Quality Management Alliance Eliminates Plug Failures

Abstract

Abstract Plug cementing is a very broad term that may include setting cement plugs for abandonment, sidetracking a wellbore, lost-circulation control, or remedial work. There are several means by which this may be accom- plished, including the balanced plug and dump bailer methods. Unfortunately, plug cementing is a process that often receives simplistic treatment. However, even plug cementing is by no means simplistic and can be very costly if not properly executed. In addition to the immediate rig time and materials cost associated with a poor cement plug, there are also potential costs from well control and environmental problems. This paper describes the activities and results of an operator/service company quality alliance. The immedi- ate project goal was to improve the success rate of cement sidetrack plugs in the US Gulf Coast operating area. All aspects of the cementing process, including slurry design, material and job quality control, and displacement practices were systematically evaluated and modified as necessary. During the latter stages of the project, a recommended plug procedure (RPP) was established that addressed many of the shortcomings of past practices. A continuous job evaluation process or "Quality Management System" was also implemented to ensure continuous monitoring and refinement of the RPP. Before this procedure was implemented, the prevailing standard in the Gulf Coast was approximately two to five attempts to achieve a successful sidetrack plug. The industry average was approximately 2.4 attempts per kickoff. As of this writing, proper use of the RPP outlined by the study group has achieved a near 100% success rate. Although originally targeted for the Gulf Coast operating area, the RPP has proven to be a global success. This program has provided a multi-million dollar cost reduction to the operating companies using it, and illustrates the value of properly structured operator/service company technology alliances.