Press Release: 13:01 WAT • 15 May 2025
In the oil and gas industry, valves are often treated as background components—small, unassuming parts of a much larger system. But when they fail, the consequences can be catastrophic: unplanned shutdowns, product loss, equipment damage, environmental contamination, and even injury. In Nigeria, where many assets operate in salt-laden coastal environments or remote swamp locations, the risks of poor valve maintenance are significantly amplified.
Despite their critical function in regulating flow, pressure, and isolation, valves in harsh Nigerian climates are often overlooked until they become a problem. At Terrawatt, we've seen firsthand how proactive valve maintenance tailored to Nigeria's unique operational environment can reduce downtime, save millions, and prevent disasters.
Nigeria's oil and gas fields, especially those located in the Niger Delta and along the Atlantic coast, face aggressive environmental conditions:
In one case, a Terrawatt inspection team found multiple ball valves on a pipeline in Escravos frozen shut due to corrosion buildup, despite being just three years old. Without routine inspection, the client only discovered the issue during a critical flow diversion—resulting in a 48-hour shutdown and a production loss exceeding ₦120 million.
Poor valve maintenance doesn't just result in mechanical failure. The hidden costs ripple across operations:
Terrawatt estimates that Nigerian operators lose over ₦20 billion annually to preventable valve-related failures—many of which could have been avoided with structured inspection and servicing plans.
In 2023, a client operating an FPSO off the coast of Akwa Ibom approached Terrawatt after experiencing repeated valve seal failures. These were causing leaks in high-pressure gas lines, forcing shutdowns and delaying export schedules.
Our team conducted a corrosion mapping and root-cause analysis. We discovered that saltwater spray had degraded external valve housing, while internal seals had become brittle due to incompatible materials.
Terrawatt replaced the faulty units with corrosion-resistant valves made from duplex stainless steel and installed sacrificial anodes for cathodic protection. In addition, we implemented a quarterly inspection schedule using ROV-mounted cameras for subsea valves. Since then, the FPSO has reported zero valve-related shutdowns, saving over ₦600 million in operational uptime and deferred penalties.
Based on our experience across Nigeria's upstream, midstream, and downstream operations, Terrawatt recommends the following:
Perform annual valve audits, especially on critical flow lines, separators, and emergency systems. Use ultrasonic thickness measurements and borescope inspections where needed.
For coastal and swamp deployments, choose valves made from duplex or super duplex stainless steel, or those with protective coatings rated for saltwater exposure.
Use elastomers rated for the specific media (e.g., H₂S, high-pressure gas) and environmental temperature ranges.
Many valves fail not due to body corrosion but because their actuators or grease points are neglected. Ensure valve stems and actuators are lubricated and tested periodically.
Incorporate valves into a centralized maintenance management system (CMMS), with RFID tags or QR codes for quick history access. This is especially useful in large facilities and offshore platforms.
Train local technicians in proper valve servicing, especially for remote areas where turnaround time matters most. Terrawatt runs quarterly workshops in Lagos and Port Harcourt for exactly this purpose.
One common mistake we see is the deferral of valve maintenance due to cost-cutting. Unfortunately, this always results in far higher costs down the line. Another is relying on generic servicing schedules not adapted to Nigeria's specific climate or field conditions.
At Terrawatt, our approach is risk-based and location-specific. We prioritize the most vulnerable and mission-critical valves, tailor materials to local environments, and train field teams to detect early warning signs.
Valves may be small, but in Nigeria's harsh operating environments, their failure can bring operations to a grinding halt. Proactive, climate-aware maintenance isn't optional—it's a strategic necessity.
At Terrawatt, we combine local knowledge with international standards to deliver valve inspection, maintenance, and retrofitting solutions that keep your assets flowing safely and profitably.
Need a valve audit or coastal maintenance strategy? Contact Terrawatt today and let's assess the health of your flow control systems before the next failure costs you millions.