Engineering of completions programs that are reliable and cost effective is a fundamental responsibility of the drilling and completion community. Reliability methods for HPHT and critical well design are the most effective means of controlling schedule, cost, performance, and risk, which combine to define Life Cycle Cost (please refer to Figure 1). Optimization requires mechanical integrity while maximizing flow capacity of the system, thereby eliminating lost production and workover costs. Deep well costs can be among the greatest of the industry.

Reliability methods are common in industry and have seen increasing application in Exploration and Production. Reliability methods are not merely concerned with quantifying risk-rather the ultimate goal is production optimization with a robust system. System analysis, operating environment evaluation, component assessment, and data management are required in a reliability program and in optimized stochastic modeling. Following a discussion regarding production system design optimization the topics of material and equipment qualification will be presented. Drilling and completion optimization involves qualification of design (often through variability assessments and worst case analysis), Manufacturing (typically suppliers, material, and component qualification), assembly (which may include FAT1 and qualified rig procedures), and operations (that is operating within design limits).

Production system optimization addresses the four principal sources of failure shown in Figure 2. An integrated team is initially applied to optimize the completion program considering these four viewpoints, and then the team efficiently and cost-effectively executes the plan with specialists. Net present value of risked production and cost are used in optimization.

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