Driving Superior Performance in Brazilian Pre-Salt - The Challenges, Solutions and Achievements of Shell and Providers in Exploratory Pre-Salt Wells in Brazil

Abstract

The Brazilian Pre-Salt has gained importance as an essential world-class province given its prolific production and thanks to its many challenges, it has incentivized the market to look for better ways to faces these technical challenges safely. This article aims to describe the main challenges faced by Shell and Constellation as well as the approach adopted to improve the operations’ safety and reduce drilling time, significantly reducing the drilling costs in an exploratory campaign in the Brazilian Pre-Salt. The campaign was based on the buildup of a partnership between the drilling contractor, operator and the main services provider, Halliburton, creating a transparent and collaborative environment, which improved all parties’ ownership and accountability. The application of many processes and techniques such as Step Seven, Stop Work Authority and Design of Work improved safety and efficiency. A precise equipment selection, detailed planning and careful execution with disciplined application of a learning mindset were also paramount to drilling performance. Four pre-salt wells were drilled in the campaign at Sul de Gato de Mato (2 wells), Alto de Cabo Frio and Saturno prospects with all of them qualifying in terms of drilling time as best in class (BIC), i.e., within the top 5% percentile. In 2019, the GdM3 well was the fastest delivery of a pre-salt well out of the 250+ wells in the region. The well GdM4 drilled in 2020 as part of the same campaign broke the previous record by seven days, being the fastest pre-salt well ever drilled with its 18 dry hole days mark. The main reason associated with the campaign´s success was the utilization of the DID-PDCA methodology, which promoted the integration of all the workforce in a cycle towards continuous improvement by: (i) carefully selecting the equipment and experienced service providers, (ii) generating detailed plans of the drilling activity and engaging all those involved in the delivery, (iii) establishing and applying a HSE strategy for safety culture enhanced and (iv) constantly monitoring of performance and discussing the next steps. Along this article a summary of well layout, the drilling phase duration, some of the key performance improvement initiatives as well as how they were generated will be shared.