Boosting oil production profits: A multi-method approach to streamline ESP assembly
Article Sidebar
Main Article Content
Abstract
The Ecuadorian oil industry relies heavily on Electric Submersible Pumps (ESP) to extract crude oil from underground reservoirs. Streamlining ESP assembly processes is crucial for maximizing production efficiency and reducing costs. This study delves into optimizing ESP assembly procedures, employing a multi-method approach that integrates time-motion analysis, process mapping, and economic evaluations. This research meticulously identifies areas for improvement within the assembly process, pinpointing bottlenecks and inefficiencies. Subsequently, a comprehensive set of solutions is implemented, encompassing standardized procedures, technological advancements, and enhanced worker training. The proposed system revolutionizes ESP assembly efficiency, particularly in critical stages like material preparation, order initiation, and waiting times. As a result of these optimizations, the average ESP assembly time is reduced by a remarkable 10%, translating into significant cost savings and enhanced production capacity. Moreover, the implemented solutions yield a positive return on investment, demonstrating the financial viability of these optimization efforts. The study's findings underscore the substantial economic benefits that can be achieved by optimizing ESP assembly processes in the Ecuadorian oil industry. While the research focuses on the Ecuadorian context, the methodology and findings offer valuable insights for optimizing ESP assembly in other oil-producing regions.
Downloads
Article Details
This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.
1. Derechos de autor
Las obras que se publican en 593 Digital Publisher CEIT están sujetas a los siguientes términos:
1.1. 593 Digital Publisher CEIT, conserva los derechos patrimoniales (copyright) de las obras publicadas, favorece y permite la reutilización de las mismas bajo la licencia Licencia Creative Commons 4.0 de Reconocimiento-NoComercial-CompartirIgual 4.0, por lo cual se pueden copiar, usar, difundir, transmitir y exponer públicamente, siempre que:
1.1.a. Se cite la autoría y fuente original de su publicación (revista, editorial, URL).
1.1.b. No se usen para fines comerciales u onerosos.
1.1.c. Se mencione la existencia y especificaciones de esta licencia de uso.
Enrique Mauricio Barreno-Avila , Universidad Técnica de Manabí - Ecuador
https://orcid.org/0000-0001-5221-7664
Enrique holds a Master's in Petroleum Engineering from Curtin University, Australia, and a Master's in Applied Linguistics from the University of the Atlantic, Spain, complemented by a Mechanical Engineering degree from the Technical University of Ambato, Ecuador. He teaches Entrepreneurship, Management, and English courses, and has published over 20 research articles in areas including Materials, Production, and Occupational Health. Contact him at ebarreno3907@utm.edu.ec for inquiries or collaboration.
Grether Lucía Real-Pérez , Universidad Técnica de Manabí - Ecuador
https://orcid.org/0000-0003-4792-6217
PhD in Technical Sciences, Master in Business Administration with Mention in Production and Services Management and Master in Occupational Risk Prevention, UNIR, Spain. Industrial engineering. Professor of the MBA at the Pontificia Universidad Católica del Ecuador, Manabí Campus and full professor of Industrial Engineering, Faculty of Mathematics, Physics and Chemistry of the Technical University of Manabí, UTM, Ecuador. He has published 5 books related to his training and more than 20 articles. Coordinator of the scientific research group: Productivity, Safety, Health and Environment (PSSA).
José Ricardo Nuñez-Alvarez , Universidad de la Costa - Colombia
http://orcid.org/0000-0002-6607-7305
José Ricardo Nuñez-Álvarez 
received a B.Eng. in Electrical Engineering from the Universidad de Oriente, Santiago de Cuba, Cuba, in 1994 and an M.S. degree in Automatic Engineering at the Universidad de Oriente, Santiago de Cuba, Cuba, in 2014. Currently, he is a full-time professor of the Electrical Engineering Career attached to the Department of Energy at the Universidad de la Costa (CUC), Barranquilla, Colombia. His research interests include renewable energy, power quality, power generation, power grids, power supply quality, power conversion, power transmission reliability, power system stability, power transmission lines, power transmission planning, power transmission protection, load flow control, and protection of electrical systems. He can be contacted by email: jnunez22@cuc.edu.co
References
Al-Jasmi, A., Nasr, H., Goel, H. K., Moricca, G., Carvajal, G. A., Dhar, J., Querales, M., Villamizar, M. A., Cullick, A. S., Rodriguez, J. A., Velasquez, G., Yong, Z., Bermudez, F., & Khain, J. (2013, October 28). ESP “Smart Flow” Integrates Quality and Control Data for Diagnostics and Optimization in Real Time (Part of KwIDF Project). SPE Middle East Intelligent Energy Conference and Exhibition, Manama, Bahrain,. https://doi.org/10.2118/167394-MS
Bauer, C. (2020). Multi-Method Evaluation: Leveraging Multiple Methods to Answer What You Were Looking For. Proceedings of the 2020 Conference on Human Information Interaction and Retrieval, 472–474. https://doi.org/10.1145/3343413.3378015
Benanav, A. (2020). Automation and the Future of Work. Verso Books.
Dachanuwattana, S., Ratanatanyong, S., Wasanapradit, T., Vimolsubsin, P., & Kulchanyavivat, S. (2022, March 18). The Deployment of Deep Learning Models for Performance Optimization and Failure Prevention of Electric Submersible Pumps. Offshore Technology Conference Asia, Kuala Lumpur, Malaysia. https://doi.org/10.4043/31612-MS
Dorling, D. (2020). Slowdown: The End of the Great Acceleration—and Why It’s Good for the Planet, the Economy, and Our Lives. Yale University Press.
Foster, S. T., & Gardner, J. W. (2022). Managing Quality: Integrating the Supply Chain. John Wiley & Sons.
Guzman, R., Hashmi, Z. F. A., Ilyasov, R., Sonbaty, T. M. E., Gupta, S., Aguilar, H., Martins, A., Ofodile, O., & Cardozo Padron, J. (2022). ESP Cable Deployment has Induced a New Paradigm in UAE to Turn the ESP Business into Rigless Operation, Presenting a Cost Efficient and Faster Application. https://dx.doi.org/10.2118/216434-MS
Halawa, F., Chalil Madathil, S., & Khasawneh, M. T. (2021). Integrated framework of process mining and simulation–optimization for pod structured clinical layout design. Expert Systems with Applications, 185, 115696. https://doi.org/10.1016/j.eswa.2021.115696
He, Y., He, Q., Fang, S., & Liu, Y. (2024). Precise Wireless Camera Localization Leveraging Traffic-Aided Spatial Analysis. IEEE Transactions on Mobile Computing, 23(6), 7256–7269. IEEE Transactions on Mobile Computing. https://doi.org/10.1109/TMC.2023.3333272
Ivanhoe Ivanhoe & Bambang Sumali. (2023). Effect Of Idle Time And Berthing Time On Loading Productivity In Surabaya Container Terminal | Ivanhoe | Proceeding Of International Conference On Education, Society And Humanity. Proceeding Of International Conference On Education, Society And Humanity, 1. https://ejournal.unuja.ac.id/index.php/icesh/article/view/5647
Korkmaz, İ. H., Alsu, E., Özceylan, E., & Weber, G.-W. (2020). Job analysis and time study in logistic activities: A case study in packing and loading processes. Central European Journal of Operations Research, 28(2), 733–760. https://doi.org/10.1007/s10100-019-00624-1
Krzywdzinski, Martin, Pfeiffer, Sabine, Evers, Maren, & Gerber, Christine. (2022). Measuring work and workers: Wearables and digital assistance systems in manufacturing and logistics. https://www.ssoar.info/ssoar/handle/document/83066
Lande, T. (2023). Unlocking Product Lifecycle Management Potential: A Self-Assessment framework for maturity. : A case study on Tetra Pak, Sweden. https://urn.kb.se/resolve?urn=urn:nbn:se:uu:diva-506228
Lim, J. (2020). Oil Rig and Superbarge Floating Settlements. Springer Nature.
Marcel Panzer & Benedict Bender. (2023). Full article: Deep reinforcement learning in production systems: A systematic literature review. https://www.tandfonline.com/doi/full/10.1080/00207543.2021.1973138
Mohamed, M., Ramasamy Thangavel, A., Huttunen, A., Eskola, M., Niemela, M., & Chernikov, V. (2022). Enhancing the Performance of the PMM for ESP and PCP Applications with the VSD Technology of Submersible Motor Control and Direct Torque Control Respectively. https://dx.doi.org/10.2118/206961-MS
Montes Vega, K. S., Carrillo, R., Baltazar, R., & Barreno Avila, E. (2021). Relación entre factores de riesgo psicosocial y calidad de vida en el trabajo en empleados de una Empresa de Servicios Petroleros. 4, 87.
Montgomery, D. C. (2019). Introduction to Statistical Quality Control. John Wiley & Sons.
Natan Augusto Vieira Bulgarelli, Jorge Luiz Biazussi, & William Monte Verde. (2021, February). Experimental investigation on the performance of Electrical Submersible Pump (ESP) operating with unstable water/oil emulsions—ScienceDirect. https://www.sciencedirect.com/science/article/pii/S0920410520309566
Ncube, L. K., Ude, A. U., Ogunmuyiwa, E. N., Zulkifli, R., & Beas, I. N. (2020). Environmental Impact of Food Packaging Materials: A Review of Contemporary Development from Conventional Plastics to Polylactic Acid Based Materials. Materials, 13(21), Article 21. https://doi.org/10.3390/ma13214994
Parasuraman, R., Sheridan, T. B., & Wickens, C. D. (2000). A model for types and levels of human interaction with automation. IEEE Transactions on Systems, Man, and Cybernetics - Part A: Systems and Humans, 30(3), 286–297. IEEE Transactions on Systems, Man, and Cybernetics - Part A: Systems and Humans. https://doi.org/10.1109/3468.844354
Pastre, L. F., & Fastovets, A. (2017, October 16). The Evolution of ESP Technology in the North Sea: A Reliability Study Based on Historical Data and Survival Analysis. SPE Russian Petroleum Technology Conference. https://doi.org/10.2118/187735-MS
Pilati, F., Faccio, M., Gamberi, M., & Regattieri, A. (2020). Learning manual assembly through real-time motion capture for operator training with augmented reality. Procedia Manufacturing, 45, 189–195. https://doi.org/10.1016/j.promfg.2020.04.093
Rhiannon Tudor Edwards & Catherine Louise Lawrence. (2021). ‘What You See is All There is’: The Importance of Heuristics in Cost-Benefit Analysis (CBA) and Social Return on Investment (SROI) in the Evaluation of Public Health Interventions | Applied Health Economics and Health Policy. https://link.springer.com/article/10.1007/s40258-021-00653-5
Schoenberg, S., & Dressler, F. (2023). Reducing Waiting Times at Charging Stations With Adaptive Electric Vehicle Route Planning. IEEE Transactions on Intelligent Vehicles, 8(1), 95–107. IEEE Transactions on Intelligent Vehicles. https://doi.org/10.1109/TIV.2022.3140894
Serrano-Ruiz, J. C., Mula, J., & Poler, R. (2021). Smart manufacturing scheduling: A literature review. Journal of Manufacturing Systems, 61, 265–287. https://doi.org/10.1016/j.jmsy.2021.09.011
Sharma, M. G., & Kumar, S. (2024). Probing frugal innovation from the quality lens. The TQM Journal, ahead-of-print(ahead-of-print). https://doi.org/10.1108/TQM-06-2023-0188
Sindi, W., Fruhwirth, R., Gamsjäger, E., & Hofstätter, H. (2023). Production Optimization Using Integrated Modelling and ESP Survival Analysis Based on Historical Data and Machine Learning. https://dx.doi.org/10.2118/216990-MS
Spagnolo, S., Pignotti, E., Scarso, M., Cappuccio, P., Pilone, S., Valente, A., Gonzalez Zamora, M., & Ciavarro, L. (2022). New Integrated Approach to ESP Management—Successful Strategy to Optimize Well Production and ESP Run Life. SPE-209740-MS. https://doi.org/10.2118/209740-MS
Suhaimin, F., Oritola, N., Fang, B. J., Cheong, H. K., & Chan, Y. K. (2023). Wireline Retrievable ESP Deployment: Observation, Challenges and Intervention. https://dx.doi.org/10.2118/203784-MS
Tortorella, G. L., Fogliatto, F. S., Cauchick-Miguel, P. A., Kurnia, S., & Jurburg, D. (2021). Integration of Industry 4.0 technologies into Total Productive Maintenance practices. International Journal of Production Economics, 240, 108224. https://doi.org/10.1016/j.ijpe.2021.108224
Turner, H. C., Hori, Y., Revill, P., Rattanavipapong, W., Arai, K., Nonvignon, J., Jit, M., & Teerawattananon, Y. (2023). Analyses of the return on investment of public health interventions: A scoping review and recommendations for future studies. BMJ Global Health, 8(8), e012798. https://doi.org/10.1136/bmjgh-2023-012798
Xiang, Z. T., & Chin, J. F. (2021). Implementing total productive maintenance in a manufacturing small or medium-sized enterprise. Journal of Industrial Engineering and Management (JIEM), 14(2), 152–175. https://doi.org/10.3926/jiem.3286