Rapid intervention following a breakdown avoids a production crisis and an occupational safety hazard
In the chemical industry, a leak represents an emergency that can threaten not only productivity, but above all the safety of the teams on site. Our customer, a petrochemical plant in Quebec, experienced such a leak in the frame of a 12-inch valve that controls the flow of steam to the entry of a dryer. This leak could have led to an interruption in the production line, increasing operational costs and causing significant delays. Considering the use of superheated steam and the valve's location in a busy corridor, this leak could have caused severe burns to employees. Since superheated steam is colorless and odorless, it is impossible to detect a leak.
To avoid serious consequences such as significant economic loss and risks to the health and safety of workers, it was essential to find a solution quickly. Maintenance teams immediately assessed the situation and implemented corrective measures to ensure safety and continuity of operations.
Urgent Collaboration for a Quick and Effective Solution
Understanding the urgency of the situation, our team went into solution mode to find a suitable replacement valve. Working with our network of Emerson impact partners, we initially searched for a 12-inch valve to directly replace the faulty valve. However, after a careful assessment of the customer's specific needs, we opted for an 8-inch Fisher V150 valve with a noise-reducing disc, which perfectly matched the steam flow and the noise level requirements. In just two days, this solution was in place, avoiding an unplanned production stoppage.
1.8 Million Dollars Saved in 7 Days
Thanks to the quick intervention of our technical team, our client was able to avoid an unexpected production shutdown that could have had major consequences. In fact, a one-week production stoppage would have represented an unrecoverable productivity loss of $1,825,000 for the factory. Moreover, the solution proposed by our team helped minimize health and safety risks for plant workers by quickly replacing the defective valve, as a steam leak represents an obvious burn hazard.
Specific Actions Taken:
- Rapid response and support
- Quick identification of the appropriate replacement valve
- Proposal of an 8-inch Fisher V150 valve with noise attenuator disc
- Collaboration with the Emerson partner network to quickly obtain the necessary parts
Commitment and Effectiveness: Winning Partnerships
This case study shows how we help plants to thrive by providing fast, effective solutions to critical problems, thereby enhancing their operational success and sustainability. Our commitment and technical expertise enable us to establish solid partnerships, fostering the growth and prosperity of our clients.