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Ethan Liebswager, Applications Engineer, has been with Swagelok Minnesota for over 12 years.
Fluid system failures cost the oil and gas industries millions in lost productivity, regulatory fines, and safety risks. Despite this, many along the oil and gas value chains continue to install standardized, off-the-shelf solutions, expecting efficiency and reliability. However, in the Upper Midwest, pre-configured systems often lead to unexpected leaks, frozen components, and costly modifications, all issues that could be prevented with customization.
“One of the biggest pitfalls of a standardized system is that it assumes perfect conditions—which never exist in the real world.” Ethan Liebswager, Applications Engineer, Swagelok Minnesota | North Dakota | Appleton. While the technical limitations are well known, the human element plays an equally critical role in system failures.
In January 2025, an oil and gas operations manager in North Dakota faced an expensive setback. His team installed a standardized grab sample system, expecting a seamless integration. Instead, the system failed almost immediately. The pre-configured design didn’t account for the subzero temperatures, moisture exposure of the oil site in North Dakota, or the facility’s unique layout.
As a result:
“The customer invested in an off-the-shelf solution, but the moment it was installed, it started creating problems, rather than solving them,” says Ethan. He found that by the time modifications were made, costs had soared well beyond the price of a custom-designed system built for site-specific conditions.
Working directly with the North Dakota customer’s operations group, Swagelok’s fluid system engineers were able to develop site-specific modifications, which ensured long-term reliability.
To combat the freezing issues, Ethan and other Swagelok field engineers incorporated specialized heat tracing and insulation to maintain optimal temperatures, while corrosion-resistant alloys and reconfigured component layouts addressed material breakdown and accessibility concerns.
By implementing Swagelok’s custom solutions, operations transitioned from constant reactive maintenance to a proactive, long-term approach that improved system efficiency, safety, an
d overall reliability. The changes reduced operational disruptions and helped the team avoid the costly cycle of repeated failures—proving that customization is not just an investment, but a necessity in extreme operating conditions.
There are a few different reasons why standardizing solutions often fails, even though messaging suggests that it’s easy and simple.
User Resistance to Change
Despite the clear benefits of custom systems, many companies resist deviating from standardized solutions due to cost concerns and rigid procurement processes.“The biggest pushback we get is companies just want to fill out a spec sheet and get a quote. They don’t consider anything beyond that”, says Ethan.
Companies prioritize quick solutions over comprehensive assessments, often leading to operational inefficiencies. However, once they experience the reliability of a custom solution, their perception shifts.
“It takes time to build trust. But when customers see that our systems integrate seamlessly and improve performance, they realize the value”, says Ethan.
Breakdown in Stakeholder Communication
Beyond technical flaws, communication gaps, resistance to change, and misaligned priorities create significant roadblocks in fluid system reliability. “If the teams operating the system aren’t involved in its design, failures are inevitable,” explains Ethan. In recent years, Swagelok has worked on projects where customers have implements designs without fully consulting engineers, technicians, and decision-makers, which have led to:
Without collaboration, systems that look good on paper often fail in the field.
With over a decade of experience, Ethan has seen first-hand how misalignment between engineering, operations, and leadership leads to costly mistakes. The Swagelok engineering team serves as a critical link, ensuring that key stakeholders collaborate from the start.
The assumption that standardized fluid systems are cost-effective can be a costly mistake. Environmental variables, operational needs, and stakeholder coordination all
play critical roles in system performance. "Custom solutions are about more than just fixing problems—they're about designing systems that prevent them in the first place. Ethan explains, "Swagelok Minnesota’s engineering support ensures that each custom fluid solution is built for real-world conditions and requirements of the upper midwest.”
The result is reduced maintenance costs, fewer failures, and improved safety standards, reinforcing that customization is the key to long-term success in fluid system reliability. These improvements have minimized operational disruptions and helped oil & gas companies avoid the costly cycle of repeated failures—proving that customization is not just an investment, but a necessity in extreme operating conditions.
