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Root Cause Failure Analysis as a Tool for Investigating Operational Failures: A Case Study

机译：根本原因失败分析作为调查操作失败的工具：案例研究

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Production liner cementation in deepwater wells is critical to contain formation pressures and provide zonal isolation. This is especially challenging in the Gulf of Mexico because of depleted zones, small drilling margins, and HPHT reservoirs. Failure to achieve zonal isolation with the primary cement job leads to added cost and time for remedial operations. A recent primary cement job failure in the Viosca Knoll Block, located in the Gulf of Mexico, prompted the use of an established tool, Root Cause Failure Analysis (RCFA), in a novel way to identify the causes of the incident and avoid repeating the same mistakes in future wells. A team of operations and engineering personnel was assembled to investigate the cause of the primary cement job failure that resulted in nonproductive time and cost of approximately 7 days and $3 MM, respectively. RCFAs have typically been performed on equipment failures; however, this RCFA was conducted by the operator on a non-equipment related failure. The RCFA team initially collected data available from both the planning and operation phases of the job in order to identify which elements of the cementing process contributed to the cement job failure. After identifying the root cause, the team communicated learnings to office and rig-based personnel, developed a new tool for real time monitoring of primary cementation, and adjusted plans for upcoming primary cement jobs. The findings from the RCFA were applied to a well on another asset owned by the operator, with which the production liner was successfully rotated throughout cementation for the first time. The RCFA identified that the cement job design was not a contributing factor; instead, the root causes were operational and started during circulation of drilling fluid prior to cementing operations. The learnings from the RCFA were transferred to both office and rig-based personnel, influencing engineering and operations plans for subsequent wells. Furthermore, the investigation identified previously unknown issues and showed that the use of the RCFA process was an effective approach that can be standardized and scaled to determine root causes of future operational failures.
机译：深水井中的生产衬垫胶合对于含有形成压力并提供区域隔离至关重要。这在墨西哥湾尤其具有挑战性，因为所耗尽的区域，小钻井边缘和HPHT水库。未能通过主要水泥作业实现区域隔离，导致额外的补救运营成本和时间。最近的主要水泥作业失败，位于墨西哥湾的Viosca Knoll块中，促使使用建立的工具，根本原因失败分析（RCFA），以一种识别事件的原因，避免重复未来井中的错误。组装了一支运营和工程人员，调查原发卫生间失败的原因，导致非培养时间和成本分别为约7天和3毫米。 RCFA通常在设备故障上进行;但是，该RCFA由运营商对非设备相关的失败进行。 RCFA团队最初收集了工作的规划和操作阶段可获得的数据，以确定巩固过程的哪些元素导致水泥作业失败。在确定根本原因之后，团队传达了对办公室和钻机人员的学习，开发了一个新的工具，即实时监测主要削补，并调整了即将到来的主要水泥工作的计划。 RCFA的调查结果对操作员拥有的另一个资产应用于井，其中生产衬垫首次在整个胶泥过程中成功旋转。 RCFA确定了水泥就业设计不是贡献因素;相反，根本原因是在挖掘操作之前在钻井液的循环期间开始运行的。 RCFA的学习被转移到办公室和基于钻机的人员，影响后续井的工程和运营计划。此外，调查确定了先前未知的问题，并表明使用RCFA过程是一种有效的方法，可以标准化和扩展以确定未来运营失败的根本原因。

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