Applying Lean Methodology to Improve the Operational Efficiency of a Well Stimulation Vessel

Abstract

Western offshore fields in the South and East Asia region are depleted and require frequent stimulation. To efficiently deliver stimulation treatments, a supply vessel has been converted into a well stimulation vessel with limited well flowback capability. This is one of only a few vessels in the world that has a zero-discharge flowback facility with certification by industry-recognized external organizations. Developing the vessel and operations plans required a systematic approach to continuous improvement. The process involved identifying the criteria for efficiency and effectiveness for an offshore stimulation vessel and building in continuous improvement methodology with a focus on visual order, organization, safety, and standardization of operations. A lean management methodology was applied to systematically analyze and improve operational process efficiency in relation to organization, orderliness, cleanliness, adherence, and self-discipline. A series of checklists were introduced to enable procedural adherence with monthly self-evaluations to identify areas of improvement and develop remedial work plans. This paper describes the vessel conversion and installation process as well as the lean approach and health, safety, and the environment (HSE) requirements. The vessel has been used for a variety of stimulation jobs such as proppant fracturing, sand control pumping, matrix stimulation, nitrogen pumping, and limited flowback. These stimulation jobs have been achieved with no recordable injuries and zero nonproductive time by introducing operating procedures, training crew members in those procedures, and monitoring adherence. Systematic efficiency improvements related to materials and procedures led to a 23% reduction in onboard crew size, thereby reducing the risk exposure to personnel. Vessel repair and refabricating expenditures have been reduced by 53%. This vessel has delivered an average of 40 jobs per month, achieving a peak job frequency of 64 jobs per month and treating more than 1,000 wells to date. This paper provides an overview of the practices developed and lessons learned for operating an offshore stimulation vessel, including process flow charts with trackers and checklists designed to improve operational efficiency.