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The Frog Legs mining site, more than 1km underground, faced serious pressure-regulation issues due to its hyper-saline environment — three times saltier than seawater. Traditional metal valves corroded rapidly, lasting only 1–1.5 years and driving up costs through frequent replacement and maintenance. To address this, the team looked for a more durable, cost-effective solution to improve reliability and reduce downtime.
Location: Frog Legs Underground Mine, Kalgoorlie, WA
The Plasson PRV significantly improves operations for underground mining sites:
The Plasson PRV lasts over three years without a service — more than twice as long as the 1–1.5-year lifespan of other PRVs on the market.
Switching to Plasson PRVs eliminated costly valve replacements — previously around $11,000 per valve over five years, including servicing — and removed the ongoing labour costs of scheduled maintenance, saving 70 hours of downtime.
Lightweight, pre-set Plasson PRVs reduced installation time and eliminated the need for manual pressure adjustments.
The Plasson PRV eliminated downtime completely. Previously, each issue meant 3 hours offline, a 3-person crew, and platform equipment just to get the job done.
The tamper-proof, lightweight design improves safety by maintaining consistent performance and reducing maintenance risk.
Operating in harsh, hyper-saline, abrasive conditions, the Frog Legs Gold mine site faced several critical issues:
Other valves lasted only 1–1.5 years, even with refurbishment.
Replacements and servicing added up to over $11,000 in five years, plus 70 hours of downtime for annual servicing by a 3-person crew.
Frequent manual pressure adjustments often caused line blowouts, and replacing valves carried significant safety risk.
A more reliable solution was essential to reduce disruption and improve operational stability.
“In underground mining, trust in your equipment is critical and we trust the Plasson PRV. It’s proven reliable in the harsh, hyper-saline conditions we work in, helping us eliminate unexpected downtime, reduce safety risks, and cut maintenance costs. Few products deliver this kind of performance without constant attention. And the support from Plasson has been excellent; responsive, knowledgeable, and easy to work with.”
Adam Vanheerden — Superintendent Underground Mining, Frog Legs
The Plasson PRV was introduced as a robust alternative, offering several advantages:
Tested to last over 48 months without failure, even in extreme conditions.
A lightweight design and pre-set components reduce installation time and remove the risks tied to manual adjustments.
A one-time purchase with no need for regular refurbishment, significantly lowering long-term expenses.
Made from the same proven plastic used in Plasson’s compression fittings, trusted for over 50 years in Australia’s toughest mining conditions, resisting corrosion even in extreme, hyper-saline environments.
