Innovative Approach Ensuring Continuous Improvement in Well Design and Operations Based on Performance Tracking, Lessons Learned and Implementation of New Technologies, Pushing the Technical Limit to Reduce Costs and Risks

Abstract

Driving efficiency to ensure cost and risk reduction in well operations is paramount for any operating company; to achieve this, the main objective was to implement a continuous improvement process that measures performance to then improve it, acquiring lessons learned and finally implement new technologies to reduce non-productive time, invisible loss time and push the technical limit to the limit. The first step was to measure the current performance to determine average and best references to compare against. The drilling operations and engineering teams defined KPIs for each well type and respective sections and activities involving all levels of the organization including every individual, ensuring effective communication inclusive of Rig Crew and Service Providers. The initial KPIs were defined, discussed, validated and agreed by both operations and engineering management, all engineers were informed and challenged to measure their performance against KPIs. Once new records were achieved, a workflow to document best practices initiated, once identified, validated and documented, becoming the new standards. Similarly, once average performance was not achieved, a ‘Lessons Learned’ workflow was initiated. Aiming to get the team engaged a communication protocol of the Highlights and Lowlights was put in place, including recognition during operations meeting and emails. The primary results of the deployment of this initiative include the delivery of a 10% additional well count compared to the initial year's plan. An overall improvement of the overall Drilling and Completion Performance was also noted. An important improvement of the overall Rate of Penetration (ROP) was observed, as one of the key performance indicators. It was also notice a considerable reduction of the Flat time. New practices for losses mitigation in hazardous areas were stablished. The lower completion design was enhanced. The upper completion design and utilize Dual Hydraulic Packer in Oil producer well was optimized. Finally, the 1st Maximum Reservoir Contact Well was completed for two of the three Fields in the Team. The added value achieved by the implementation of these innovative practices includes the implementation of the KPI Gauges as a visual instrument to be used on daily operations meeting by the engineers and management, to quickly and effectively understand performance and improvement in multiple dimensions. Additionally, the implementation of a continuous improvement mind-set, focus in introducing changes gradually instead of radically to ensure a soft and solid adoption embraced by all team members. Finally, the improvement of the office-field communications, including a sense of ownership and achievement for each goal to achieve and record to break, to the point that every colleague involved in a specific operation, independently of their organization (Operator, Contractor or Service Company) is equally committed and engaged.