An emergency call-out answered the next morning

The valves and their duty

The call came from a large fertiliser plant with plug valve trouble in service. Fertiliser plants run continuous processes, so a leaking valve rarely waits for paperwork.

Plug valves at such plants handle process gas and utility duties around the clock. A leak that grows can force an isolation nobody wants to take.

The plant needed a service engineer with tools and material at once. Speed mattered more to the plant than its own commercial routine.

The intervention

The plant waived the usual work-order paperwork to speed up the mobilisation. The paperwork was regularised after the job was safely done.

1. Our technician flew in at dawn the next morning and started work.
2. The plant extended his stay by a further day, arranged by phone.
3. The work ran online, using injection equipment rather than valve removal.

Flying a technician with tools and material removed days from the response time. Extending the stay let one mobilisation serve more valves than the original call.

Emergency mobilisation still follows the same safety gates as planned work. The valve, its fittings and the line conditions are checked before any injection begins.

The live leak sealing guide explains how leaks are assessed and arrested online.

The repeat call and the record

The plant called again a month later, describing a leak similar to the first. That 8 inch, 600 class plug valve carried natural gas at 45 kg/cm².

Our technician flew in, sealed the valve online and flew out the same day. Online sealing at that pressure needs rated fittings, equipment and a controlled procedure.

A planned campaign followed, with a materials order, gate passes and a two-stage online service. It completed with the plant's no-dues closure on the account.

We also trained one of the plant's own technicians for future emergencies. A repeat call on new valves is the clearest verdict a plant can give.

Three years on, the same plant scheduled us into its own plant turnaround.

Explore field services for emergency call-out and planned campaign support alike.

See the field results from the full directory of live valve cases.