Successful Delivery of Top Quartile Drilling Performance for Multiple Extended-Reach Wells Using an Integrated Multidisciplinary and Novel Operational Excellence Approach in Malaysia
Authors: Abdelaal Khaled , Elamparuthi Ramane , Sidek Rosli , Vasquez Jorge , Huat Chuah Cheng , Fong Wai Lim , Kaur Palvinderdev , Knight Andy , Balasingam Kulandra 
Published: February 2025

Long-extended-reach drilling (ERD) wells have become necessary to reach untapped resources. The successful implementation of an integrated multidisciplinary approach to plan and execute multiple ERD wells is discussed in addition to how the culture of continuous improvement and operational excellence between all parties resulted in top quartile performance and proved proper planning can push the boundaries and provide confidence to safely drill even deeper.

An integrated plan was constructed using holistic offset well data analysis to identify improvement opportunities. The on-bottom rate of penetration (ROP) is rarely the key to performance in ERD wells; it's about safely and consistently drilling a quality hole. A detailed geomechanical study was undertaken to better understand the stress regime and rock mechanics. Optimal mud weight recommendations were provided to achieve a better wellbore quality and improve ROP. Advanced rotary steerable system (RSS) drilling with real-time analytics monitoring were used to track performance and equivalent circulating density (ECD) changes as well as other drilling parameters.

The subject well was the longest of any well drilled in the operating block by far. Success involved implementation of technically modeled engineered solutions and customized operational procedures, including but not limited to optimized connections and backreaming practices to ensure removal of fine residual drilled cuttings. Dynamic and enhanced ROP road maps were used to ensure maximum cutting loads were below 3% at all the times across the wellbore. Optimized fluid rheology helped improve hole cleaning with minimum tendency of barite sagging.

The integrated approach was successfully trial tested on a shorter ERD well to validate the concept. Later, the project team drilled the longest ERD well to 19,800 ft with an ERD ratio of 3.2, and maintained, good hole quality, proven by a smooth BHA trip out of hole at well TD with no tight spots. Hole cleaning and fluid strategy were planned and executed efficiently as actual friction factors (FFs) were below 0.25 for both drilling BHA and casing runs, which demonstrated the team's capability to drill long ERD wells efficiently and independently. The optimal wellbore quality and extensive torque-and-drag monitoring assisted the team to run and cement 9 5/8-in. casing conventionally without the use of a casing floatation sub, saved approximately one day per well.

The operational challenges and step-by-step chronology of solutions deployed are discussed (Abdelaal, K. et al. 2024), wherein the multidisciplinary approach along with the effective collaboration led to the successful delivery of the ERD wells with optimal hole cleaning, without cuttings buildup or tight-hole issues, and reduced the FFs. The successful implementation of operational excellence approach during this drilling campaign will become the new culture to plan, design, and execute future drilling operations.