REPORT ON Brainstorming Session for Enhancing Performance in Down-hole Drilling Activities

Transcription

1 REPORT ON Brainstorming Session for Enhancing Performance in Down-hole Drilling Activities 23 rd May 26 th May-2011

2 Oil India Limited Brainstorming Session for Enhancing Performance in Down-hole Drilling Activities TABLE OF CONTENTS CONTENT PAGE NO INTRODUCTION 2 PURPOSE 3 ESSENCE 3 MEMBERS INVOLVED 3 AREAS IDENTIFIED 4 IDEAS ON WELL PLANNING (WELL ENGINEERING & PROGNOSIS) 6 IDEAS ON EXECUTION AND MONITORING 11 IDEAS ON PROJECTISATION OF RIG 23 IDEAS ON CHALLENGES (PRESENT AND FUTURE) 28 CONCLUSION & ACKNOWLEDGEMENT 34 ANNEXURE - I 35 ANNEXURE - I I 36 1

3 Oil India Limited A Report on the Brainstorming Session on Enhancing Performance in Downhole Drilling Activities held at Kaziranga from 23 rd May, th May INTRODUCTION The first brainstorming session on Exploration of Oil and Gas Field was held from 15th to 18th March, 2009 at Kaziranga, Assam. Subsequently, the second and the third sessions were held at Shillong and Guwahati on Development, Management and Monitoring of oil and Gas fields and Work over performance respectively during July 2009 and February In line with these earlier sessions, fourth Brainstorming session on Enhancing Performance in Downhole Drilling Activities was held from 23 rd May th May 2011 at Kaziranga where a total of 19 participants from Drilling, G&R, Chemical, Well logging, Production and Drilling (TS) departments, were brought together on a common platform to deliberate on issues to enhance performance in down hole drilling activities. The discussions that followed for the next four days were guided by BP coaches to keep the session aligned with the objective as well as to provide equal opportunity to all the participants. With the several ideas that have come up during the sessions, four broad areas were identified and a presentation on these areas along with the ideas was made to ED (Operations), GM (G&R), GM (Drilling - OSD) on the final day of the session, i,e, on The inaugural session of the brainstorming session was graced by Shri B.N.Talukdar, Director (E&D) accompanied by Sri. K.K.Nath, Executive Director (Operations). With his thought provoking words and a detailed picture of the current Indian hydrocarbon scenario, Director (E&D) set the tone for the intense sessions that followed. Director (E&D) also highlighted that a fresh look has to be given for our performance challenges that are ahead and asked the participants to contribute in OIL s way forward by actively participating in the session and coming up with new ideas. ED(O) also while encouraging the participants for active participation, called for radical ideas that are going to give breakthrough in drilling operations. He invited all to have self confidence as one of the core competence. The brainstorming session concluded on 26 th evening and culminated after a presentation on the ideas generated during these four days of brainstorming session to Executive Director (Operations). The concluding session was also attended by Sri R. Borgohain, General Manager (G&R) and Sri. P. Borgohain, General Manager (Drlling - OSD). This document is a compilation of all the ideas and views of the groups of participating executives emerging out of the discussions that took place in the four-day brainstorming session. The draft is structured to include the purpose, ideas generated, comments and recommendations drawn thereafter. Furthermore, the ideas generated, may also go through further modifications over time. It may be mentioned here that action at various levels may already have been initiated trat different levels of the Company. However the discussions of these ideas reinforce the belief and confidence that the participants have on that particular idea. 2

4 2.0 PURPOSE To identify areas and generate ideas proposing for enhanced performance in drilling downhole activities. 3.0 ESSENCE Achieving Drilling Breakthrough 4.0 MEMBERS INVOLVED The participants were executives from various departments viz. Drilling, G&R, Well Logging, Chemical, Drilling (TS), Production who are actively participating in the drilling activities. The members are: Name of the Executive Designation Sri J K Bhowmik Sri B Ganguly Sri K Rajput Sri N K Medhi Sri A Borgohain Sri A K Das Sri D Rajkumar Sri M Gogoi Sri P P Bhattacharya Sri M Saikia Sri G K Sharma Sri R Borkotoky Sri S Verma Sri S P Das Sri D Deka Sri S K Sarma Sri D Borah Sri P Sarmah Sri A K Bhattacharjee Dy CED Dy CED Dy CED Dy CED S. E. Drilling S. E. Drilling S. E. Drilling S. E. Drilling S. E. Drilling Sr. E. Drilling Chief Geologist Chief Chemist Dy. C.E. P.O. S.E. Drilling T.S. Sr Geologist Sr Engineer(WL) Sr Engineer(WL) Geologist Chemist 3

5 The members were guided by B P Coaches Sri B K Das, Sri Prakash Deka and Sri Arindam Bordoloi to keep them aligned to the objective of the session. 5.0 AREAS IDENTIFIED The participants identified four areas wherein the participants feel that they can contribute ideas in these areas. The identified areas are: Area-I: Planning (Well Engineering & Well Prognosis) Ideas Drilling well-on-paper (Well Engineering) Well Prognosis Area-II: Execution and Monitoring Ideas Monitoring through MLU in all Exploratory & Critical wells Proper mode of communication between rig personnel Synergy between mud and drilling parameters. Just-in-time compulsory training to tackle down-hole problems Effective utilization of E&P data bank (Landmark) software Documentation of down-hole data while drilling at rig site Close monitoring of Safety and Environmental hazards GTO should be discussed among the core groups along with the lower level personnel and set internal goals Some information like logging data may be percolated down the line to know the quality of the hole Drilling Risk monitoring-preparation of contingency plan for down hole problems. Real time monitoring of the drilling activities (Onshore Operating Centre) Manpower deployment at rig site as per international practice Up gradation of rig and equipment (e.g. Top drive in place of rotary drive, independent rotary drive) Maximum age of work persons working at rig should be limited to 50 years Improvement in Cementation job Full theory training before independent charge at well site Mud policy as per Field requirement and use of NDDF & non-invasive drilling fluid while drilling the pay zone. For using NDDF in the pay zone casing policy may need to be revised Area-III: Projectisation of the well Ideas Implementation of the concept of projectisation in 1 or 2 in-house drilling rigs as pilot project Dedicated manpower for the project 4

6 To provide training and motivating all personnel associated with the project Implement the concept of projectisation in all in-house drilling rigs Mixed-Fleet-Rig concept can be implemented, where after completion oil string casing the drilling rig will be replaced with mobile rig in exploratory wells for detailed production testing Area-IV: Challenges Present and Future Ideas High angle high displacement J-bend/horizontal drilling for Eocene wells Drilling deviated wells with LWD-MWD as a regular practice Standardization of vital rig equipments, spares Exploring thin pay zone Reservoir care Reduction in Non Productive Time (NPT) Comprehensive gas well policy Core competency in Offshore drilling technology 5

7 AREA-I WELL PLANNING (WELL ENGINEERING & PROGNOSIS) 6

8 AREA-I: WELL PLANNING (WELL ENGINEERING & PROGNOSIS) IDEAS GENERATED: 1. DRILLING WELL-ON-PAPER (Well Engineering) 2. WELL PROGNOSIS IDEA - 1: DRILLING WELL-ON-PAPER (DWOP) or WELL ENGINEERING DWOP is a process of analyzing each step of the well construction process, to generate ideas or improving ideas for improving performance and reducing cost. It is one way of managing budgets (as well as risk and uncertainty). The real value of DWOP is to identify opportunities where non productive time can be eliminated. The health safety and environmental risks are reduced by dissecting the well construction process and sharing experiences. With DWOP, each team s targets are checked against those of the whole group and a consensus is reached. The DWOP sets the technical limit for each activity, or minimum time required to complete each task in a perfect world. It serves as a theoretical value only and can never be achieved as an actual target. Next, a realistic target based on the best performance is established, which becomes the performance benchmark of the well. Removing the job mask can be liberating because it fosters a different kind of thinking. It gives people space to think about operations without the pressure of being on the rig and making instant decisions. Apart from the depth charts, DWOP adds a curve representing targets set by the group directly responsible for operations. In this way the project can be tracked until completion and subsequently compared with like wells. Once the project has been completed, the closeout meeting enables the operator to review service company performance and transfer lessons learned. RECOMMENDATIONS SHORT TERM IMPLEMENTABLE IDEA-1: BENCHMARKING with international drilling companies ON DRILLING WELL-ON-PAPER (DWOP) or WELL ENGINEERING : Presently not available in OIL and proposed to implement as per the international practice. For better well management during drilling. DWOP is the technical limit for each activity, or minimum time required to complete each task. Bringing the complete well engineering data, procedures with all contingency plans, etc. at one place. 7

9 DWOP covers: o All programme & designs. o Downhole problems, its management and mitigation. o Side-tracking, Fishing and Abandonment policy. o Waste management and disposal/ treatment plan. o Risk Management & Safety. Increasing operational efficiency by proper planning & documentation. Minimizing Decision Making Time. Formation of Team (Drilling, G&R, Logging, Chemical & Production) for study & benchmarking purpose. Team to submit report on finalization of formats & procedures. WHOTO GM (OD & RS) GM (OD & RS) TO ED(O) ED(O) RECOMMENDATIONS LONG TERM Same Benchmarking Team to continue (Drilling, G&R, Logging, Chemical & Production). Complete well engineering using suitable software including training. Also to make use of E&P Databank. Making available (DWOP), Drilling well-on-paper to all concerned 2-3 months prior to spud-in GM (OD & RS) TO TEAM TEAM ED(O) GM (OD & RS) GM (OD & RS) IDEA - 2: WELL PROGNOSIS The present Depth Data Drilling Policy (DDDP) covers a very brief well prognosis together with gist of casing design, mud parameters, cement rise in annulus, deviation plan (if applicable), well head pressure rating is being published for each & every well. The depth data drilling policy includes presgraf and also mentions briefly about probable mud loss zone and expected bottom hole pressure, etc. Apart from the depth data policy a drilling progress plan chart indicating the well depth v/s plan days is also published by G&R department. These are very brief in nature and do not give the full information, design & procedures as per the international drilling practices. To make the present DDDP as common platform for interdepartmental communication & information sharing, the idea of software based Well Prognosis Report having online facilities has been proposed. 8

10 Well Prognosis is a working document that varies depending on the well, which can be for exploration or development. Establishing an exploratory drilling program requires gathering the most information possible beforehand and knowing the degree of reliability of the data. A well prognosis is developed before and during the planning of a well. However, it is not a static document. Information gathered during the drilling of a well can be used to update the document. The information can come from analysis of the cuttings generated during drilling. If available, the results of biostratigraphy analysis of microfossils or palynomorphs are also included to determine stratigraphy from cuttings information. RECOMMENDATIONS SHORT TERM IMPLEMENTABLE IDEA-2: Well Prognosis to be prepared in line with international standard, initially for exploratory wells using suitable software having online facility. Presently, the depth data drilling policy covers some of the parameters of well prognosis which are not sufficient, are very brief in nature & doesn t contain the detailed information. The well prognosis should minimum include: o The well site & location (coordinates, altitude or water depth) o The drilling objective(s) i.e. type, relative size, estimated depth(s) o Basic data on Geology and geophysics o Information on nearby wells (if there are any) o Constraints and deadlines to be complied with Better policy making, timely execution and detail understanding of the well. Saving time by facilitating inter-departmental communication through online. Formation of Team (G&R, Geophysics, Drilling, Chemical, Production) Study the available well prognosis report as followed by international drilling companies including procurement of suitable software & training. Also to make use of E&P GM (G & R) TO TEAM Databank. Finalization of formats & preparation of report TEAM ED(O) GM (G & R) Head Operations (G&R)

11 RECOMMENDATIONS LONG TERM IMPLEMENTABLE IDEA-2: Well Prognosis to be prepared in line with international standard for all wells (Exploratory & Development) using suitable software, including online accessibility. Better policy making, timely execution and detail understanding of all well. Saving time by facilitating inter-departmental communication. It can be made available online to add, edit or review & also enhance safety efficiency and effectiveness of drilling programme. Same Team to continue for preparation of well prognosis for all wells. GM (G & R) TO Training of personnel, if required TEAM Generation of well prognosis reports for all wells. Also to make use of E&P Databank. TEAM ED(O) GM (G & R) Head Operations (G&R)

12 AREA-II EXECUTION AND MONITORING 11

13 AREA-II: EXECUTION AND MONITORING After thorough discussion in this brainstorming session, the common understanding drawn is as follows: 1. To prepare a knowledgeable, dedicated, multi-skilled workforce. 2. To lead in this competitive E & P business, we must upgrade our rigs and equipments. 3. A fast and effective coordination and communication system has to be developed. IDEAS GENERATED: The ideas formulated during the brainstorming session on the sub-surface assessment domain were as follows: Monitoring through MLU in all Exploratory & Critical wells. Proper mode of communication between rig personnel Synergy between mud and drilling parameters. Just-in-time compulsory training to tackle down-hole problems Effective utilization of E&P data bank (Landmark) software Documentation of down-hole data while drilling at rig site Close monitoring of Safety and Environmental hazards GTO should be discussed among the core groups along with the lower level personnel and set internal goals. Some information like logging data may be percolated down the line to know the quality of the hole. Drilling risk monitoring preparation of contingency plan for down hole problems Real time monitoring of the drilling activities (Onshore Operating Centre) Manpower deployment at rig site as per international practice Up gradation of rig and equipment (e.g. Top drive in place of rotary drive, independent rotary drive) Maximum age of work persons working at rig should be limited to 50 years. Improvement in Cementation job. Full theory training before independent charge at well site. Mud policy as per field requirement and use of NDDF & non-invasive drilling fluid while drilling the pay zone. For using NDDF in the pay zone casing policy may need to be revised. RECOMMENDATIONS-SHORT TERM IMPLEMENTABLE IDEA-1: Monitoring through MLU in all Exploratory & Critical wells. Mud Logging provides subsurface geological information while drilling a well which can help in identification of pay zones and fluid contacts. The unit provides electronic monitoring of drilling parameters such as weight on bit, torque, penetration rate, mud levels, pump speed which can help to optimize drilling processes. Mud Logging also provides critical safety functions such as determining pore pressure, kick control and ambient gas monitoring. While Mud Logging Units are being used during drilling of 12

14 exploratory and critical wells, it should also be used for monitoring during the drilling of development wells as well. Presently, OIL has 4 nos of mud logging units on hiring basis. The participants feel that services may be hired for another 4 nos. of MLUs to adequately cover all the wells as mentioned above. Better well management during drilling Reduction on down-hole problem and formation damage Improvement in geo-modeling Identify all the Exploratory and Critical wells and deploy them on priority basis Initiate hiring 4 nos of MLU s (Presently we have only 4 nos. available ) Till then Data will be made available in critical events diary which should be formulated. Head OPS (G&R) TO D (E&D) do D (E&D) Installation Manager GM (OD&RS) IMPLEMENTABLE IDEA-2: Proper mode of communication between rig personnel by the use of suitable Communication system, internet connectivity, CCTV & two telephone connections There is no faster mode of communication at present among rig personnel e.g. Drilling Engineer, Chemical attendant, Drilling T/S personnel etc. for which it becomes very difficult to communicate when the need arises. Rigs of other leading drilling companies (Jay Bee, Shiv-Vani) are equipped with these above mentioned communicating devices. Better communication and thereby minimizing communication errors as well as ensuring safety. This will improve co-ordination among the rig personnel also. Procurement of adequate nos. of communication devices, extra telephone connections, internet connectivity and CCTV for all the rigs GM (OD&RS) TO Already Initiated ED(O)

15 IMPLEMENTABLE IDEA-3: Drilling performance greatly depends on Mud parameters, Mud hydraulics and BHA design. Therefore there has to be close co-ordination between Drilling Engineer and Mud chemist so that synergy can be obtained between mud and drilling parameters. To enhance drilling performance. Close co-ordination between Installation Manager, Drilling engineer and Mud Engineer. Close co-ordination between Installation Manager, Drilling engineer and Mud Engineer GM (OD&RS) & Head-Chemical TO ED(O) IMPLEMENTABLE IDEA-4: Just in time compulsory training to tackle down-hole problems To educate all personnel working at rig site for better understanding of their jobs at hand. It will reduce confusion and ensure quality of work and safe operation and minimize accident. This will also act for increasing motivation and improving confidence. Provide in-house /in country or overseas training on cementation, stuck pipe, fishing and loss circulation Head T&D and Head Drilling D (E&D) Training on SOP In house Head T&D and Head Drilling GM (OD&RS)

16 IMPLEMENTABLE IDEA-5: Close monitoring of Safety and Environmental hazards like contamination in drinking water zone. To reduce environmental pollution, safe operation and to avoid conflict with local people. It will reduce environmental pollution and ensure safe operation Deployment of dedicated safety officer and complying with Environmental norms strictly. Head (S&E) GM (OD&RS) IMPLEMENTABLE IDEA-6: Depth Data Drilling Policy/ GTO should be discussed among the core groups along with the lower level personnel and to set internal goals. Well GTO should be discussed among the operational group including lower level fields personnel in each rig so that internal goals can be set to minimize drilling time and the complete operation is understood by all the rig personnel. Awareness among all the people and achievement of rig target within the scheduled time. To organise Pit Level meeting among all the rig personnel GM (OD&RS) ED(O) IMPLEMENTABLE IDEA-7: Some information like logging data may be percolated down the line to know the quality of the hole. Some of the Logging information like caliper log should be discussed among the operational group including lower level fields personnel in each rig so that importance of the operations like cementing job is understood by all the rig personnel. 15

17 Awareness among all the people and perfection in the job done. To organise meeting among all the rig personnel before an important job. (e.g. cementing) GM (OD&RS) ED(O) IMPLEMENTABLE IDEA-8: Drilling risk monitoring preparation of contingency plan (Risk monitoring charts) for down hole problems. Approved drilling risk monitoring charts (as proposed in annexure I and II) are required to take immediate decision in case of any down hole problem, thus reducing NPT. Prompt decision and action taken in case of down hole problems will greatly reduce NPT. Operational group of all the rigs to prepare risk monitoring charts and get approval from competent authority. GM (OD&RS) ED(O) RECOMMENDATIONS-LONG TERM IMPLEMENTABLE IDEA-9: Real time monitoring of the drilling activities (Onshore Operating Centre-OOC). To monitor operations of all the wells centrally from the OOC. Quick decision making and problem solving To hire OOC services GM (OD&RS) ED (O)

18 IMPLEMENTABLE IDEA-10: Effective utilization of E&P data bank (Landmark) software To determine the best drilling parameters, better reporting to higher ups while the drilling is on progress and record well data. Presently not being used by OIL as AMC has been lapsed and training has not been provided to concerned executives. EXPECTED RESULT Faster drilling and quality holes 1. To activate the AMC for the E & P Databank software 2. Start training executives. Head Contract ED(O) Head-IT GM (OD & RS) ED (O) IMPLEMENTABLE IDEA-10: Manpower deployment at rig site as per international practice As one shift-in-charge is not enough to monitor all the activities happening around the well-site, more competent persons like chemist, geologist, assistant driller, and installation manager himself must be present at well-site round the clock. This will enhance overall efficiency and better compliance with OISD norms. Quick decision making and problem solving. Deployment of competent persons round the clock at well-site, by concerned departments. GM (OD&RS) ED (O) IMPLEMENTABLE IDEA-11: Up gradation of rig and equipment (e.g. Top drive in place of rotary drive in some selected wells, Pipe Handling Machine, Independent rotary drive to be procured). 17

19 To better equip the drilling engineer for carrying out the drilling activities and to comply with OISD norms. Reduction in connection time and enable upward reaming to avoid pipe stuck situations and faster/safer drilling in critical formation. Also reduce MTBF (Mean time between failures) of all rig equipments. To buy auto driller, centrifuges, top drive, LMSS, Remote control choke panel, Advanced Instrumentation system, torque gage, ROP meter, Drilling Jar, MGS (mud gas separator), Diverter, Drill Pipe spinner with silencer, Kelly spinner for all rigs. GM (OD&RS) ED (O) IMPLEMENTABLE IDEA-12: Maximum age of work persons working at rig should be limited to 50 years. Increase efficiency of work force; reduce human failure and safety hazards. Reduction in down time and faster drilling Identify the people and engage them in suitable areas like monitoring group, work man inspector. Head- ER GM ( OD&RS) Urgent new recruitment and replacement policy Head- HR Head- ER GM ( OD&RS)

20 IMPLEMENTABLE IDEA-13: Improvement in Cementation job Cementing is a critically important operation in the construction of any well by providing a continuous impermeable hydraulic seal in the annulus, preventing any uncontrolled flow of reservoir fluids behind the casing. Many serious problems can arise from uncontrolled flows. It was felt by the participants that problems of isolation failure, losses in well productivity, and flow behind the casing along the annulus could be drastically reduced by further improving our cementing techniques and technology. Reduced water cut Enhancement of production Less workover jobs Improved cementation in gas and oil wells to avoid isolation failure 1. Making the existing mixing unit operational. 2. Procurement of new cementing units with latest technology. GM (OD&RS)/ Head-Chemical GM(OD&RS) ED(O) Already Initiated ED(O) Hiring of service providers for oil string cementing jobs in all wells. Head-Chemical ED(O) Procurement of gas migration additives for gas wells. GM (OD&RS)/ Head-Chemical ED(O) Cementing Guidelines from IDT, ONGCL, Dehradun i) For pumping cement slurry always cementing unit should be used ii) BOP testing should be done by cementing unit or test pump due to their higher pressure ratings. iii) Displacement of cement slurry can be done with the help of rig mud pumps or cementing units. iv) Final plug hitting, however, should be done with the help of cementing unit. v) Cementing unit should be used for better control & adequate pressure ratings. vi) Also preferable to mix and displace the slurry with a cementing unit since normal surface rig facilities are not suitable due to their low mixing rates. Using the cementing unit gives more accurate volume control. 19

21 IMPLEMENTABLE IDEA-14: Full theory training before independent charge at well site. Full theory training should be imparted to all rig personnel before giving independent charges so that they understand the job fully and work with confidence. Improved Drilling Efficiency with minimum down-hole problem and minimize accident rate. This will also increase the motivation factor within the workforce. To initiate training programme in consultation with T&D Deptt. GM (OD&RS)/ GM (T&D) D(E&D) IMPLEMENTABLE IDEA-15: Mud policy as per field requirement and use of NDDF & non-invasive drilling fluid while drilling the pay zone. For using NDDF in the pay zone, casing policy may need to be revised. The group felt that mud parameters should be designed based on geological, lithological and geo-mechanical studies of the specific field. There should be detailed study of the geomechanical properties and pressure regime existing in the particular field and use the same as input for planning the bit, hydraulics and mud policy. Further, it was suggested by the group that as done in the horizontal wells, the possibility of using NDDF in the pay zone of critical wells should be explored for which casing design may need to be modified / revised. Minimum formation damage Higher productivity Minimize down-hole problems Geo-Mechanical study Pore pressure Study Designing of drilling fluid as per field specifications and suitable casing design to reduce the length of pay zone section GM (OD&RS)/ GM (G&R)/ Head-Chemical D (E&D)

22 PRACTICES TO STOP: 1.0 To stop using Rig Pump during cementation It is preferable to mix and displace the slurry with cementing unit since normal surface rig facilities are not adequate due to their low mixing rate. Using of cementing unit gives more accurate volume control. Better quality cementing Start using cementing unit as per international standard. GM (OD & RS) ED (O) To stop shallow grouting of falls conductor. To avoid cellar suction failure problems, especially in cluster wells. Minimize down-time Grouting false conductor up to a depth of 2 meters. Head Drilling (Operations) GM ( OD&RS) PRACTICES TO CONTINUE: BOP drill, mock fire drill, Cold/ Hot work permit, near miss report. To ensure Safe operation 21

23 Less number of accidents. To continue Installation Manager Head Drilling (Operations) FURTHER STUDIES REQUIRED ON Smart Drilling Technology Onshore Operating Centre (O.O.C) Rotary Steerable System (R.S.S) Under balanced Drilling(UBD)/ Managed pressure Drilling (MPD) Mono-bore Drilling To gain knowledge of the state-of-the-art technology available at present We will be able to drill difficult wells Just in Time training to deserving candidates who are to be deployed to the projects. GM (OD&RS) ED(O)

24 AREA-III PROJECTISATION OF RIG 23

25 AREA-III -PROJECTISATION OF RIG Projectisation" means the act of turning something into a project, or structuring something like a project and introduction of formal procedures, such as scheduling, planning, resource management, etc. into an activity which is more business-like in general. CONCEPT Every rig to be considered as a project, headed by a project Head, supported by fixed executives and work persons. Annual target for the particular rig should be considered as Project Target. RECOMMENDATIONS SHORT TERM IMPLEMENTABLE IDEA-1: Implementation of the concept of projectisation in 1 or 2 in-house drilling rigs as pilot project To establish the concept of projectisation and to initiate the feeling of belongingness. Effective minimization of performance gap. As drilling activities itself is a team work, creation of the core team with functional responsibilities, will boost up the motivational level of the members. Identification of rig. To create a core team* GM (OD&RS) ED (O) Note- * Core team comprising of Installation manager, Drilling Engineers, Chemist, Geologist, Rig Engineer, Electrical Engineer and Safety Officer IMPLEMENTABLE IDEA-2: Dedicated manpower for the project By projectisation, belongingness of the persons attached to the rig will improve. This will create an atmosphere where man to man and man to machine relationship will be much better, contributing safe and successful completion of its common goal. 24

26 Improvement in team spirit and hence productivity. Deployment of fixed manpower GM (OD&RS) ED(O) IMPLEMENTABLE IDEA-3: associated with the project To provide training and motivating all personnel To execute the project safe and effectively. Training and motivation will increase the efficiency level and team spirit of the work force. The team will become cost conscious. Multiskilled workforce will reduce shut-down hours and that in turn will reduce downhole problems. Reduction in NPT, improvement in safety of man and machine. Rewards & recognition# Personal growth Multiskill assignment to crew Training on project management GM (OD&RS) ED(O) Note- # Incentive scheme may be introduced on the basis of savings of rig days against planned days. 25

27 RECOMMENDATIONS LONG TERM IMPLEMENTABLE IDEA-4: Implement the concept of projectisation in all in-house drilling rigs Once the pilot project is established, projectisation of all the rigs may be done. Effective minimisation of the performance gap, enhancement in safety, smooth operation, healthy competition among the projects and good quality holes. IMPLEMENTABLE IDEA-5: Implementation of Mixed-Fleet-Rig concept in exploratory wells (drilling rig will be replaced with mobile rig for production testing) Maximum utilization of rig. Effective minimisation of the performance gap. Utilisation of mobile rig for production testing of exploratory wells GM (OD&RS) ED(O) PRACTICES TO CONTINUE Regular review meeting, Tool box meeting, Pit level meeting, Pre job safety meeting. Regular review meeting will make the team aware about the progress of the project. Tool box meeting will give a brief idea on jobs to be carried out and safety aspects. Pit level meeting solves the logistics and safety aspects. To create awareness on safety aspects of special operations e.g. logging, cementing etc. Based on evidences it has been found that majority of the ground level problems are sorted out through these types of meetings. Planned, smooth and safe operations. 26

28 CONTINUE On regular basis Core team To continue Project Head Monthly PRACTICES TO STOP Frequent changing of manpower. To increase the belongingness and team spirit. Expected Results: Reduction in NPT and improve in productivity. Deployment of fixed manpower for rigs GM (OD&RS) ED(O)

29 AREA-IV CHALLENGES (PRESENT AND FUTURE) 28

30 AREA-IV: CHALLENGES (PRESENT AND FUTURE) IMPLEMENTABLE IDEA-1: High angle high displacement J-bend/horizontal drilling for Eocene wells Due to present logistic problems, land acquisition has become a big problem for drilling a well. To overcome such challenges, importance of High angle high displacement wells has increased to a great extent. Apart from that, to enhance production from lesser number of wells also has become a vital issue. Near future multilateral completion from horizontal wells is also a challenge to mitigate with. EXPECTED RESULT To mitigate logistic problems especially land acquisition Maximizing production through lesser number of wells Core competency of in-house personals Integrated group of expertise Horizontal wells for future planning of multilateral completions Training for Core competency of inhouse personals Study by reputed consultants for J-bend well design campaign in areas like Dikom GM (OD&RS) D (E&D) Quarterlyw.e.f IMPLEMENTABLE IDEA-2: Drilling deviated wells with LWD-MWD a regular practice The disadvantage with present single shot survey of S-bend wells is that it can t be taken at deeper Kick off Point (KOP). Present S-bend wells also create difficulty in carrying out work-over jobs in later stages of the well. Limitation of total horizontal displacement is also a disadvantage of present type of S-bend wells. Implementation of MWD-LWD system in S-bend/J-bend wells adds in getting real time data as well. 29

31 EXPECTED RESULT More horizontal displacement Real time data acquisition for quick decision making Less torque & drag More efficient drilling because all down hole tools can be operated within specification Initiate study for finalization of drilling program Poor man MWD tool GM (G&R) & GM (OD&RS) D (E&D) Quarterlyw.e.f IMPLEMENTABLE IDEA-3: Standardization of vital rig equipments & spares Quality Assurance and reduction of premature failure of equipment, mechanical components and consumables in drilling operations. Use of standard product of reputed company increases the efficiency and drilling metreage. In addition, it will avoid purchase of sub-standard spare parts and equipment which will reduce cost to company in the long run. EXPECTED RESULT Drilling efficiency will increase with reduction in breakdown of equipment Product standardization cell to be set up for identifying reliable source for procuring equipments, spares and consumables; instead of procuring through L-1 option. This cell should consist of interdepartmental personnel. GM (OD&RS), GM (S), GM (E) D (E&D) Quarterlyw.e.f

32 IMPLEMENTABLE IDEA-4: Exploring thin pay zone To alleviate present energy demand in the country, exploration of hydrocarbon from thin pay zones has immense importance in coming days. This may, in turn, proves to be source of considerable economic revenue earning. When we have discovered almost all the thick sand reservoirs, thin sand exploitation has become a very important source of oil & gas. But in OIL, this aspect has not been looked into very seriously and as a result, extraction of thin reservoir hydrocarbon has become a challenge for the company. EXPECTED RESULT Delineation of thin pay zone Discovery of newer horizons of hydrocarbon in the same old areas High resolution logging tools from service provider Proper image log study Horizontal wells using Rotary Steerable system Adequate technology like HRLA, DDBBI etc. GM (G&R) ED (O) GM (OD&RS) ED (O) Quarterlyw.e.f Quarterlyw.e.f IMPLEMENTABLE IDEA-5: Reservoir care Reservoir is the bread and butter of any E&P company. That is why we should take the best care for the reservoir, only then we can get the maximum out of it. Maximum reservoir information can be gathered only when we have a good undamaged reservoir. Adequate care is also necessary to save it from drilling related damages. EXPECTED RESULT A good reservoir for maximum extraction of hydrocarbon proper mapping of reservoir 31

33 Additional logs in horizontal wells Scientific drilling with proper bit selection Selection of proper hydraulics, mud policy and solid control system Geomechanical & pore pressure studies GM (G&R) D(E&D) Well planning team D(E&D) IMPLEMENTABLE IDEA-6: Reduction in Non Productive Time (NPT) Reduction in NPT is one of the key factor for overall improvement in efficiency of drilling. It will contribute in minimizing drilling cost EXPECTED RESULT High efficiency and metreage Better cost to company Drilling target achieved Formulate comprehensive maintenance policy Implementing comprehensive maintenance policy Review of mud policy, casing policy and solid control system Deployment of specialist for specialized jobs like fishing, cementing etc Technical & motivational training to all Feasibility study to adopt multi skilled workforce Monthly face to face interaction of sectional heads GM s ED (O) GM s ED (O) Quarterly Well planning team ED (O) Concerned GM s D (E&D) GM (OD&RS) GM (OD&RS) RCE RCE Concerned GM s RCE

34 IMPLEMENTABLE IDEA-7: Comprehensive gas well policy Importance of gas wells has increased many folds in recent time. Huge demand for natural gas has become a challenge for OIL to fulfill. Hence, to obtain sufficient gas as required by the Company, a detail policy is to be formulated for drilling successful and flawless gas well. EXPECTED RESULT Sufficient gas production will fulfill the commitments made by the Company Comprehensive study by experts GM (P-Gas), GM (G&R) ED (O) Involvement of all related departments Complete new gas well design Concerned GM s ED (O) GM (P-Gas) ED (O) Implementation GM (P-Gas) ED (O) Quarterly IMPLEMENTABLE IDEA-8: Core competency in offshore drilling technology With number of NELP projects coming up for offshore block in the coming years, capability enhancement is a must. EXPECTED RESULT Adequate knowledge will fulfil the commitments made by the Company. Comprehensive training on Offshore drilling technology Exposure to offshore drilling operations Core competency in offshore drilling operations ED(O) D(E&D) ED(O) D(E&D) ED(O) D(E&D)

35 VI. CONCLUSION Even with improved rig equipment that makes solids control and pipe handling easier, the key to efficient operations remains the personnel on the rig. Without properly trained and motivated drillers, supervisors and mud chemists, NPT will remain unchanged. The above was commented by Gaffney, Cline & Associates (GCA) in their report on Post Drill Analysis of 60 exploratory wells drilled by OIL between April, 2002 and March, To elaborate further what has been quoted above, we would like to mention the following few lines: We all know for sustenance of any effort there is no fix formula or model. But, for sustenance of any industry or any society largely three factors are responsible. They are People, Planet and Profit. We are largely profit oriented but the question lies whether we are people and planet oriented or not. During the brainstorming session we were unanimous with the view that to ensure profit for the long term in a sustained way the driver behind any effort is People only. With the growing realization of the present day industry scenario we need to be serious about the Planet also. Hence we need to give equal and non-failing attention to these three vital factors. This document contains recommendations related to attention to these critical factors in a balanced way. Also during deliberation it has been kept in mind the theme line, as emphasized by BP coaches, Expectation vs. Practicability. Hence, the generated ideas have been focused primarily towards practical solutions which can lead to Enhancing Performance in Downhole Drilling Activities. As strategic initiatives we would like to suggest for constant monitoring and planning of the strategic moves suggested above by forming a team under your direct intervention which we strongly feel will pave the way for realizing the real benefit of the outcomes of the Brainstorming sessions. Further deliberations will lead to addressing delicacies on the issues highlighted. The spirited feeling is that the presented outcome of the concerted and committed effort of the entire group promises a bright future ahead for all OIL Indians when recommendations see the light of realization through committed actions. VII. ACKNOWLEDGEMENT The participants of the session are extremely grateful to Mr. B N Talukdar, Director (E&D), for initiating the idea of the brainstorming session and providing a truly learning experience for the participants. We would also like to place on record our sincere gratitude to the OIL Management for providing us the opportunity to participate in this wonderful session. We are grateful to Sri K K Nath, Executive Director (Operation) for his encouraging presence and word during the beginning and closure of the session. We shall remain grateful for his valuable suggestions during our presentation on the outcome of the brainstorming session. We are also thankful to Sri R Borgohain GM (G&R) and Sri P Borgohain, GM (Drilling - OSD) for their valuable guidance during the presentation on the outcome of the session. The group is also overwhelmed by the meticulous planning and execution of the session by the BP coaches. 34

36 Annexure-I Sample of Down-Hole Problems Monitoring and Action Plan Risk Hazard Denominat description ion Consequ ence descripti on Impact factor ProbabRisk ility of reducing the measures Hazard Actions /Comments Circulation Loss Loosing great amount of drilling fluid, kick hazard Stucking of bottom hole assembly, Formation damage, Well kick 4 80% Analyse historic drill data to predict possible circulation loss zone Spot about 50 Bbls of 3.5% assorted LCM, pull back inside shoe. Go down to bottom. Establish circulation with slow SPM. Shale Problems Big size of cavings on the shale shaker Mechanic al stuck 4 60% Use mud with proper parameters. Circulation with high GPM. Flush with high viscous pill in case of stuck. Treat the mud with Shale Stabilizers Note: Idea taken from a paper entitled Risk Management and Contingency plan authored by Sebastian Homuth. 35

37 Annexure-II Probability Categories Probability 0-20% 20-50% 51-75% 76-85% % Description very unlikely unlikely likely very likely almost sure Impact Factor categories Impact Factor Description negligible minor serious but tolerable major Hazardous to whole project 36