Core Problems
No reliable visibility
into actual valve condition
Attention to detail
Regarding the planning process
The Challenge
A power generation facility facing major issues
Our customer was facing persistent control valve issues that undermined both maintenance shutdown planning and process efficiency across the site.
Before this program was in place, maintenance teams were regularly caught in a difficult position: 1) Overestimation of repair time when valves could be serviced quickly. 2) Underestimating it when unexpected parts availability issues caused delays beyond the planned window. These inaccuracies created repeated scheduling disruptions and excessive rush fees, adding unnecessary cost with every reactive intervention.
$3M
in uptime planning value. Risk avoided and efficiency gains recovered across three impact areas: accurate valve condition data eliminated over- and under-estimation of maintenance windows, scheduling disruptions avoided, resource allocation optimized.
$4M
In process efficiency gains. Valve performance issues identified and resolved before affecting operations, process deviations caught proactively, efficiency losses prevented before they compound.
$50K
in expedite cost avoidance. Avoidance Parts anticipated in advance through targeted inventory recommendations:
Last-minute sourcing eliminated,
rush fees avoided entirely
Total Verified Value
$7.1M
