Lean Start-Up Procedure for Optimized Heavy Oil Well Operations

Abstract The South Ratqa Heavy Oil field in Kuwait, a key initiative in the nation's thermal recovery endeavors, employs the cyclic steam stimulation (CSS) method within its challenging sandstone formations. The field's operational efficiency was hampered by the original well layout, which necessitated the dismantling of critical components such as the 4-inch production flowline, 2-inch casing gas vent line, and 2 1/16-inch wellhead sensors for maintenance and intervention access by the flushby unit (FBU). This process significantly extended downtime, contributing to a monthly production deficit of around 5, 000 barrels and impacting the field's goal of 60 MBOPD. In 2020, an initial process modification allowed the 4-inch production flowline to remain in place, reducing downtime from 10 days to 5 by avoiding its removal. Building on this improvement, a Management of Change (MOC) implemented by the Fields Development Heavy Oil Team (FDHO) in 2022 further optimized operations. The MOC enabled the immediate operation of pumps post-installation, without waiting for the reconnection of the dismantled casing gas vent line and wellhead sensors. These components could be reconnected later, aligning with the maintenance crew's schedule, thus minimizing non-productive time (NPT). Adopting this approach, rooted in lean methodology principles of efficiency and waste reduction, reduced well downtime further from 5 days to less than 24 hours, markedly improving production rates and reducing overall well downtime. This initiative, projecting annual savings of 4, 900, 000, has redefined operational efficiency and cost management in the South Ratqa Heavy Oil field. The optimized flowline configuration and wellhead layout, validated through this project, will guide the design of future expansions, ensuring operational efficiency from the outset.