The Importance of Third-Party Oversight in Oil & Gas Projects: Lessons from the Field

In the oil and gas industry, the risks are consistently high. The systems that are designed and deployed must operate under some of the most extreme conditions on Earth—thousands of feet underwater, under immense pressure, and/or in highly corrosive environments. The margin for error is thin, and when things go wrong, the consequences are severe, both in terms of financial impact and safety risks.

Having spent over a decade in the oil and gas sector, designing equipment and conducting failure analyses, I’ve seen firsthand how even the best-laid plans can unravel when they encounter the realities of the field.

Why Testing Isn't Enough: The Value of Third-Party Oversight for Real-World Reliability

One of the biggest challenges in oil and gas projects is ensuring that the systems we design work as intended once they’re installed. This isn’t as straightforward as it sounds. For example, in subsea environments, we deal with water depths of up to 12,000 feet. The equipment must be lowered into place and secured, often without the ability for human intervention. Testing this equipment in a controlled environment is one thing, but ensuring it functions reliably in the real world is an entirely different challenge.

In one case, we designed a locking mechanism intended to stay securely in place at the bottom of the ocean. During installation, everything appeared to go smoothly—until a video camera, still observing the site, captured the lock disengaging on its own after just 30 seconds. This was a product that had been installed in hundreds of locations worldwide, and this failure meant that every one of those installations was now suspect.

This is an example of how impactful third-party oversight can be. In the oil and gas industry, internal teams are often highly capable, but they can also be too close to the problem. A fresh set of eyes—particularly one not tied to the outcome—can provide an objective assessment of the situation.

When Small Mistakes Lead to Big Losses: Why Third-Party Oversight and Early Detection are Crucial

The financial implications of not catching these issues early can be staggering. Land side developments often cost millions of dollars per well drilled and completed. The off-shore developments easily top the cost of land developments by a factor of ten.

Even some seemingly innocuous observances during the installation of field proven equipment have ended up spelling the beginning of a catastrophic event chain. In one such instance, a component was being retrieved from a subsea well when it became dislodged from the retrieval tool. No official notice was taken. That object fell and damaged critical geometry that ultimately led to an $80 million dollar loss. The root cause was traced to a design flaw within the retrieval tool that had been in use for over 30 years.

The Role of Forensic Engineering: Turning Mishaps into Learning Opportunities

While prevention is key, the reality is that things can and do go wrong.

This is where forensic engineering plays a critical role. At EDT, we’re often called in after the fact, when equipment has failed, projects have been delayed, or operations have been disrupted. Our job is to dissect these failures and provide clear, actionable insights that help prevent recurrence.

For instance, I once worked with a team struggling with a piece of equipment that kept failing in the field. They had gone through all the usual troubleshooting steps and couldn’t identify the root cause. When I came in, I applied a structured approach called Failure Modes and Effects Analysis (FMEA), breaking down every component and assessing how each one could potentially fail. Through this process, we identified a previously unconsidered failure mode that was causing the issue. Moreover, executive management had gained visibility of all of the considerations for potential design failures.

Building a Stronger Foundation: Third-Party Oversight Key to Preventing Failures in Oil and Gas Systems

In the oil and gas industry, the systems we design are only as good as the oversight we apply to them. By involving a third-party consultant early in the process, you can ensure that all potential failure modes are considered, that your installation procedures are robust, and that your equipment will perform as expected in the field.

At EDT Forensic Engineering & Consulting, we bring a wealth of experience and a rigorous approach to every project we touch. Our goal is to help you avoid the pitfalls that can lead to costly failures and provide the peace of mind that comes with knowing your systems have been thoroughly vetted by experts.

In a field where the cost of failure can be astronomical, investing in third-party oversight and forensic expertise isn’t just a good idea—it’s a necessity.

About the Author:

Lucas Brown, P.E., is a mechanical consulting engineer at EDT Forensic Engineering & Consulting with over a decade of experience in subsea equipment design, pressure vessel systems, and forensic failure analysis in the oil and gas industry. His expertise includes root cause investigation, risk mitigation, and advanced mechanical systems analysis, ensuring reliable operation in the industry's most challenging environments. Lucas holds a Bachelor's Degree in Mechanical Engineering from the University of Texas at Austin and is a licensed Professional Engineer in several states, including Texas and Alabama.