Egina Deep Water Completion Operations Continuous Improvement Achieved by Implementing Process Optimization Practices
Authors: Johnson Kenneth , Morand Christophe , Williams Mark , Okengwu Victor , Chaloupka Vladimir , Djenani Romain , Okpalla Chinedu , Achich Achref 
Published: April 2019

The Egina project has delivered best-in-class upper and lower completions, utilizing deep water completion experiences, global best practices, and lessons learned using a "factory" approach providing robust completion processes. Continuous improvement throughout the completion process was achieved through process optimization practices that contributed to the overall success of the project. Lower completion (LC) times have been reduced by 60 % between the first and 26th well, while reducing upper completion (UC) times by 40 % for the same wells. Well construction durations, including drilling and completion, currently averages 24 days per well, with lower and upper completion operating efficiencies (OE), and run reliabilities (RR), exceeding 98 %. Mechanical skins average approximately 2.5, while productivity/injectivity indices recorded 26 wells, during initial flowback and injection testing, average around 150 B/D/psi (325 m3/D/bar).

Standardized completion designs identified the fundamental process tasks and estimated cycle times associated with those tasks. A disciplined process approach was maintained to help minimize potential risks—by using Failure Mode, Effects, and Criticality Analysis (FMECA) and Failure Risk Analysis (FRA)—during all stages of the project, anticipating requirements and potential issues. Implementation of lessons learned from previous deep water operations during the project was fundamental to design optimization and the allocation of local resources. Following in the spirit of a "factory" approach in executing the completions, all times for tasks and subtasks were captured from the onset of project inception, allowing the project team to establish benchmark task times, while demonstrating continuous improvement throughout the project.

The project has delivered best-in-class completions, leveraging deep water completion experiences and referencing global best practices and lessons learned. Fundamental tasks for both the lower and upper completions were identified as the areas where the most significant efficiency improvements could be gained. The team developed a data tracking process to help ensure tasks and subtasks were monitored during the completion process, allowing the project to establish best practices. Statistical analysis of lower and upper completion tasks and subtasks was constantly monitored, with results communicated to the team. Since project kickoff, lower completion run rates have been reduced by 60 % between the first and 26th well, while reducing upper completion rates by 40 %. Well construction durations currently average 24 days per well, and lower and upper completion operating efficiencies and run reliabilities exceed 98 %.

The project established Key Performance Indicators (KPIs) for fundamental tasks monitored during the completion process, establishing benchmark metrics for each while monitoring continuous improvement. Reviews of these tasks within the completion process for completed wells have helped identify the improvement of best practices and lessons learned, at the task and subtask level, which have been applied to future completion activities in Nigeria and additionally shared within the operator’s global deep water operations.