LEAN SIX SIGMA IMPLEMENTATION TO IMPROVE ACID UNLOADING ACTIVITY IN STEAM FLOOD OPERATION FIELD: A CASE STUDY OF WELL SERVICE ACTIVITY - PT. PAS

• Main Author: Pratama Purba, Niko
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/58004
• Institution: Institut Teknologi Bandung

PT. PAS is one of the largest oil producers in Indonesia with average daily oil production 170,000 barrels oil per day in 2020. Since 2016, the company has transformed and shifted its focus to improve operation efficiency and put workover and well service as the top priority to maintain the decline rate of oil production. Acidizing is one of the well service effort routinely conducted and expected to clean the well formation from scale, paraffin, and other debris so the productivity of oil wells could be increased. However, data from last 2 years show that 2-3% of total job annually were experiencing failure during unloading acid from the well. Failure during the unloading process force a WOWS rig to be deployed for continuing the job until complete and this led to additional cost for the rig operation. Besides, the impact of the failure also causes Loss Production Opportunity (LPO) for the company. The company experienced total loss of $52,000 last year. Project team was formed with the objective to find out the root causes of the problem and formulate a fit for purpose solution on this issue. Using Lean Six Sigma methodology and Define-Measure-AnalyzeImprove-Control or known better as DMAIC roadmap, the project team is expected to be able to conduct process improvement and prevent failure that would cause additional cost to the company. In Define Phase, the team conducted feasibility study on the project, determine the boundary and scope of the project, as well as vision of success of the project. In the next phase, Measure Phase, value stream mapping was conducted, parameters and measure system were set and initial data from previous practice were collected. Entering Analyze phase, the team found out two factors that contributed to the failure in the process are low entry fluid and possibility of the upstroke/downstroke process did not function as should be. In Improve Phase, there are two solutions generated for improving the process, utilizing killing line or utilizing WCT unit for killing well. Each of the solution comes with its own plus and minus but in the end after assessment and scoring by the project team, solution to utilize killing line is selected due to its advantage in safety, availability, and efficiency. The improved process was implemented to 18 oil wells in trial period during May-June 2021. There was no failure during this trial and from the data it was also observed that average cycle time of the process is 184 hours/job, which resulting $ 6,625 revenue from accelerated well to be produced. Control phase will be carried out for next 10 months with full implementation for all wells in-scope.