Contextual Failure Analysis Improves Reliability While Pushing the Envelope of Extended Reach Wells in a Giant Brown Field, UAE

The current combination of increasingly complex wellbores and tightening budgets forces operators to do more with less and find new ways to expand the drilling envelop. Often this pushes the parameters to the limit in order to achieve faster penetration rates. Operating at the limit or beyond impacts equipment reliability and project cost. A thorough failure analysis of the root cause(s) of every incident can help identify and address areas that need improvement. Identifying a cause fosters improvement while it simultaneously pushes the boundaries so the profitability of mature assets can be maximized. Typical failure analysis attempts to determine the cause of a failure and establish corrective actions to prevent reoccurrence. In a large extended reach drilling project targeting a mature field, the approach to a single failure was expanded and projected in a proactive manner to anticipate the impact of current failure modes in future more challenging scenarios. This innovative method combines the classic failure analysis approach with a comparative approach designed to identify and classify each factor that contributed to the failure. This information is then compiled into a dynamic predictive risk matrix to improve the planning. This method, thanks to the contextualization of individual failures and the multi-facet comparative analysis, revealed a pattern between reliability trends and environmental challenges. The pattern was correlated with the increased drilling difficulty over the lifetime of the project, and suggested that the long-established practices had to be revised to overcome the new scenario. The analysis contributed to the delineation of a strong action plan that immediately revealed a consistent service quality improvement quarter on quarter and nearly a 50% decrease in failure rate. The enhanced reliability had a direct impact on the performance that registered a significant reduction of the drilling time, thus lowering the overall well construction cost. In today's economics where cost reduction, resource optimization and sustainability are at the top of the operator's priority list, failure analysis has become paramount to ensure continuous improvement. Effective analytic methods to identify and eliminate showstoppers are needed to minimize unplanned events and deliver within budget. By digging deep into the root cause of incidents, this new approach to failure analysis enabled an enhanced, broader and more effective quality improvement plan that tackled service quality from multiple angles. From refining bottomhole assembly (BHA) design and risk matrix to drafting field guidelines and roadmaps, this approach also provided extra guidance and risk awareness for future well planning improvement. This particularly applies to mature fields where wellbore complexity increases at the same time budgets decrease and it's necessary to improve operational excellence to assure profitability.