Session: 20-04: Optimization Through Digital Tools

Paper Number: 151671

Maximization of Thermal Development Through Improvement of Heat Recovery Steam Generator Integrated Availability for Heavy Oil Field – an Application of Lean Approach 

1. Objectives/Scope:

Petroleum Development Oman LLC (PDO) is Oman’s premier oil producer and operates several fields at “A”. “A” East and “A” West are located on the eastern flank of the South Oman Salt Basin.

“A” West Steam system is using a saturated steam generated by Once Through Heat Recovery Steam Generator (HRSG). This unit is utilizing the exhaust heat generated by Gas Turbine (GT) to convert the water into steam.

This integrated unit availability plays a key role in sustainability of supply steam for ultimate oil recovery.

This has an impact of losing of steam generation (183k Ton annually) which is equivalent to (30k m3 annually). In addition, there is allocated higher GHG emissions from GT side with respect to steam produced (50k TonCo2e/yr).

By improvement this process, it will help to contribute to organization goals in term of production increase, deferment reduction, GHG reduction and cost reduction.

 

2. Methods, Procedures, Process:

 

In This project, different approaches and process had been used such as lean practice including process mapping, root cause analysis, fishbone.

In addition, Energy efficiency Surveillance Tool (EEST), exception-based Surveillance Tool (EBS) and Managing Threats and Opportunities (MTO) Tool were used for this project.

 

3. Results, Observations, Conclusions:

This paper has led to significant economic benefits of cost savings around $14mln/year by increasing the unit availability and ability to produce the steam for ultimate oil recovery.

Detailed value Stream Map (VSM) was built based on the As-Is process & then all possible cause identified using fishbone resulted in finding three main causes as below:

1) Delay in rectifying / attending fault instruments:

- long process for material repair and supply back to site even in urgent cases

2)   Faulty instrument signal

- No PM replacement of key cards for ultrasonic meters

- Existing pass flow control not tackling process medium condition

3)  Communication issues between GT and HRSG systems

- lack of interface documents and troubleshooting SOP between GT and HRSG

As an outcome, the Availability was improved and reached by average of 95% by improving the processes and minimize downtime.

 

4. Realized Benefits:

Level 2: Cost Avoidance of more than 14 $mln through oil securing

Level 2: (FTE) Savings = 2.1

Level 3: Emission to steam ratio improvement KPI from 0.087 to 0.083TCo2e/Ton steam

 

5. Novel/Additive Information:

Lean and availability Tools were proven to be a strong enabler to mature the opportunities and leading to improvements in Oil & Gas industry. As key outcome of this processes, standardization and sustainability are key to ensure continuity of the outcomes. Leader Standard Work sheet for various leaders Gemba walks & Visual management used to track the performance and identify any deviations to process.

Presenting Author: Mohamed Al-Fazari Petroleum Development Oman LLC

Presenting Author Biography: 13+ years’ experience in oil & Gas. Wide experience in process engineering covering concept, engineering, commissioning, and operation (including Thermal Operation).

6 years’ Experience in Gas Processing covering Gas conditioning units and stabilization process.
5 years’ Experience in Thermal operation & process looking after production & steam system optimization.

In addition, wide experience in water treatment and water management for process water and boiler feed water.

Graduated from Sultan Qaboos University (bachelor degree on chemical and process engineering) on 2011

Authors:

Mohamed Al-Fazari Petroleum Development Oman LLC