KEY CAPABILITIES
- Rapid on-site testing and certification - Allows for immediate on-site testing and certification, eliminating the need to transport PSVs offsite.
- Immediate valve rebuild and repair - The mobile unit's complete set of specialised tools and equipment enables technicians to perform full valve rebuilds on-site when issues are detected. This capability reduces the time and cost of sourcing replacement parts and avoids lengthy delays associated with waiting for spares
- High-pressure compressed air system - Unlike competitors who may rely on nitrogen quads, GRPS’s mobile trucks includes an integrated high-pressure compressed air system, eliminating the need to handle or transport nitrogen. This feature not only increases safety but also reduces setup time, allowing for quicker testing cycles. Additionally, this setup reduces operational costs, as there’s no need for costly nitrogen refills.
- Flexible scheduling and availability - For clients needing an urgent response, GRPS’ mobile units can be deployed on short notice and operate around the clock. This flexibility enables testing and maintenance during non-peak hours or scheduled downtimes, allowing operations to resume swiftly without disrupting production schedules.
- Real-time data and instant reporting - The mobile unit provides on-the-spot test reports and certification data, accessible through a digital platform that clients can view in real-time. This data capability allows for immediate record-keeping, regulatory compliance checks, and faster decision-making for maintenance planning. The digital access also supports efficient asset management.
PROJECT OVERVIEW
GR Production Services (GRPS) provides mobile field testing of Pressure Safety Valves (PSVs) for major clients including Santos, Arrow Energy and Origin. Leveraging a fleet of specially built trucks, GRPS provides these clients flexible, on-site testing services tailored to the unique demands of each project site or location. The mobile units are designed for rapid deployment and include self-sustaining high-pressure compressed air systems, eliminating the need for costly nitrogen supply while enhancing safety by minimising nitrogen handling and associated risks.
GRPS' mobile units allow for efficient PSV testing, rebuilding and certification directly at client facilities and remote assets, supported by skilled PSV technicians and NATA-accredited processes. These mobile solutions not only reduce downtime and logistical costs but also ensure compliance with Australian (AS) and America standards (API), providing a streamlined approach to PSV maintenance and certification that prioritizes safety, cost-effectiveness and rapid response to client needs.
SCOPE
PSV testing and certification
GRPS’ technicians conduct thorough PSV testing and recalibration, ensuring all valves met strict safety standards and industry regulations. This includes:
- Valve rebuilding and repair: As needed, PSVs were dismantled, inspected and rebuilt to restore functionality and extend operational life.
- Customized reporting and data management: Each testing unit was equipped to generate detailed test reports with real-time updates, allowing clients to access and review PSV records, maintenance history and failure trends instantly via custom databases and QR code scanning.
- Safety and cost efficiency: By using compressed air systems rather than nitrogen, GRPS' mobile service reduced the need for nitrogen quads, lowering operational costs and eliminating the risks associated with nitrogen handling, storage and transport.
This tailored mobile solution enabled GRPS to deliver high-quality PSV maintenance and compliance assurance on-site, supporting the clients' operational safety and efficiency across remote and challenging locations.
CHALLENGES
Remote and challenging locations: Many of the testing sites for Santos, Arrow Energy and Origin are in remote areas. Ensuring that all necessary tools and replacement parts are available on-hand is essential to minimise downtime on client assets.
SOLUTIONS
Highly skilled field technicians: GRPS deploys a team of experienced PSV technicians who are specifically trained to work under challenging conditions. These technicians bring expertise and versatility, capable of adapting to the unique needs of remote locations, including troubleshooting, planning to ensure tool and replacement part availability, valve rebuilding and repairs on the spot.
OUTCOMES
Cost savings: The mobile unit's compressed air system allowed clients to avoid extra expenses associated with nitrogen quads and refills. Additionally, on-site testing eliminated transportation costs and the need for spare valves, offering a budget-friendly solution for maintenance and certification needs.