Feedback
“The setup of the container workshop is impressive. Its well-organised and ensures seamless operations. Moreover, the inclusion of the hydraulic bench is a real win, significantly reducing the time required to turnaround a valve.
The elimination of the need for transport is another major advantage. With the container workshop conveniently stationed on-site, the logistical complexities and costs associated with sending valves to an external workshop are completely mitigated. This streamlined approach not only saves valuable time but also contributes to a more sustainable and efficient process.
Having technicians readily available on-site is a real is also advantageous. The immediate accessibility to skilled professionals facilitates quick decision-making, troubleshooting, and efficient communication. This personalized interaction ensures that any concerns or queries are promptly addressed, leading to quicker resolutions, and enhanced overall satisfaction.“
– Maintenance manager
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Project Overview
TIS have over 15 years experience serving New Zealand’s industrial sector. We excel in industrial electrical construction projects, Instrument fitting, tubing, mechanical installations, servicing and overhaul of all types of valves. We are also experts in calibration with both our lab and valve testing facility holding IANZ accreditation. We pride ourselves on being able to offer solutions fully concept and manufactured in house to meet client needs.
In this particular case study we are highlighting our ability to come to you and service relief valves. Reducing risk of damage during transport, cost of transport, increasing visibility, encouraging efficiency through on-site communication and schedule reporting.
The Client
The client in this case study is the one of the largest onshore gas producing sites in the country. They are challenged by their remote location and condition of roading infrastructure.
Project Objectives
- Our scope for this campaign was to as-found test all relief valves (safety critical elements). 72 valves in 11 days.
- We needed to address 72 valves within an 11-day timeframe.
- Strip all valves and internal inspection.
- New soft goods and lapping as required.
- As left test and full report.
Project Solution
TIS identified that when servicing multiple PSV’s such as shutdown times it was more efficient to take the workshop to the valve rather than the valve to the workshop. Using a purpose built, self-contained test workshop we can minimise transport issues.
- We test and repair valves up to 300 bar using dry air as a test medium or test with water if required.
- During shutdowns we provide multiple technicians to provide a faster turnaround of work.
- As we are on site the customer can monitor quality, solve any issues faster with access to site stores for parts or replacements if needed.
- In this case we customised our standard report to include internal condition photos and detailed observations.
- We provide a specific test certificate for each valve we test showing a real time digital graph of the full complete test for future reference.
Results
New Zealand roads can be bad at the best of times but, when you are transporting your safety critical elements on them there can be added issues. Transporting pressure relief devices is required to be in a secure vertical position, this is to avoid discs moving across nozzles thus avoiding seat damage. All valves should be subject to an ‘as found test’, this test confirms the condition the valve was when it was last in process. Seat damage, either by transportation or bad handling, can give a false indication of the condition of the valve in service. Testing onsite removes this risk. Moving valves across site and not across the country.
- Utlising this method we were able to reduce the scheduled days for valve work by 2 days.
- Ensuring vales were priortised accurately as site conditions changed meant less hold ups on critical work fronts.
- Safer for plant and personnel by reducing number of physical moves.
- Better for the environment reduces transport emissions.
- Control quality – a true open-door policy – watch the testing as it happens.
- Rapid problem solving – customer collaboration at the work front.
- Fast, high quality, value adding service.
Conclusion
The TIS approach reduces the risk of valve damage in transit, increases test accuracy, increases efficiency, provides simple communication, a high rate of schedule reporting and provides open honest approach. TIS strives to provide the best value to customers by upholding high quality, HSE and efficiency standards. With Work safe requiring full reporting of valve failures, you must ask yourselves – how many of these failures are from transport issues travelling on our country roads from site to workshop? We deliver quality giving you confidence your valves will protect you plant when you really need them.