Energy

Cutting frack time in half

July 19, 2011

Global

July 19, 2011

Global
Our Editors

The Economist Intelligence Unit

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Replication is not just about building structures faster. “It’s about learning to learn faster,” says Mr Wetselaar, executive vice-president of finance at Shell Upstream International. He points to Shell’s development of unconventional shale gasfields in North America. Shell began development of its first field in Pinedale, Wyoming in 2002, drilling hundreds of multistage fracturing wells over the 20,000-acre resource. The first well took 60 days to drill, but thanks to efforts to replicate and streamline the project management process, by 2010 the schedule had dropped to 25 days, and costs were reduced by 25%, despite a surge in material costs.

Using the lessons learned at Pinedale, Shell began development of Groundbirch, a shale gas field in Canada. The first well took 40 days to drill. Within three years, they were down to 15 days. “It wasn’t only that we were able to proportionately achieve the same learning, we were able to learn faster,” says Mr Wetselaar. The trick, he adds, is getting all of the internal development teams and external contractors to focus on the common goal of optimising the final outcome. “Typically in these projects, you get siloed bits where each team works on a task then hands it over to the next group.”

When they work in isolation, workgroups tend to optimise their own efforts, but unless those efforts are aligned with the broader project goals, that can be counterproductive. At Pinedale, for example, the team linking the wells to the pipeline system would wait until several wells were ready to connect. This reduced their cycle time, but left many wells sitting idle for several days with no gas flowing. “The project only makes sense when gas flows,” says Mr Wetselaar. By examining the lifecycle of the project with the end goal in mind, the teams identified cross-functional optimisation strategies, including hooking up each well as soon as it was ready, even if it added time to the overall hook-up process.

Shell is now applying these same strategies for optimisation and project replication in China, where they anticipate faster and more streamlined drilling operations thanks to the lessons learned in North America. “It’s only when you approach integrated optimisation from a lifecycle standpoint that you achieve these benefits,” comments Mr Wetselaar.

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