STATISTICAL production operator has many roles and responsibilities during

 

STATISTICAL
QUALITY CONTROL

CASE STUDY

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ON

Marmul Production
and Production Operator

 

Ibrahim Mohammed Masoud Al-Rajhi

 

930-15PT

 

PE 3CW3

 

Fall Semester, 2017-18

 

31- December-2017

 

 

 

 

 

 

                                               
Teacher:
Muhammad Javed

 

Introduction:

Petroleum
Development Oman has discovered and. put into production more. than 74 oil fields in the desert. interior of Oman, where
the company’s concession area encompasses about two thirds of the land area of
Oman. The Marmul Main Production Station (MMPS) is located in the south of
Oman, approximately 800 kilometers south of Muscat, and 60 kilometers inland.

The
primary function of Marmul Main Production Station (MMPS) is to dry the crude
oil received from the nearby Marmul Gathering Stations and from other connected
fields. Marmul Main Production Station separates gas and water from the oil.
The produced water is treated prior to disposal. The Marmul Main Production
Station teams are divided in two groups or two shifts, one shift is on duty 15
days and other shift is in rest days 13days. The work time in Marmul Main
Production Station (MMPS) started at 6:00am and finished at 18:00Pm. During
working hours Production Operator contact with many people from different
departments likes (Instrumentation maintenance department, commissioning and
start-up department, Electrical maintenance department, Pipeline maintenance
department, Mechanical maintenance, Rotating equipment maintenance, Static
equipment maintenance). All these people work with Production Operator to help
operator to keep station running with high efficiency, also to ensure that the
station is in safe manner. The Production Operator also work with contractor
people whose have different skill and knowledge, therefore the operator needs
to be very conversant in communication dealing with all people with different
levels of skills and knowledge.

Production Operator Roles:

The
production operator starts the work at 6:00am and finishes it at 18:00pm during
15 days duty. The operator is also responsible to attend the duty in night if
any process upset requires urgent actions. Normally, production operator at 18:00pm
handover the station to CCR operator (Central Control Room Operator) this
person will take the control of station full night. But if some things happen
in station during this time the CCR operator will call out the production
operator to go to the station and take action to normalize the station. The
production operator has 15 days duty and 13 days rest, so if there is any
public holiday during duty days the company provides extra payment (premium)
for operator allowance for holiday depends on group salary of operator. The
purpose of production operator job is to operate the total integrated
production system, ensuring that production and environmental targets are
realized in a safe and efficient manner whilst maintaining operational
integrity of the assets. Also the production operator has many roles and
responsibilities during working days should follow them.

Ensure
that all production.
assets are operated in a safe, and efficient manner, in line with agreed. plant operating
philosophies, and in line with.
current Production Procedures and practices.Take
effective..action
to control emergencies and contain hazards. within area of responsibility.Execute
all production operations according to schedule/plan.Keep
relevant documentation in the station up. to date.
and readily available for use.Log
all relevant data relating to the production. of Hydrocarbons- for entry into the
Production.
Management System.Report
to senior operator on daily activities, work progress, facility Integrity and
lock valve register.Interface
with Maintenance department.
staff to coordinate breakdown and routine maintenance. work in facilities and plants- to, ensure
minimum deferment of production.Maintain
a high level of safety awareness and standards in all daily duties and tasks
and guide the subordinate staff and contractors’ safe working practices.Ensure
HSE. ( Health
Safety and Environment), and PTW (Permit To Work) system are followed before
starting a job, ensure proper use of tools and PPE. ( Personal Protective Equipment), conduct
regular site.
visits, advice co-workers on potential hazards, check safety. equipment, notify
management of unsafe working conditions, report HSE incidents, actively. participate in HSE
meetings and tool box talks.

Interaction with QC staff:

For quality control and assurance every day during working hours
Lab Technician comes to station and take sample from oil line and water line of
tanks outlet after separation process completed. The Technician takes these
samples to lab to check the quality of oil, by seeing how much percentage of
water present in oil. Laboratory staff 
use OIW (Oil in Water) analyzer to check the quality of water by seeing
how much percentage of oil present in water. The staff uses oil viscometers to
get the correct results of oil viscosity. The Lab Technician prepare one report
about the result which finding it during analyzing the sample. Then the
Technician sands this report to the Production Operator in Marmul Main
Production Station. The production operator will call the Lab Technician to
discuss the results against the standard quality norms. Operator and lab
technician also discuss the actions required if any, e.g. to change the
chemical injection rate for different chemical. In case required to increase
chemical injection rate the production operator will inform the Production
Supervisor about the situation, so the Production Supervisor will call Process
Engineer to finalize the chemical rate. Not only there is fluid quality check,
but also there is quality check for all equipment and pipes inside the Marmul
Main Production Station. This job is carried out by Conditioning Monitoring
Team. The team checks the quality of equipment and pipes by using SKF micro log
analyzer. The things which are going to check it in rotating equipment are
vibration, temperature and pressure. The condition monitoring team uses the
instruments like Infrared and Contact thermometer, On the other hand, team are
going to check corrosion and wall thickness for pipes and static equipments
using ultrasonic thickness gauges. After the Conditioning Monitoring team
complete the job, the Production Operator site with team to discuss the status
of all equipment and pipes inside station, whether everything is normal and the
equipments are safe to keep them running or the team find something which is
abnormal and required from Operator to take action on it. This type of job is
planned for every six months.

Tools and Software used by Production operator:

The Production Operator every day morning, before start any job
inside station, the Operator do something called SOSO (Start Of Shift
Orientation) during this rotation inside station the Operator use one tool
called gas tester and checks hydrocarbon gas, toxic gas and oxygen. During SOSO
the Operator confirm the station is safe to work and there are no leaks on it.
The Production Operator use two type of software, one is Microsoft Office like
(Word, Excel, Power point and Outlook) and second software is DCS (Distributed
Control System). DCS is a flexible and powerful integrated control system that
provides data acquisition, advanced process control and the continuous data
logging capabilities. There are different suppliers supply DCS in PDO like
Honeywell, Yokogawa, Foxboro and Emerson; Delta-V. The Production Operator
should get training on these types of DCS before start work as control room
operator. The company provide courses for operator about DCS to be aware about
this system.

Important data:

Every day at 10:00am Production Operator prepares daily production
report by using Microsoft office Excel. Operator collects the daily figures
from DCS system and logs in to the Daily production report. The production and
maintenance data is integrated using very famous software called SAP (Systems,
Applications and Product). These below data shows how much Marmul Main
Production Station (MMPS) produced of oil and water in October 2017, which is
recorded by Production Operator. The production supervisor has granted
permission to use the data for study.

 

 

 

 

Dates

Oil Produced
in M3

Water
Produced in M3

1-Oct-2017

16414

96309

2-Oct-2017

16778

95639

3-Oct-2017

16119

96807

4-Oct-2017

16386

96246

5-Oct-2017

16987

86958

6-Oct-2017

16407

91418

7-Oct-2017

16854

94087

8-Oct-2017

16665

93128

9-Oct-2017

17185

95144

10-Oct-2017

16182

95112

11-Oct-2017

16839

93037

12-Oct-2017

16754

95373

13-Oct-2017

16580

96657

14-Oct-2017

16378

98298

15-Oct-2017

16170

98119

16-Oct-2017

16498

96707

17-Oct-2017

17058

96225

18-Oct-2017

16968

95964

19-Oct-2017

16471

95211

20-Oct-2017

16684

96391

21-Oct-2017

16567

97053

22-Oct-2017

16734

96270

23-Oct-2017

16577

96045

24-Oct-2017

14017

96895

25-Oct-2017

16045

97694

26-Oct-2017

16377

97256

27-Oct-2017

16589

96236

28-Oct-2017

17380

97606

29-Oct-2017

17230

96968

30-Oct-2017

17327

96835

31-Oct-2017

17211

94132

 

Objective for the Case study:

“The objective of the case study is to identify and optimize the
Production operator job role. To improve the oil production and achieve the
Monthly target avoiding any upsets of quality parameters. To define clear
actions using current data and statistic.”