For oil and gas operations, that’s definitely the case with valves — they serve as linchpins for the entire system, as they control the flow of oil, gas, and other media across both upstream and midstream facilities.
Valves teach us the importance of paying proper attention to the small-scale details that support larger goals. Because their reliability is crucial to operational efficiency — from production well pads to compressor stations.
But the catch is that these tiny, hardworking MVPs are vulnerable to the harsh conditions they need to function in. Exposure to abrasive sandy water or corrosive hydrogen sulfide, for example, can cause wear and tear that eats away at valves over time.
That’s dangerous because unplanned valve failures can set off a chain reaction of negative consequences — including the ability to damage other parts, rack up hefty fines, jeopardize human safety, and bring production to a standstill.
Careful planning and preparedness for valve failure, especially on an emergency basis, is another necessary linchpin that your operations depend upon.
Knowing in advance that all valves fail eventually, and will need to be repaired, is the first step toward putting safety nets in place to make sure you’re ready when it happens. Planning to ensure reduced downtime and improved operational resilience is critical for long-term success.
Valves play the crucial role of regulating flow, pressure, and temperature — but their ability to perform depends on their components and materials as well as the conditions they’re operating in. Manual valves, control valves, and relief valves are all subject to eventual failure. Without proper maintenance and inventory planning, that failure can have catastrophic consequences.
For example:
Some of the main causes of valve failure include:
And time is of the essence when it happens. The crucial importance of valves means that minutes and seconds matter when they fail. A delayed response due to lack of preparedness can wind up magnifying the negative impact — with consequences such as:
An oil and gas emergency response plan requires forethought and strategic planning — as well as the availability of a supply partner who can provide expert assistance on short notice — can tamp down the negative consequences.
For example, when a North Dakota upstream operation experienced the failure of a critical control valve, production temporarily ground to a halt. But the delay was kept to a minimum because the required trim and actuator were pre-stocked in a nearby consignment inventory (also known as VMI – vendor managed inventory) system managed by MCE Automation.
That meant that repairs were completed in just six hours — a rapid response that saved the operator an estimated $2 million in lost production.
Putting your emergency preparedness plan in place is not difficult because experience has taught us to include these essential pillars:
As an example of how this planning pays off, a compressor station in Texas was able to avoid the prospect of a costly and potentially devastating week-long shutdown thanks to a consignment (VMI) inventory program in place with MCE — which provided it with immediate access to the specific NACE-compliant relief valve trim it needed.
Smart inventory planning can come to your rescue in a variety of ways, addressing challenges like these:
Four inventory management steps to prepare your organization for emergencies:
This kind of proactive inventory management with the MCE team wound up saving $500,000 during a planned midstream turnaround in Louisiana, by avoiding downtime thanks to pre-ordered trim components for high-pressure valves — which allowed repairs to be completed a full week ahead of schedule. Successful planning strategies like that can have positive ripple effects throughout your business.
>> With MCEs Stocking Agreements and Vendor Managed Inventory, your most crucial equipment is on -hand when you need it.
There’s no substitute for hard-earned expertise when it comes time to put this planning in place — the selection of valve materials demands specialized knowledge that goes beyond a one-size-fits-all approach.
For example, experts need to analyze factors like:
Leveraging the necessary level of expertise helped an operator in Colorado reduce valve failure rates by an impressive 25% — thanks to consultation with MCEs experienced team who recommended replacing soft stainless steel trims with hardened Alloy 6 trims for better resistance to sand-laden production media.
Technology can play a transformative role in enabling smart inventory planning as well as rapid response. Electric and electro-hydraulic actuators are a great example of this effect, enabling faster and more cost-effective solutions.
Embracing this technology saved the day for an upstream facility in Alaska when it experienced a power outage. Because of advance planning, it had already upgraded to electric actuators with battery backups — which enabled rapid valve closure during the outage. This foresight prevented a potential production loss of $1.5 million.
With all of that in mind, once you have an experienced partner in place to help guide your progress, here’s a four-point plan to implement your emergency preparedness.
Ultimately, the combination of emergency preparedness and robust inventory planning can take both the stress and the danger out of valve repairs — transforming them from costly crises into manageable events.
By thinking ahead of the game and adopting proactive strategies like pre-stocking critical components, leveraging subject-matter expertise, and taking advantage of emerging technologies, you can minimize downtime, improve safety, and ensure compliance. By partnering with a supplier like MCE, that collaborates with your team on inventory management, you can ensure operational readiness while minimizing supply chain risks.
The rewards include not just protecting your operations and investments — but the potential to position your business as an industry leader in terms of efficiency and reliability.
MCE can help your organization future-proof your valve maintenance strategy — to make sure you’ve always got timely access to the parts, assistance, and expertise you need to keep your operations flowing smoothly. Contact us for a free assessment.