From Unplanned Shutdown to Full Production in <24 Hours

Overview

From unplanned shutdown to full production within 24 hours.

The client is a national gas distribution company that operates and maintains a national gas network spanning thousands of kilometres of pipelines across Denmark. Operational continuity is non-negotiable. Any planned downtime directly impacts supply security and end-customer operations. 

Situation: A critical shutdown with no redundancy

When a compressor at an end-customer’s biogas site failed unexpectedly, there was no backup to maintain production, and the site came to a complete stop. 

With every passing hour, the technical and commercial consequences grew:  

• Gas flaring – unprocessed gas being burned off into the atmosphere 
• Lost production and revenue 
• Mounting pressure on both our client and their end-customer 

Normally, overhauling a compressor like this takes up to five days. But with the distribution network depending on a steady supply, our client needed their end-customer’s site back in production – fast. 

The Challenge: When every hour counts

A compressor failure in gas distribution context creates a ripple effect of technical and operational issues. Without a redundant unit, the end-customer had no means of maintaining gas compression or injection. Flaring continued for as long as the compressor was offline, compounding environmental exposure and production loss. 

Waiting five days wasn’t just costly, it meant continued production loss for the end-customer and growing pressure on our client to deliver a fast resolution. The situation called for specialists who could act immediately and work effectively under pressure. 

Our Approach: Speed with safety in mind 

We mobilised an experienced compressor technician to the site immediately. The on-site inspection confirmed the compressor needed a full mechanical overhaul. But rather than sticking to the standard five-day repair timeline, we came up with a temporary solution that could restore compression safely and significantly faster. 

After a quick alignment between our client, their end-customer, and our engineering team, the execution plan was agreed: 

• Implement a controlled temporary repair to restore gas compression.
• Return to full production within 24 hours. 
• Plan and schedule a full mechanical overhaul under controlled conditions at a later stage.

This approach required precise technical assessment. The temporary repair had to be safe, compliant, and robust to operate reliably until the full overhaul could be completed. 

“From the moment our client called us, the plant was back in operation within just 24 hours.”  - Client Quote

The Solution: Ready when it matters most

Rapid response in critical situations isn’t improvised. It’s a result of preparation, stocked inventory, and experienced personnel. This job worked because the right resources were already in place. 

Result: Uptime restored in record time  

• Site back in production within 24 hours – not five days 
• Gas flaring kept to a minimum 
• Major financial losses avoided 
• Single point of contact ensuring smooth coordination between all parties under pressure 
• A controlled solutions to an urgent and complex situation 

After the incident, our client chose to install a permanent backup compressor to create redundancy and eliminate single-point-of-failure rush at the site. Terotech was appointed to carry out the installation. 

What made the difference: 

• Years of hands-on experience with reciprocating compressor overhauls and fault diagnosis
• A large and well-stocked inventory of compressor spare parts available on-site
• Critical spare parts in stock – available immediately, no waiting on procurement or delivery lead times
• Technicians with the competencies to assess, decide, and execute under pressure 
• Specialised tools available and ready for immediate use
• Back-office engineering supporting providing real-time technical guidance 
• Established partner network with lifting and heavy equipment on standby 

There was no 24/7 service agreement in place with this client. But given what was at stake, we chose to act. 

‍

‍OMS means being ready before the breakdown

Unplanned shutdowns happen. What matters is how quickly – and how well – you respond. 

With Terotech OMS, you get a partner who:

• Mobilises fast with the right technical competencies
• Applies engineering assessment to find solutions that fit the situation, not just the standard procedure  
• Maintains focus on uptime, safety, and environment compliance throughout 
• Turns unplanned breakdowns into controlled, manageable situations  

That’s the value of preparation, experience and the right partner.