strengthening are recommended.
Once assessments are complete and measures implemented, ONGC secures a fit-for-purpose certificate from an accredited third-party agency, confirming the platform’s safety and operational viability.
This comprehensive process ensures the continued reliability and safety of offshore platforms, reducing operational risks and safeguarding environmental and personnel safety standards.
MI: Could you share specific examples of offshore platforms where significant challenges were encountered during integrity assessment or life-extension studies? How were these challenges addressed and what key learnings emerged in resolving the operational or structural issues?
RN: ONGC has addressed several complex challenges during structural integrity assessments and life-extension studies, especially in mature fields like Mumbai High. A notable case is the NF platform, commissioned in 1978 and crucial to the Mumbai High North (MHN) complex. After the 2005 MHN fire, extensive topside debris and interconnecting bridges to MNW and NA jackets posed major obstacles during underwater inspections. Restricted access, especially on the west and south faces, combined with poor visibility below 40 m and hazardous debris, made traditional diving operations and MSV [multiservice vessel] positioning extremely difficult.
Despite these challenges, ONGC successfully completed the certification of the NF jacket through meticulous planning and collaboration between IPEOT, the inspection team and the MH Asset team. A 3D seabed survey provided detailed debris mapping, enabling safe and targeted underwater inspections.
IPEOT then conducted a comprehensive life-extension study, aiming to extend the platform’s service life to 2030. Using international standards (API RP 2SIM, API RP 2A-WSD, DNV-OS-C101), the study recommended load reduction, member strengthening, and deployment of a structural health monitoring system.
As a result, NF received a fit-for-use certificate, validating its structural integrity. This case showcases ONGC’s expertise and use of advanced technologies to ensure the safety and sustainability of aging offshore assets.
MI: How are you scaling innovation through international collaboration, technology commercialization, and visibility-building efforts?
RN: We are scaling innovation through international collaboration, technology commercialization, and a dynamic knowledge management system (KMS). Our digital, searchable KMS captures and shares institutional knowledge, integrating project data, lessons learned, and technical case studies to foster collaboration and technology adoption.
A live Technology Compendium tracks innovations and global trends, while an AI-powered regulatory database unifies fragmented safety guidelines from OISD [Oil Industry Safety Directorate], OMR [Oil Mines Regulations], PNGRB [Petroleum and Natural Gas Regulatory Board], and CEA [Central Electricity Authority]. An offshore geotechnical database supports deepwater planning, and locally trained large language models ensure secure, accessible regulatory intelligence.
Our strategy emphasizes global partnerships through conferences, joint industry projects, and alliances with technology leaders, accelerating solutions for ultradeepwater and energy transition challenges.
On commercialization, we leverage platforms like I-STEM to showcase capabilities, execute industry R&D projects, and offer specialized training. These initiatives generate revenue and strengthen India’s energy and technology ecosystem.
MI: One of the chemicals recently developed by IPEOT earned the prestigious Golden Peacock Innovative Product/Service Award 2025. Could you elaborate on the development process and impact of this and other innovative chemicals developed by IPEOT and how they are setting new benchmarks in the oil and gas industry?
RN: IPEOT achieved a milestone with the development of the single-phase retarded acid system (SPRAS), winning the Golden Peacock Innovative Product/Service Award 2025 in Dubai. Designed for limestone reservoir stimulation, especially in offshore environments, SPRAS addresses key limitations of traditional acidizing, such as rapid reaction, shallow penetration, and high cost. It integrates retardation chemistry, thermal stability, and environmental compliance, reducing stimulation costs to just 20% of conventional methods.
Though early field trials showed limited success, IPEOT’s diagnostic review identified poor acid placement and excess surfactant. The team refined the formulation, introducing foamed acid with nitrogen and XC polymer. This data-driven re-engineering led to a performance breakthrough yielding 1,151 BLPD, including 601 BOPD and over 11,000 barrels of incremental oil, generating more than $680,000 in revenue with a 2- to 6-day payback.
Selected from 448 global entries, SPRAS is versatile, effective in horizontal/vertical wells and depleted formations, and compatible with standard operations.
