Key Words: Project Planning | Asset Protection

INTEGRATED CSG CURTAILMENT PLAN

Situation:
A large energy provider on the East cost of Australia built and commissioned a wide fleet of major gas facilities to dehydrate and compress wet coal seam gas (CSG) received from an extensive network gathering hundreds of wells. Periodically, it was necessary to complete a complex campaign of preventative maintenance (PM) tasks on these gas facilities to meet safety standards. Some PM tasks dictated that the facility must be blown down and totally free of pressurised gas. The CSG wells would forward flow to these facilities utilising both reservoir pressure and downhole water pumps. These pumps experienced the highest levels of reliability when they were left in a steady state operation. The cost to repair just a single CSG downhole pump could be in excess of $150k. So what to do when a major facility shutdown event forces the need for hundreds of wells to be taken offline? Is a multi-million dollar financial impact deemed acceptable as a justifiable cost of operation expense or is it avoidable?
Task:
We were responsible for an enterprise level well curtailment plan that sought to redirect gas flows to neighbouring online facilities or alternatively to safely take offline wells that presented the lowest levels of financial risk exposure. Additionally, the plan needed to safely restore gas flows to full pre-shutdown production rates.
Actions:
  • Facilitated project level reviews of shutdown schedules for alignment, opportunity identification and risk avoidance.
  • Defined clear roles and responsibilities across Operations, Production, Gas Trading, Upstream Control Room and the Shutdown Team (40+ Staff).
  • Utilised existing available operational data to design and build a fit for purpose curtailment model within 2 weeks.
  • Pioneered forward supplying modelled gas profiles to the Gas Trading Team to allow for fully optimised end to end value chain optimisation.
  • Implemented exception based surveillance tools to protect the realtime safety case of the asset (700+ wells | 6 major facilities).
  • Coordinated daily onsite project meetings, managed SIMOPs complexitiies and mitigated schedule risk dillemas as they emerged.
  • Deployed a visual management dashboard with live links to the production system to keep Senior Management and Gas Trading teams informed in real time. 
Results:
  1. A team spirit galvanised around shared delivery towards a clearly understood common goal.
  2. Zero safety incidents involving staff, the environment or the company’s assets.
  3. Zero well failures and the avoidance of $5m worth of expected well failures.
  4. $11m worth of additional revenue flowing from optimised gas deal pricing and reduced gas deferment.