The project between the two companies has also achieved 100% valve compliance with health and safety regulations. Tyco's contract has been renewed for a further three years.
In 1998, Chevron chose Tyco to instigate a root-based inspection program to ensure the reliability of pressure relief valves at the refinery and to provide full time on-site coordination and spares for all 2,729 pressure safety relief valves at the plant.
By implementing Tyco’s performance history database software (PhD) the partnership has collated performance history data on each valve and scheduled an accurate valve servicing program.
This has increased efficiency on site and led to a significant reduction in maintenance costs and in spares stock, according to Tyco.
A root-based inspection program covers complete disassembly of each valve and inspection to OEM standards.
The partnership also instigated a root-cause failure analysis (RCFA) program to identify the cause of valve non-conformity, said Project coordinator, Andrew Evans.
“This has enabled plant engineers to identify and remove problem valves and has highlighted areas for improved installation practices in order to prevent recurrence,” Evans said.
“Since the first quarter of 2004 we have successfully maintained a zero overdue pressure relief valve listing. This means that every single pressure relief valve is now fully compliant with the health and safety executive regulations.”
The Tyco valve management contract deals primarily with pressure relief, thermal relief, pressure vacuum and vacuum safety valves.
Tyco also provides new, replacement valves, including instrumentation, gate and ball valves to Chevron, as well as detailed guidance on safety codes and practices and comprehensive training on pressure relief valve repair.
