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Everything Planned Perfectly, Except for One Small Part...
I had been transferred in specifically for my offshore drilling experience. This was the first drilling campaign the customer had ever done and I was brought in to manage the entire project - subsurface, drilling, completions, facilities and production operations. It felt ok as I had done this job many times before in many areas, but this felt special - it was new for this company, and they were nervous, which meant everything was reviewed closely. It is normal in the industry to never have enough time for planning, and this was no different, but the schedule wasn't too bad and the people I worked with were all experienced professionals so the planning went smooth.
This drilling project kept gaining momentum and we blew through the AFE decision gate and kept rolling into the execution phase. The Drill Well on Paper (DWOP) was productive and had lots of good comments and ideas. It was also the first (and only) time I have had a DWOP attended by the regulator and all the contractors felt comfortable to speak their minds. This was an unique situation where the right people with the right attitude really supported each other to try to get the best outcome for all.
Last Minute Change? - No ProblemThen we had an issue - one of many that came into the register and we managed to clear off. The met-ocean analysis came back with a new model showing that our 30" conductor design wouldn't be able to take the fatigue loading from wave action. We needed to run 36" to meet the design requirements. Like lots of projects, panic sets in while trying to source the revised equipment specification, but fortunately we were able to locate the pipe and get it delivered in time. There was enough for our two wells and one string for back-up as well.
Plan for Success and Prepare for FailureLuck Favours Those Who Have a Plan B
The crossover from the 36" to the 30" - it had collapsed! But why? The circulating pressure was high, but not close to the collapse on the pipe. Check the pressure chart from the cement unit - it's ok. Check the collapse rating of the 30" - it's ok. Check the collapse rating of the 36" - it's ok. Check the collapse rating of the crossover - it's...missing? No, it was never done! It wasn't part of the original design, and the revised design focused on the 36" conductor but not the crossover...we missed it. How could we miss it - we documented everything? We just missed it, and the circulation pressures for topple were supposed to be eligible anyway, until we had to change the template. I saw the slices of Swiss cheese in my nightmare as their holes were lining up, and the next site was of a time-depth curve that would go off the page...
