EVALUATION AND PROPOSE THE IMPROVEMENT OF ELECTRIC SUBMERSIBLE PUMP (ESP) OPERATION AT PT PEP USING SIX SIGMA DMAIC FRAMEWORK

• Main Author: Irfan
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/79081
• Institution: Institut Teknologi Bandung

The oil production target as a key performance indicator (KPI) of the ABC Field was not achieved in the last 5 years. It was because of the natural decline of the existing oil production cannot be maintained well. Decreased in production from the Electric Submersible Pump (ESP) wells was contributed significantly to the not achieve in the existing oil production, which resulted in Loss Production Opportunity (LPO) 235,330 barrels of oil. The LPO occurred because the ESP often has problems. The objective of this final project is to conduct an evaluation to find the root causes of the frequent damage of the ESP, and propose the best solution to improve the ESP performance in order to eliminate or minimize the losses of the Company. The research utilizes the Six Sigma DMAIC framework which has been widely used and has been proven to improve operational performance in various business sectors. The improvement procedure is carried out by following the phases of Define, Measure, Analyze, Improve, Control. The best alternative solution determined using the Analytical Hierarchy Process (AHP) method. The evaluation results shows that there are 3 subsurface components that are often experiencing damaged, namely the pump, motor, and downhole cable, which caused by overcurrent. The ESP run life has been measured to evaluate the performance of ESP operating process. The average ESP run life is 201 days, with 134 days of standard deviation. The minimum run life should be 120 days. The average value is already above minimum limit, but there are still 39% below the limit. It shows by the capability index (Cpk) is 0.19, which indicated that the process does not meet the specification, because there is still the ESP operating below minimum target. The sigma level of the process is 2.11, which can be categorized as non-competitive. A cause-and-effect analysis has been carried out to identify the potential root causes. A risk analysis also has been done to determine the risks and impacts that result in low ESP run life. The result of analysis is high gas produced from the wellbore is the main root cause of low ESP run life. High gas production is at risk of causing the pump failure, gas lock, overcurrent, and motor failure. The best alternative solution has been determined using Analytic Hierarchy Process (AHP) method, which resulted that using a Tapered Pump is the best solution to overcome low ESP run life in the ABC Field. The Tapered Pump was chosen by considering cost, safety, production sustainability, deliverability, and facility availability. To ensure that the improvement can be implemented properly, several things need to be carried out, namely: data acquisition, material planning, rig allocation, and coordination meeting. Cost and benefit analysis has been done to identify the benefits of using a Tapered Pump. The Tapered Pump can extend the ESP run life, and provide the revenue to cost ratio is 2.14, which means that the revenue earned is twice the costs incurred, and a benefit of USD 2,683,487. The improvement using a Tapered Pump can prevent the loss and increase the revenue of the Company.