The Duri oil Field has 3,000 active wells divided into 9 (nine) areas. To measure the volume of oil and water produced, each well is tested approximately twice a month. When an NFD (no fluid detected) condition occurs during the test, the well is not performing properly and should be checked to see what requires repair.

Cycle time to put the well back to production depends on: response time to NFD wells, number of NFD wells found that day, the type of repair required, and the resources available to make the repair. Without intervention, the NFD wells automatically are put back into retest by the programming logic. Historical data from Area-4 in 1999 shows that wells were off production an average of 405 days/month due to NFD status. With a median production of 34 BOPD / well, 450 BOPD was not being produced. At a crude price of 12.5 US $ / barrel the total lost opportunity cost is 2 MM US $/ year.

Starting in late February 2000, the project team began deployment of Six Sigma tools, with the result that the response time was reduced to only 300 days in March and then farther reduced to 140 days in April and May. The number of individual NFD wells was reduced from a 1999 average of 69 wells to 54 wells in March and 25 wells in April and May. The effort resulted in a production increase which equates to an annualized opportunity gain of 1.0 MM US $/ year. The background, objectives, and results of the Area-4 respond time to NFD wells improvement program are presented in the report.

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