Case study
53 hours too late: How early warnings could have prevented stuck pipe and three days of NPT
Published: May 16, 2025
Location: Onshore, Oman
Products used: Exebenus Spotter, Stuck Pipe Agent
Share:
The operator’s first attempt to run casing in the 12¼” section resulted in a stuck pipe event. Although the casing was eventually pulled out, the operation required extensive hole-cleaning and wellbore preparation before a second attempt. While the second run succeeded, the casing had to be set shallower than planned—ultimately causing three days of nonproductive time (NPT).
A historical analysis using Exebenus Spotter’s machine learning (ML) agents revealed that early stuck pipe risk warnings were issued up to 53 hours before the event, first during reaming and later while tripping and running casing, each time at or near the same depth where the stuck pipe eventually occurred. Had these insights been available in real time, the team could have acted earlier and potentially avoided the delays.
Summary of case study for a quick browse:
Challenge
Your Subtitle Goes Here
The first 12¼” casing string became stuck. In preparation for a second attempt, the operator carried out extensive hole-cleaning operations, resulting in three days of NPT and costly deviations.
Solution
Your Subtitle Goes Here
A historical analysis using Exebenus Spotter’s ML–powered Stuck Pipe Agent reviewed real-time operational data and identified early risk warnings.
Results
Your Subtitle Goes Here
Exebenus Spotter flagged the first major stuck pipe risk 53 hours before the incident, at 02:00 on Day 1 during reaming between 1260–1130 m. Over the next two days, additional alerts were triggered during tripping and running casing indicating debris build up and escalating risk of pack-off, risks the rig team could have proactively mitigated.
Challenge
Casing gets stuck at 1033 meters
The operator’s first 12¼” casing string got stuck at 1033 m. Prior to the second run, the team executed extensive hole-cleaning and wiper trips, resulting in three days of NPT and deviations from the original drilling plan. A root cause analysis was performed to understand what went wrong and how similar failures could be avoided.
Solution
Stuck Pipe Agent expose early warning signs
The operator conducted a historical analysis using Exebenus Spotter’s ML-powered Stuck Pipe Agent, which continuously analyzes time based operational data, detecting subtle patterns in mechanical drag, hookload variation, equivalent circulating density (ECD), and pressure fluctuations. These patters often go unnoticed by traditional monitoring but offer early signs of deteriorating hole conditions.
The analysis revealed that actionable alerts were triggered multiple times across different operations—reaming, tripping, and casing—at or near the same depth. These were missed opportunities where intervention could have prevented the event.
Exebenus Spotter Stuck Pipe Agent identified stuck pipe risk at the same depth during three different operations: (A) while reaming at depth 1260-1130 m, (B) while tripping out of hole at depth 976-895 m, and (C) during the first failed casing run at 800 m and again when performing the second casing run at 950-1033 m.
Results
Agent flags repeated risk at same depth
The first stuck pipe risk warning was flagged at 02:00 on Day 1, during reaming between 1260–1130 m. Over the next 53 hours, Exebenus Spotter issued additional alerts:
While tripping out, between 976–895 m, the agent flagged drag and pressure anomalies indicating that increasing amounts of debris were being dragged along the borehole from the original accumulation zone, leading to restricted flow.
During the first casing run, the agent highlighted excessive drag at 940 m, shortly before the casing got stuck at 1033 m
Each of these alerts occurred near the same depth, signaling escalating risk due to accumulation of debris that could have been mitigated.
The analysis shows that these were not isolated warnings, they represented a consistent pattern of deteriorating hole conditions over time and across operations. Had Exebenus Spotter been used in real time, the rig team could have taken targeted action such as extended circulation, additional reaming, or adjusting casing strategies to avoid the event.
Drilling the build section
While drilling the 12¼” build section with a dogleg of 4°/30 m, the crew back-reamed from 1260 m to 1030 m to expand the wellbore through the kickoff point at 1020 m.
Exebenus Spotter flagged elevated mechanical drag and stuck pipe risk between 1260-1130m, pointing to a tight zone caused by the borehole geometry.
Tripping out of hole (Day 2-3)
Between 08:00 pm on Day 2 and 02:00 on Day 3, while tripping out at a depth of 925 m, Exebenus Spotter flagged high ECD and pressure fluctuations indicating excessive debris accumulation restricting flow, and mechanical and dynamic drag indicating pipe restrictions. Overall, reinforcing an escalating risk situation.
Hole Cleaning and Mechanical Sticking modules issued multiple warnings between 976-895 m, indicating deteriorating conditions.
First casing run and outcome (Day 3)
During the first casing run, between 07:30 – 11:00pm, Exebenus Spotter detected significant mechanical drag, most notably at 940 m. Mechanical sticking alerts indicated that free movement of the casing was not possible. The casing became stuck at 1033 m, the same interval previously flagged.
After substantial effort the casing was pulled free. A full wiper trip was performed, however, drag warnings persisted, indicating insufficient debris removal.
On the second attempt, the final five joints encountered resistance. Exebenus Spotter analysis confirms that they had to work casing past the previously identified tight spot. Ultimately, the casing was set at 1420 m TD, slightly short of the planned target. Resulting in three days of NPT and significant deviations from the original drilling plan.
Mechanical drag warnings were issued at approximately 800 m, at 950 and again at 1033 m, consistent with the depth interval where the stuck pipe event occurred.
Lessons learned
Warnings came early. Actions came too late.
The 53-hour window of escalating alerts was an opportunity for proactive mitigation. Relying on manual interpretation only may miss important patterns. Exebenus Spotter’s real-time ML analysis provides granularity, context, and visual cues that make risk actionable.
Had Exebenus Spotter been used during the operation, the rig could have received clear, timely alerts and adjusted accordingly, potentially avoiding the stuck pipe and three days of NPT.
This case underscores the value of real-time, ML-based monitoring. Exebenus Spotter transforms risk management from reactive troubleshooting to predictive intervention, helping operators deliver wells more safely, efficiently, and with fewer surprises.
Contact us
Want to learn more about our products and services? Send us an email, and we’ll connect you with the right expert.
Sometimes the moment that never happen matter the most — lessons learned from 53 hours of early warnings.