STATISTICAL
QUALITY CONTROL
CASE STUDY
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.”
