Executive viewpoint

To meet the ever-increasing demand for energy, and reduce dependence on foreign oil, the U.S. oil and gas industry continues to unlock new reserves, both on and offshore; a process that is driving growth.

This growth continues to yield advancements in deepwater drilling, directional drilling and hydraulic fracturing. However, such advances are not the exclusive realm of downhole operations. Tremendous process improvements are also being made at ground level, to increase efficiency, minimize costs and protect the environment. 

Advanced-composite mat systems are one such improvement. They reduce site construction costs and offer greater protection to the environment. The visibility of these mats has the added benefit of improving the industry’s public image.

Heading into 2014, regulators throughout many oil- and gas-rich areas are looking to shale plays like the Marcellus—where environmental standards are high—for guidance on best practices. This process is likely to lead to the adoption of more stringent standards and practices in other parts of the U.S. Operators can stay ahead of the regulatory curve by adopting existing best practices, which are already prevalent in America’s northeastern shale plays. While these measures have become integral to operating in this region, they also increase operational costs. To meet these strict requirements, while maintaining the bottom line, innovations—such as composite mats—are being utilized in shale plays throughout the U.S., and other regions.

Prior to the use of advanced-composite mats, site preparation was limited to the use of subgrade, which provided a foundation for drilling equipment. Local regulations then led operators, in northeastern shale plays, to apply an additional layer of poly-liner, for spill and leak prevention. However, with the heavy equipment traffic at drill sites, the liners proved to be prone to wear and tear.

As a result, operators turned to wooden mats to protect their liners, but it soon became evident that these were simply compounding the problem, with frequent pinches and tears. The cost and time spent on liner repair and replacement, as well as proper disposal, began to escalate, causing operational delays and—in some cases—stiff fines, for spills related to torn liners. 

However, today’s operators are meeting such challenges head-on with the growing use of advanced-composite mats.  These heavy-duty mats are liner-friendly, with an interlocking design that prevents shifting, gapping and tearing. This complies with environmental regulations and significantly reduces maintenance, and rig downtime, due to liner repair and leak mitigation.

While traditional wooden mats absorb contaminants and retain debris, advanced-composite mats can be cleaned quickly and thoroughly. The ability to efficiently clean composite mats addresses concerns related to site-to-site contamination. It also reduces the risk of roadway hazards, caused by falling debris.

When contamination makes cleaning impossible, wooden mats require additional expense for incineration or disposal in landfills. However, advanced-composite mats, which are recyclable, can be cleaned and reused. Using specially engineered automated cleaning systems, an entire rig’s worth of these mats can be washed in hours, rather than days. This speeds rig remobilization and saves both time and money.

Advanced-composite mats provide a wide range of additional benefits for operators.

Reduced trucking costs. The mats weigh considerably less than their wooden counterparts and cost nearly two-thirds less to transport. With fewer truckloads, road wear diminishes and traffic is minimized around the worksite, making for safer, and more efficient, site operations.

Return-on-Investment. The interlocking design and load distribution capability of the mats reduces the need for subgrade when constructing the drilling pad. This lessens the costs, which in turn contributes to a better ROI, associated with the trucking, and eventual removal, of the subgrade.

Health, Safety & the Environment. While complying with increasing environmental regulations, the mats’ design also improves worksite safety. The resulting work surface eliminates gapping and uneven surfaces, thereby lowering the risk of trips, slips and falls.

Improved Public Image. The use of advanced-composite mats helps oil and gas operations offer safer, and more environmentally sound, drilling and completions. Responsible operating practices demonstrate a more proactive approach to spill containment. They allow operators to stay ahead of growing regulatory demands, and engender further goodwill with both property owners and the local communities in which they operate. Greater potential exists for building positive public perception of drilling and completion operations in general, as well as of the operators themselves. The composite mats can help prevent negative public reports that may result from recurring safety and environmental incidents, which can, themselves, lead to site delays, closures, stiff fines and more regulations.

As 2014 approaches, innovation will be crucial to developing America’s oil and gas resources in more populated, and environmentally sensitive areas. Above-ground innovations, such as advanced-composite mats, allow operators to meet regulatory demands while reducing operating costs, and protecting both workers and the environment.

Ongoing advances, both above and below ground, are a public demonstration of the oil and gas industry’s “can-do” spirit. Innovations ranging from new drilling and extraction methods, to the use of next-generation advanced-composite mats and spill containment, will continue to grow this expertise and precision engineering; enabling the industry to effectively and responsibly further U.S. energy independence.