quality in drilling and completion
TRANSCRIPT
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G R O U P
QUALITYIN DRILLING & COMPLETION
ACTIVITIES
C. LANZETTA
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QUALITYIN DRILLING & COMPLETION
ACTIVITIES
C. Lanzetta
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WHAT IS QUALITY?
WHAT IS QUALITY ASSURANCE?
WHAT IS QUALITY CONTROL?
WHAT IS TOTAL QUALITY MANAGEMENT?
Quality Definitions
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• It is the capability of a product or service to
satisfy the specified Customer Requirements• It is the key to Customer satisfaction
• It is the main tool to reduce / eliminate : – mistakes
– defective materials (and extra costs)
– inefficiencies in the processes
What is Quality?
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What is Quality?
Agreed Upon Requirements
Wants
Needs
Agreed-Upon
Requirements
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• extra costs
• something that is added to the process
• a method to produce extra paper
• a more expensive method to do the same job
• a new idea
Quality is not
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What is Quality Assurance (QA)?
A useful definition of QA is that it is:
A Management System designed to givemaximum confidence that a given acceptable
level of quality is being achieved in a Product orService with a minimum total expenditure.
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What is Quality Assurance (QA)?
– QA is what a lot of us call Good Management
Practice– The essence of QA is contained in the statement:
• GET IT RIGHT
• FIRST TIME (no reprocessing)• EVERY TIME (process consistency and repeatibility)
• ON TIME
- To achieve this, business must be managed in alogical and organised manner.
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What is Quality Assurance (QA)?
IT IS NOT:
• something that is added on or into a process orsystem,
• a method of producing more paper,
• a more expensive way to do the same job,• and its not a new idea.
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What is ISO 9000
ISO 9000 is a series of standards that establish minimum
requirements for Quality Systems.They describe a system for planned and defined activitiesthat assures attainment of a minimum level of quality thatmeets the requirements of contracts and evidence that those
requirements have been met.
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Evolution of ISO 9001 QMS Standards
• ISO 9001:1987
• ISO 9001:1994
• ISO 9001:2000
• ISO/TS 29001:2003 &API Q1 (7th Ed.)(Identical Standards)
– ISO 9001 Published and began gaining popularity worldwide as a QualityManagement System Standard.
– Recognized as a set of “good business practices”, many of which most “good” companies already implementing.
– Contained 20 Quality System “elements” covering all phases of anorganization’s activities (excluding commercial).
– Retained 20 element format and tightened up some verbiage to reducebroad interpretations of some requirements.
– Added new requirements for “Design Validation” to existing “DesignControl” requirements.
– Added requirements for “Preventive” actions in addition and to supplement “Corrective” actions.
– Changed from a 20 element format to a 5 element format.
– Objective to cover all industries (including service organizations, software,etc.).
– Added new requirements for Quality Objectives, Customer focus andcommunication, continuous improvement.
– Reduced number of documented procedures from 19 to 6 [ i.e., 1)
Document Control, 2) Records Control, 3) Audits, 4) Control ofNonconforming Product, 5) Corrective Action, 6) Preventive Action.]
– QMS Requirements for Petroleum, Petrochemical and Natural GasIndustry. (Effective Sep 15, 2003 and Dec 15, 2003 respectively)
– Incorporates ISO 9001:2000 verbatim and includes supplementalrequirements of 9001:1994 and API Spec Q1 6th Ed.
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What is a Quality Management System?
A Quality Management System means that all your:
– SYSTEMS,
– PEOPLE AND
– PROCESSES
are welded into one cohesive system to give you and yourcustomers the maximum confidence that you are consistentlyachieving an acceptable level of quality. To remain
competitive you must achieve this objective with a minimumtotal expenditure.
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What is Quality Control (QC)?
Quality Control is the totality of activities (measurements,
tests,...) that ensures that bad Products and Services areseparated from good products and that the customer doesnot receive the bad products.
Quality control activities (e.g. inspection) are a cost which donot directly add value to the product or service – however,they do provide confidence that all problems will be identified
and resolved before it is too late.
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What is Quality Control (QC)?
Q.C. is part of the Quality System.
Q.C. is the physical checking that the work has been performedaccording to Contractual Requirements.
The results of Q.C. are such things as:
– Reports (NDT/Destructive Testing)– Pressure tests charts/NDT Graphs
– Mill Test Certificates
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QA and QC
If your QC activities continually find errors it means that your
QC system is working well but that your fundamental QASystem is not working.
If you have a good QA System your QC will prove that workis being done correctly.
The Quality of a product starts at the beginning not at theend when you do your QC.
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Quality Management System (QMS)Drilling & Completion
ContinuousImprovement
EngineeringWell Design
Construction /OperationalExecution
Goods / ServicesProcurement
Customers’ Requirements
Engineering Well Design
Goods Procurement
Services Procurement
Incorporate and DisseminateLessons Learned
Final Well Documentation /
Evaluate KPI’s / Lessons Learned
Well Completion(Installation of Equipment)
& Execution of Services
Well Drilling(Installation of Equipment
& Execution of Services)
Planning & Budgeting (P&B)
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DRILLED WITH MINIMUM SHIFT FROM DESIGN TRAJECTORY
ORE TARGET ACHIEVEMENT WITHOUT ANY FORMATION DAMAGE
REGULAR HOLE SURFACE (SKIN FACTOR)
GOOD CEMENTING OF ALL CSG. STRINGS
CORRECT FUNCTIONING OF ALL SEALING PARTS
DRILLED AND OPERATED WITHOUT ANY ENVIRONMENTAL DAMAGE
Quality Requirements in Wells Construction
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SUPPLIERS QUALIFICATION
VENDOR LIST UPDATING
PROCEDURES REVIEW
TECHNICAL SPECIFICATIONS
QUALITY PLANS
CLARIFICATION AND KICK-OFF MEETINGS
CONTINUED...
Q.A. in Well Operations
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FIELD AND MANUFACTURING SURVEILLANCE
AUDIT AND ASSESSMENT
FAILURE ANALYSIS
FEED-BACK MANAGEMENT
QUALITY RECORD MANAGEMENT
Q.A. in Well Operations
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NOT REPEAT THE SAME ERRORS
MAKE STATISTICS AND CALCULATE QUALITY INDEX FOR SUPPLIERS,GOODS AND SERVICES
CONTROL THE TIME EVOLUTION OF PARAMETERS AND INDEXESRELEVANT TO SUPPLIERS AND SERVICES
SUPPORT SUPPLIER QUALIFICATION
MEASURE IMPROVEMENTS AND FIX NEW QUALITY TARGETS
FEED-BACKIs essential to:
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PERFORMANCE EVALUATION
SYSTEMS FOR Eni-Agip VENDORS
Drill ing, Completion & Workover
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TOOLS USED TO COLLECT FEEDBACK
• Form FB 01 (rig-site)
• Form FB 02 (District)
• Form “Evaluation of fluids assistance
service suppliers”
• Audit and technical assessment report
Performance evaluation systems for Eni vendors
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FB01 - Malfunction & Failure Report
Originates the report
Contractor’s comments
Rig site
Operating Base
District
Add comments
and cost lossClassification
Data base
Headquarter
Performance evaluation systems for Eni-Agip vendors
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FB02 - Contractor Evaluation
FB01
Originates the reports
at the end of the job
Operating Base
DistrictRig si te Headquarter
Classification
Database
Performance evaluation systems for Eni-Agip vendors
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Performance evaluation systems for Eni-Agip vendors
FB01
Rig site
FB02
Operating base
DistrictHeadquarter
Elaborates Data
Evaluates Indicators
Analyses Trends
Contractor’s Evaluation Process
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PERFORMANCE AND RELIABILITY
INDICATORS
• Failure indicator (IF) from forms FB 01
• Performance indicator (IP) from forms FB 02
• Deviation indicator (IS) from fluids service evaluation
forms
• Scoring model for audits
Performance evaluation systems for Eni-Agip vendors
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FAILURE INDICATOR (IF)
I.F. = Economic value of failures x 100
Total Invoiced
Performance evaluation systems for Eni-Agip vendors
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Performance indicator (IP)
I.P.Rig = (scores x weights)
I.P.Supplier = (scores x weights)
n° of wells
Performance evaluation systems for Eni-Agip vendors
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USING FEEDBACK AND INDICATORS
• Monitoring the quality of the services offered by each Contractor – Updating of the Vendor List
• Performance of inspections/audits of vendor quality systems
• Support for technical opinions in tenders• Update of technical specifications, internal standards and company
procedures
• Identification of particularly critical areas• Calculation of indicators and coefficients to realign economic
aspects in the tenders when assigning “type A” contracts
Performance evaluation systems for Eni-Agip vendors
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ORGANISATION CHART
STAP DEPARTMENT
Drilling & CompletionStandards
Well DataAcquisition &Management
TechnicalSpecificationsEquipment &
Services
OperatingManuals & Procedures
&KnowledgeManagement
Well Equipment& Materials
Q.C.
OperationsFeedback
Cost Control
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Eni E&P Division - SPEO/STAP
Drilling & Completion Manuals & Procedures System
Best Practices and Fundamentals
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The Drilling & Completion
“Manuals & Procedures” System
of Eni E&P division
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Provide a corporate standard for all contexts where
Eni Agip operates either directly or through its Subsidiaries, in
order to lay the foundations of
Aims of the “Manuals & Procedures”
improved integration between men and tools
and synergy between Corporate Headquartersand Operating Districts/Companies worldwide
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The manuals issued over recent years by theSPEO/STAP “ Manuals and Procedures” Unit
Drawn up on Eni E&P experience
The technical know-how and experience that SPEOpersonnel has gathered working in the operative districts
in Italy and abroad
The external “ state of art” , through the contribution of
contractor company specialised in preparing manuals for
several major oil companies
The Drlling & Completion manuals are prepared on the
basis of :
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Drilling & Completion
Manuals & Procedures
System Manuals
Best Practices
Procedures
Corporate Headquarters
Technical Know-how and
Experience gathered in the
Districts and Subsidiaries
Integration of the
external “ state of
art”
SPEOSpecialists in SPEO
The Manuals & Procedures System
O i i f h
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Agip Charter of
Fundamental Company
Principles
Drilling & Completion(SPEO) Activ ity Process
Design / EngineeringManuals
General OperativeProcedures
Specific Manuals
Specific Procedures
Operative ProgramsJob Instructions
Agip Charter of
Fundamental Company
Principles
Drilling & Completion(SPEO) Activ ity Process
Design / EngineeringManuals
General OperativeProcedures
Specific Manuals
Specific Procedures
Operative Programs
Job Instructions
Organisation of the
“Manuals & Procedures” System Agip Charter
SPEO Activity
Best Practices
M a n u a
l M a
n u a l
M a n u a
l
P r o c e d
u r e
P r o c e d
u r e
P r o c e d
u r e
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Manuals & Procedures
“Best“Best PracticesPractices and Minimumand Minimum RequirementsRequirements for for
Drilling & CompletionDrilling & Completion Activities Activities” ”
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They are a sort of “ route map” which gives the best
operative practices and addresses to the documentsof the Manuals & Procedures System
BP & MR Contents
The contents are organised in 3 main sections:
Planning
Operations
Reporting & Feedback
(PL)
(OP)
(RF)
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A sample of BP & MR Contents
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Manuals & Procedures
““DrillingDrilling && CompletionCompletion Fundamentals” Fundamentals”
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The “Drilling & Completion Fundamentals”
Drill ing Design Manual
Drilling Procedures Manual
Casing Design Manual Directional Control and Surveying Procedures
Well Control Policy Manual
Overpressure Evaluation Manual
Drilling Fluids Operations Manual
Completion Design Manual
Completion Procedures Manual
Well Test Procedures Manual
General Wireline Procedures Manual
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Casing and Tubing Design
Down Hole Safety Valves Engineering and Maintenance Tubing Connections Selection
Well Name Designation
Preparation of the Geological and Drilling Well Program
Preparation of the Final Well Report
Reporting Forms preparation after each operation
Handling and Running Procedures for Tubular Equipment
Wellsite Safety Procedures in H2S Environment
Simultaneous Operations Procedures
etc.
Contents of the 11 “ Fundamentals”
A step beyond the titles to understand what is inside :
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Covering the main Drilling & Completion activities
(for both Planning and Operations)
Reduced spreading of information on numerous documents(the “Fundamentals” are 11 manuals)
Organisation of the manuals to allow easier diffusion in Eni Agip Districts and Affiliated Companies (all documents are
written in English)
Features
A)
B)
C)
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The manuals are available to all Eni AGIP Districts and
Subsidiaries worldwide in the following formats :
HARDCOPY - both A4 and A5 (this is the very poular pocket book format)
SOFTCOPY - accessible by logging onto the SPEO Web site in the Eni
Intranet network (feasible for the Corporate Headquarters Units, the Italian Districtsand several Eni Agip Subsidiaries worldwide)
SOFTCOPY - on dedicated CD-Rom (very useful for foreign Subsidiaries where
connection with Eni Intranet is not available or for rig site utilisation)
Distribution of the “Manuals & Procedures”
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Drilling & Completion WORLDDril ling & Completion WORLD--WIDE ACTIVITIESWIDE ACTIVITIES
CHINACHINAUKUK
NORWAYNORWAY
AZERBAIJAN AZERBAIJAN
KAZAKHSTANKAZAKHSTAN
EGYPTEGYPT
LIBIALIBIA
ALGERIA ALGERIA
TUNISIATUNISIA
USAUSA ITALYITALY
ECUADORECUADOR
BRAZILBRAZIL ANGOLA ANGOLA
NIGERIANIGERIA
CONGOCONGO
DRILLING SHIP Saipem 10000DRILLING SHIP Saipem 10000
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Eni Agip Division
Drilling & Completion Manuals & Procedures System
JOURNEY THROUGH THE MANUALS
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The Best Practices & Minimum Requirements document is
the basis for the preparation of the Check Lists we use to
carry out the Assessments of Drilling & Completion
Operations in the Districts and Subsidiaries
Audit Check Lists
Organisation of the
Agip Charter
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Organisation of the
New “Manuals & Procedures” System
g p
SPEO Activity
Best Practices
M a n u a
l M a
n u a l
M a n u a
l
P r o c e d
u r e
P r o c e d
u r e
P r o c e d
u r e
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