How Flogistix Turned 2.5 Billion Data Points Into a Fleet That Thinks for Itself

Flogistix, a Flowco brand, operates in the most demanding oilfields in the country. These units keep production moving, cutting emissions and protecting margins across sites from the Permian to Appalachia—generating over 2.5 billion individual rows of telemetry data per day in the process.

The team had been collecting and using this telemetry data for years, relying on it to guide decisions in the field and beyond. But as the business grew, so did the volume and complexity of that data. It became harder to view and use it efficiently, and that’s where the collaboration with Sigma made a difference. We spoke with Ali Sylvester (Director of Business Solutions) and Danny Burrows (VP of Software Engineering) about what changed and why data visibility has become core to Flogistix’s growth, safety, and environmental strategy.

Why data matters in the oilfield 

Once a well is drilled, oil and gas production becomes a 24/7 operation with no room for error. Flogistix's job is to keep that production flowing efficiently, safely, and within regulatory limits. And in that work, data is the difference between guesswork and precision. 

For instance, every compression unit in the field acts like a real-time sensor network, constantly streaming telemetry—tracking pressures, temperatures, flow rates, and more. It adds up fast: over two terabytes of data per day from their equipment, across some of the harshest operating environments in the country. That data gives the team visibility into every moving part. It lets them detect issues before they cause downtime, monitor operating conditions in real time, and optimize performance across the fleet.

“There’s a lot of uncertainty in oil and gas,” said Sylvester. “The more data we can collect, the more confident we can be in the decisions we make—whether it’s about scaling production, managing resources, or reducing risk.” It also transforms how field mechanics do their jobs.

“Every time we send someone to a site, that’s a cost,” said  Burrows. “If we send the wrong person, or they bring the wrong parts, that cost doubles.” But with access to operational insights, the team knows exactly which units need attention, what tools to bring, and how to fix issues the first time. The result? Fewer trips, faster repairs, and higher uptime across the board.

There’s a lot of uncertainty in oil and gas. The more data we can collect, the more confident we can be in the decisions we make.”
_{- Ali Sylvester, Director of Business Solutions @ Flogistix}

And for customers, that data delivers clarity. Facility-level reports give producers the insights they need to track capacity, monitor performance, and meet regulatory standards.

“We can show where things are working, where emissions are creeping up, and where we need to act,” said Sylvester. “It’s how we help our customers stay compliant—and how we prove we’re all working to be responsible stewards.”

Too much data, not enough access

Before Sigma came into the picture, Flogistix had already made a major investment in their data stack. They’d been running on Databricks for nearly six years. The infrastructure was there, but the problem was getting that data into the hands of the people who actually needed it.

“We had an open source tool for visualization,” explains Burrows. “It was tough to work with and to operationalize into the business. There wasn’t a whole lot of adoption.”

For a company with data flowing in from every corner of the field, that disconnect was costly. Engineers and analysts had access, but the teams closest to the work often didn’t.

“What we were really looking for was a business intelligence platform that would plug into Databricks and just kind of work,” Burrows said. “But even more than that, we needed something our business users could actually use. Something that didn’t require a technical background to navigate.” Sigma quickly became the link between the Flogistix’s massive data pipeline and the day-to-day decisions that keep the business running.

“The biggest thing that led us to Sigma was the spreadsheet functionality,” Burrows noted. “It was simple. It was familiar. Everyone in business understands Excel. They don’t need to learn something new just to explore what’s going on.”

That familiarity made it easier for teams to start using data in their own workflows. At the same time, Sigma introduced more flexibility with visualizations and reports that made complex systems easier to understand and discuss.

“Business leaders want to see what’s happening at a glance,” Burrows said. “Being able to create that view easily—and still get back to the data when you need it—is what made Sigma stick.”

“The biggest thing that led us to Sigma was the spreadsheet functionality. Everyone in business understands Excel.”
_{- Danny Burrows, VP of Software Engineering @ Flogistix}

Sylvester saw the shift immediately. “It was user-friendly. We’d been missing the ability to download and manipulate reports. Now we could pull something out, validate an assumption, test a theory. And the visuals actually looked good—which, working in product, matters a lot more than people think.”

How Flogistix uses Sigma to find and fix unhappy units

Not every unit in the field behaves the way it should. When conditions shift and systems start to deviate from their baselines, those units get flagged internally as “unhappy”—and that’s when the real optimization work begins.

Field service is one of the most complex parts of Flogistix’s operation. Their mechanics are constantly navigating shifting weather, pressure, and production conditions across thousands of remote sites. The job isn’t just to fix broken equipment. It’s to keep smart compression units running as efficiently—and consistently—as possible.

That starts with identifying anomalies. Using a combination of internal tools and Sigma, the team filters incoming alerts to surface units that are trending out of spec. High fault counts land those units on an “offenders list,” which helps mechanics and dispatchers prioritize their time.

From there, Sigma becomes a diagnostic hub. Teams can drill into the telemetry for each unit, compare normal versus abnormal operating periods, and examine the machine’s speed, pressure, temperature, and set points over time. That visibility allows mechanics to pinpoint the root issue—whether it’s a mechanical fault, a change in well conditions, or something else entirely.

Sometimes the fix can be handled remotely. Other times it requires a technician on-site. Either way, Sigma ensures that fix is informed, efficient, and measurable. After adjustments are made, the team monitors changes in performance to validate the fix and, if successful, scale that approach across similar units or geographies.

Teams can drill into the telemetry for each unit, compare normal versus abnormal operating periods, examine the machine’s speed, pressure, temperature, and set points over time. That visibility allows mechanics to pinpoint the root issue.

This workflow—what Flogistix calls “showing how optimization works”—lifts the performance of the entire fleet. In one case, a single optimized vapor recovery unit saw emissions capture jump from 210 to 816 metric tons of CO₂e in a single month. That’s the equivalent of taking 177 cars off the road or eliminating the energy usage of 64 homes. At that scale, the impact is undeniable.

“Run time is king,” said Sylvester. “If the unit’s running, the producer is making money. But how well it’s running—that’s where the real difference is. That’s where optimization, and the data that enables it, becomes critical.”

More than 2 terabytes of data

Diagnostics and fixes are only part of the picture. Flogistix uses Sigma to experiment, adapt, and move faster—because in field operations, speed is just as critical for safety as it is for efficiency. 

With input tables, business users can drop in reference files, assumptions, or quick adjustments and instantly merge them with live telemetry. That kind of ad hoc analysis used to be impossible without engineering support. Now it’s routine.

“It lets people test a theory or plug in context without filing a ticket,” said Burrows. “It’s one of the biggest unlocks for how we work.”

Paired with drilldowns, it gives the team a way to isolate issues across more than 2 terabytes of daily telemetry, identify true anomalies, and trace them back to specific timeframes or units. They can decide which machines require attention, whether the fix can be remote, and—if not—what kind of technician or part to send. That clarity eliminates wasted trips and shrinks the gap between problem and resolution.

This saves time and, most importantly, it keeps people safe.

With Sigma, Flogistix can map known hazards—like H₂S-producing wells—against location data, creating visual alerts that help teams assess risk.

“Field service is dangerous work,” said  Sylvester. “Sometimes it’s 120 degrees in the desert, next to a 235-degree compressor. Sometimes there’s H₂S gas onsite, which can kill you at the wrong concentrations.” With Sigma, Flogistix can map known hazards—like H₂S-producing wells—against operational and location data, creating visual alerts that help teams assess risk before they ever roll a truck.

That’s critical. Because when a unit throws an alarm, it’s not just a cost question—it’s a safety one.

“We need to know what we’re walking into,” Sylvester said. “Is it a fire risk? A high-pressure event? Do we actually need to send someone, or can we resolve it another way?”

Sigma helps the team make that call with eyes open.

Data makes good stewardship possible

Oil and gas isn’t going away anytime soon. But how companies operate within it—how responsibly they produce, process, and prove it—matters more than ever. That’s why Flogistix puts data at the center of its environmental strategy.

“The EPA has strict rules. Our data helps producers prove they’re staying within those limits.”
_{- Danny Burrows, VP of Software Engineering @ Flogistix}

With Sigma, the team can combine production and telemetry data to measure what’s being emitted, what’s being captured, and where intervention is needed.

“The EPA has strict rules,” said  Burrows. “And so do states like New Mexico and Colorado. You can only flare or vent so much per day—if at all. Our data helps producers prove they’re staying within those limits.”

But it’s not just about compliance. It’s about improving how energy gets made. By isolating problem units and tracking improvements over time, Flogistix is able to show the tangible impact of its work.

“In our 2022 annual report,” said Sylvester, “we calculated that Flogistix helped abate more than14 million metric tons of CO₂e. We’re not just a field services company in Oklahoma. We’re proving that responsible energy production is possible.”

For Sylvester, the data is personal. “I care deeply about the planet. This industry gets villainized, sometimes rightfully so. But the truth is, most people don’t want to look at the data—at the reality of how much energy we need and will continue to need. Charts are just how we tend to visualize it. What really resonates is when we make it tangible. Can we show them how many homes were powered? How many flights were offset? How many phones stayed charged? That’s how we make the story of better energy real.”

And Sigma helps Flogistix tell that story—with clarity, credibility, and impact.

What’s next? Embed everything.

Flogistix uses Sigma alongside internal tools to run day-to-day operations—powering decisions across emissions, field service, and even the C-suite. The CEO checks sales dashboards to track quote velocity. The CFO monitors financial trends with live views pulled from NetSuite. Sigma is more than a BI tool. It’s how the business stays aligned. Next up: embedding.

“We’re proving that responsible energy production is possible.”
_{- Ali Sylvester, Director of Business Solutions @ Flogistix}

“There’s already a familiarity with Sigma,” said Sylvester. “We want to bring those visuals directly into our apps to create a more seamless experience.”

They’re also eyeing expansion into new business verticals—like manufacturing and sales—where operational data has untapped potential. The goal? Tighter feedback loops, faster decisions, and more proof that better data leads to better stewardship.

“We’re trying to do good,” Sylvester said. “Sigma helps us show it.”

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