Publications

Sumatra Light Operations (SLO) South Gathering Station (Minas and PetKo) have been facing challenges to recover oil from injected water. Outgoing water from wash tank had oil content around 150 ppm on average. From outgoing of clarifier tank was around 60 ppm, and after surge tank till being injected the oil content was around 25 ppm. Total amount of water injected in SLO South was around 6.5 - 7 MMBWPD. Though oil content was only a few ppm, with such a huge volume of water, the barrel of oils lost per day were not inconsequential. Oil content of injected water must be a concern for business and process sustainability, especially for Water Injection Pump reliability and reservoir performance plugging issue. The business objective is to reduce oil content in water produced for injection, in order to have better injection performance and increase oil production by improving oil-water separation through Lean Sigma method. The improvements include additional chemical usage and optimization of chemical injection point in Gathering Station. However, recommendation for chemical additives from first Lean Sigma effort has affected previous chemical contract, because using additional chemicals increases expense, reducing financial benefit and affects sustainability of chemical contract. To address this issue, additional Lean Sigma analysis has been done to minimize the additional cost of chemicals by adjusting the chemical contract terms. By applying these two Lean Sigma initiatives, CPI has succeeded in recovering additional 30 BOPD (on average) by reducing oil content in injection water from average 25 ppm to 15 ppm leading to increased revenue generation in Minas and Petapahan – Kotabatak Operations without disrupting routine operations and while maintaining reliability of assets.