Running to Succeed: Why Preventative Maintenance Is a Winning Strategy for Oil and Gas Facilities

Experienced car owners understand that skipping routine maintenance can lead to costly repairs and serious risks, such as brake failure. Similarly, in the oil and gas industry, delaying maintenance increases the likelihood of unplanned downtime, safety hazards, and expensive fines for environmental violations.

Yet, too often, oil and gas companies—particularly in upstream operations—rely on a “run to fail” approach to maintenance. This can stem from a misguided attempt to save money on upfront costs, a lack of visibility, or neglect of long-term planning. Simply keeping vital equipment like valves and actuators running until they fail leads to unnecessarily inflated consequences.

Oil and gas businesses can shift from running to fail to running to succeed by adopting a proactive maintenance culture. This approach reduces downtime, ensures regulatory compliance, and addresses environmental concerns—while also boosting operational efficiency and improving the bottom line.

Why “Run to Fail” Is a Recipe for Failure at Oil Pads and Fracking Operations

The failure to plan ahead can have serious consequences, including:

• Higher repair costs when equipment fails unexpectedly and must be replaced on short notice.
• Higher prices for parts due to emergency procurement.
• Unplanned shutdowns and production delays, resulting in financial losses and lost business opportunities.
• Environmental violations, leading to fines and reputational damage.

Valves, in particular, play a critical role in oil and gas operations and require extra attention to ensure reliable performance.

The Importance of Proper Valve Maintenance

Valves consist of a body, bonnet, or cover that retains pressure, along with the trim—internal parts that directly interact with the fluid flowing through the valve.

Harsh conditions can significantly impact valve trim. Exposure to abrasive sandy water or corrosive hydrogen sulfide can shorten valve lifespan, and incorrect valve specifications can exacerbate the issue.

Additionally, manual valves that are not regularly greased or relief valves that are not tested can result in catastrophic failures, leading to equipment damage and production shutdowns. Relief valves are designed to prevent pressure buildup, but a stuck valve can cause pipe ruptures or explosions, putting safety and operations at risk.

>> Find top-quality valves for your oil and gas operations at MCE.

Environmental Compliance and Valve Maintenance

With increasing regulatory focus on emissions reduction and environmental protection, compliance is a critical factor. Quad O regulations impose strict emissions standards on oil and gas operations, requiring retrofitting of existing equipment. Subpart OOOOb (Quad Ob) introduces additional standards for sources built or modified after December 6, 2022.

These regulations heighten the risks for facilities with poorly maintained valves that may leak emissions, leading to fines or shutdowns.

Proactive maintenance serves as a safeguard against these risks by ensuring that equipment operates efficiently and remains compliant with environmental standards.

Checklist: Key Preventive Maintenance Practices for Valves and Actuators

Here are best practices for maintaining valves, actuators, and other essential components:

1. Routine Valve Greasing

• Manual valves require regular greasing to prevent jamming or seizing, especially in variable climates where temperature fluctuations can cause issues.
• Action item: Incorporate routine greasing into regular site visits to maintain functionality and longevity.

2. Relief Valve Testing

• Relief valves should be tested annually or bi-annually to ensure they open under pressure and prevent system overloading.
• Regulatory compliance: Government-mandated testing schedules vary, but MCE experts recommend annual testing for optimal safety.
• Example: A malfunctioning relief valve in an upstream facility could lead to overpressure and pipeline ruptures, resulting in environmental hazards and fines.

3. Function Testing of Critical Components

• Regular function testing of actuators, control valves, and other key components ensures operational readiness and prevents small issues from escalating.
• Example: Testing battery-backed actuators ensures continued operation during power outages, particularly in remote locations.

4. Component Inspection and Material Selection

• Inspect valve trims for signs of wear, corrosion, or material failure. Choosing the right materials for specific conditions is critical.
• Materials matter: For sandy or abrasive conditions, use hardened materials like Alloy 6 trims instead of soft stainless steel to prevent rapid wear.

Inventory Management Strategies for Preventive Maintenance

Once the basics are in place, strategic inventory management can improve preparedness and efficiency.

1. Vendor-Managed Inventory

For high-production operations with limited staff, implementing Vendor-Managed Inventory (VMI) can ensure a consistent supply of essential components, reducing in-house inventory management burdens.

2. Expertise and Consulting

Partnering with an experienced supplier provides benefits such as:

• Tailored valve specifications and material recommendations based on environmental conditions.
• Application-specific recommendations to reduce costs and improve reliability.
• Expert guidance on navigating environmental regulations.

3. Stocking Critical Spare Parts

Maintaining an inventory of essential components, such as valve trims and actuators, ensures quick response times and reduces downtime. Example: A midstream plant pre-ordered special alloy trims to avoid a 24-week lead time during a planned maintenance window.

4. Remote Managed Consignment Inventory

Facilities in remote locations can benefit from consignment inventory, ensuring a reliable stock of critical parts. This is especially valuable in areas like Alaska, where extreme weather can delay deliveries.

Proactive Maintenance for Oil and Gas: Shifting Culture and Leveraging Emerging Technologies

Transitioning to an effective maintenance strategy may require a cultural shift.

• Moving from reactive to proactive maintenance requires training field operators on compliance, risks, and financial/safety implications.
• Leveraging new technologies can make preventative maintenance more cost-effective, such as:
  • Electric actuators that replace expensive high-torque options.
  • Valve controllers with diagnostic capabilities for predictive maintenance.

Prioritizing Environmental Compliance

Emphasizing environmental compliance is critical for avoiding financial and reputational damage.

• Retrofit valves with emissions-reducing technology to meet Quad Ob/Oc standards.
• Use emissions control components to minimize environmental impact and reduce regulatory penalties.

Putting It All Together for Smart Proactive Maintenance

Shifting to proactive maintenance in upstream and midstream facilities enhances operational resilience, empowers teams, and frees up valuable time.

Key benefits of this approach:

1. Reduced Downtime: Preventive maintenance minimizes production interruptions.
2. Regulatory Compliance: Meeting environmental standards prevents fines and enhances reputation.
3. Cost Savings: Long-term repair and replacement costs are reduced.

MCE’s expert team can help you achieve these goals. If you're ready to put these strategies into action, contact MCE for a free assessment to ensure continuous access to the parts, assistance, and expertise needed to keep your operations running smoothly.