12 valves treated during a fertiliser plant turnaround

The valve and its duty

A large urea fertiliser plant scheduled sealant injection for 12 valves in a turnaround. The scope covered two ball valves and ten plug valves.

The 12 valves made a single planned scope inside one shutdown window.

Plug and ball valves seal differently, so each type needs its own procedure. A turnaround gives planned access to valves that run untouched the rest of the year.

Fertiliser plants run continuous processes, so most valves see attention only at turnarounds. Sealant injection restores the seal between the closure member and its seats.

The intervention

The campaign opened with a joint pre-job meeting held on site. The plant required separate written procedures for plug and ball valves. It then audited the material grades delivered on site against those procedures.

The scope used a cleaner and three sealant grades, matched to those procedures. That audit trail matters: the material in the gun must match the written procedure. Agreeing procedures early avoids disputes once the short window is open.

1. Agree a separate written procedure for each valve type in the scope.
2. Match delivered material grades to those procedures before any injection.
3. Treat each valve in controlled steps within equipment and fitting ratings.
4. Record the work so the plant can close the campaign formally.

The plant held the audit role throughout, from procedures to delivered materials. Our product by valve type guide explains why plug and ball valves take different products.

The outcome and the record

The campaign closed with our service report and the plant's completion and no-demand certificate. The account began three years earlier with an emergency call-out.

It grew from that single urgent visit into planned turnaround work. A no-demand certificate records that the plant holds no outstanding claim on the work.

Turnaround windows are short, so the valve scope must arrive agreed, supplied and ready.

See the field results from the full directory of 22 field cases. You can also explore valve products supplied for campaign work of this kind.