(97f) Optimizing Energy Consumption In Gas Oil Separation Plant Using Lean Six Sigma Methodology

Alqahtani, B. J., Saudi Aramco (Saudi Arabian Oil Company)
Nour Eldin, M. B., Saudi Aramco (Saudi Arabian Oil Company)

An energy assessment was conducted to technically and economically identify energy conservation opportunities in one of the largest Gas Oil Separation Plant (GOSP). The assessment was based on Lean Six Sigma methodology to identify, quantify, and rank potential energy conservation actions.

Six Sigma uses statistical process analysis and control tools to find and address root causes of energy wastes and variation. Lean Six Sigma project follow a methodology composed of five phases each; bear the acronyms DMAIC which stands for Define, Measure, Analyze, Improve and Control phases.

In this approach, the group first defines the project and the plant’s processes to be improved, then measures process performance. Measured data is analyzed and process bottlenecks and problems are identified. After analysis, the group develops an improvement program and determines how to remove defects and minimize the energy consumption. At the end, the team develops mechanisms to track the implementation and the energy savings out of the study’s recommendations.

The assessment team initially identified 24 potential areas of energy saving. Using a process map and cause-and-effect matrix, followed by a traditional cost-benefit analysis, and finally by a detailed engineering analysis, the list was reduced to eight major areas of improvement.

This paper will present the subject energy assessment methodology along with the major recommendations to reduce the power consumption index in Gas Oil Separation Plant that has an average oil and gas production of 270 MBOD and 140 MMSCFD, respectively.