Vista Proppants and Logistics: The Path to Operational Excellence

Oil and gas is often highlighted as the most important industry in the United States. With recent developments, the US is relentlessly holding the position as top producer in the world with no signs of slowing down. While the glory goes to the men and women working directly in the fields, and rightfully so, we often miss the work being done to support this industry.

One of the most pivotal industries supporting oil and gas is related to the resource needed to successfully extract their product: sand. Frac sand is pumped into the well to prop open the fractures beneath the surface allowing the resources to make their way out of the ground. Historically, most of the sand came from states such as Wisconsin as well as regional plays in states closer to the activity. Over the last several years, though, the trends have changed to in-basin sand mines within miles of the wellsite. The logistics of delivering sand from an in-basin mine rather than halfway across the country provides cost, efficiency, and time savings for the companies utilizing the sand to extract oil and natural gas.

KCF Technologies recently sat down with the crew from Vista Proppants & Logistics in West Texas. Vista’s goal is simple: consistently have the highest quality product readily available for their customers. This process starts at the mine and processing plant where Vista has been working diligently to develop and execute a world class maintenance strategy with the goal of zero unplanned downtime leading to further reductions in maintenance costs. In a competitive industry, focusing on these things will assist in providing the product and service customers require. Vista’s speed in executing this strategy is the differentiator needed to make sure they come out on top.

Victor Mwaba and his Vista team in Kermit, Texas knew they would eventually run into some equipment issues working in a harsh environment such as a sand plant. The question posed was “How do we prevent this and ensure we can be the most reliable source for our customers?” From there Vista implemented rigorous preventative maintenance schedules with the intent of preserving all of the equipment’s life. Once established, Vista knew they had to take an additional step to safeguard the equipment and implemented predictive maintenance technologies on some of the critical pieces of equipment subject to difficult operating conditions. As a seasoned Plant Manager, Victor knew vibration and temperature were two of the best indicators of machine health and contacted KCF Technologies for assistance. The two companies worked to implement a way to continuously analyze this subset of data through wireless nodes magnetically attached to monitoring points of critical equipment. This is allowing them to not only identify issues but to help their maintenance strategy determine what is causing premature issues and how to avoid them.

“It’s enabled us to see the future. It adds that missing link now that we can see and predict when we’re going to suffer a mechanical failure that may disrupt the surety of supply.”

-Bill Singmaster, Vista Proppants & Logistics

Victor and his team made an important distinction where many others fail. It wasn’t a sensor or data alone that would prevent any issues in a plant, but rather a partnership that would allow Vista’s team to keep their plant running efficiently.

Upon implementing our predictive maintenance program, Vista’s team was committed. KCF Technologies could have collected all the data in the world, and it wouldn’t have made one ounce of difference if it wasn’t for the work Vista put in to make it successful. From being in constant contact to work on fine tuning processes, changing PM practices, and follow up on early detection's, it allowed Vista to target their work on the most critical issues. All of this to ensure they are exceeding the expectations of their customers. KCF heard this throughout the team, but Bill Singmaster emphasized Vista’s relationship with their customers by saying “We prioritize our customers’ best interests above our own.”

Vista’s team has developed a maintenance program that ensures a few things:

• They are operating at their best at any given time.
• They are efficient and agile.
• They are ensuring their customers reap the benefits.

Vista’s operational efficiency ensures they are meeting and exceeding demand and doing it quickly and efficiently to control costs. If you’ve ever had to sit at a load out for an extended period or get a call that your delivery isn’t on time, you understand the importance of this.

The passion, grit, and drive to be a reliable source for their customers is beyond honorable. From executive leadership, to plant leadership, to the front-line employees; everyone is executing at a high level to support the biggest industry in America. The work being done here is a true example of the dedication to keeping American industry the shining example of world class excellence.