In 2004, a global pharmaceutical company engaged VRC Protx to conduct a field survey of existing devices to help standardize and consolidate devices in the field, combine existing inventories, institute site standards, and establish a PM program that could be overseen by a site expert.

“At issue were both safety and economic impact,” stated the VRC Protx associate. “Individuals were ordering product without knowledge of what was already in inventory. Some products in inventory were of an old, obsolete design. Now, our VRC Protx Process Safety Engineer works directly with site personnel to develop site standards which greatly simplifies the ordering process, controlling runaway inventories.

“In addition to controlling inventories, safety has to be a priority. Untested PSV’s can pose a considerable risk because, over time, their faces may become “glued” together. The pressure now required to release the valve can exceed the ASME safety factor of the vessel. As a “VR” certified company, VRC Protx inspects, tests and if need be rebuilds valves to OEM standards. In some cases, devices were not being properly sized and evaluated. VRC Protx involvement ensures that the devices are adequately sized and applied per ASME code.”

Over the past years of monitoring and maintenance, VRC Protx has been able to help this company realize significant savings in three specific areas: Inventory, Maintenance and Expenditures.

By phasing out dated product and consolidating inventory, VRC Protx assisted in the reduction of their overall relief devices inventory by $90k.

Having oversight of the relief valves and instituting the PSV – PM program, tracking valve history, VRC Protx has been able to prohibit the spending of $375k in unnecessary maintenance costs. This has been primarily accomplished through extending PM intervals.

The combination of the site expert working with A&E firms and a dedicated VRC Protx engineer has helped reduce total rupture disc expenditures by 75%.

The company’s site manager stated, “VRC Protx has been instrumental in helping us rein in our expenditures. Over the years they have been on site, their responsibilities have morphed in many directions and through their capabilities and professionalism; they have proved to be an invaluable partner.”