The expansion phase of the offshore Mafumeira major capital project in Angola commenced in 2015. Because ofthe global low-oil-price environment, the team was challenged to revise the basis of design and operational procedures to help reduce well construction time by more than 50% and accelerate the date of first oil production.A major focus of this effort was to conduct as many offline activities as possible during the well construction. Offline activities were performed before or after the jackup rig movedonto the slot, reducing the overall project cycle time. The feasibility of conducting offline cementing was evaluated and risk-assessed for several of the planned casing strings. The concept was conceived and implemented, initially for the 20-in. surface casings, for the second batch of wells in the expansion project. The ability to cement the surface casing offline allowed the rig to move to another slot and drill the next well in the batch campaign while simultaneously cementing, cutting the casing, and installing the wellhead on the previous well. Nine tophole sections have been cemented in Angola using the offline cementing technique, providing USD 4 million intotal cost savings and reducing rig time approximately 18 hours per well, which helped achieve the overall target of reducing well construction time by 50%.The cementing objectives were successfully achieved in all cases, including adequate top of cement (TOC) and formation integrity tests (FITs) upon drilling out the shoes. As part of continuous performance improvement, the opportunity to perform cementing offline in deeper hole sections of the well is being assessed.
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