Microsoft Word - Report Pasantia MAM SYD 2007 - English

7/28/2019 Microsoft Word - Report Pasantia MAM SYD 2007 - English

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MAMM a s t e r i n A s s e tM a n a g e m e n t

Master in Asset managementInternational Pasantia

Coordinator : Mr. Marco MacciTutor : Mr. Luca FumagalliAuthor : Mr. Sebastin Yez

Fundaments: Asset cycle life

The assets associated at productive process have risks of no payback their investment values. Therisks can to have causes related to the different stages of assets cycle life and no necessary showstheir consequences at the same time, even often its consequences are shown past the earliestasset age during their operation and maintenance stage.

An optimummanagement shall be

concern an adequatecycle life estimation ofequipments to get theright opportunity toreplace the equipmentsand get the maximumNet Present Value (NPV),as its shown on attachfig.

To concern an integralvision of assetmanagement, since of

the conceptual stage, itsdesign, its manufacture,

erection, start up and dismissing, is necessary to understand and apply different kinds oftechniques and methodologies that allow to take the right decisions to maximize NPV during their

cycle life.The choices that wehave depend ofdifferent criteriaadopted during theearliest stages of theassets cycle life,giving differentbehaviors of the totalcost of the project.Lows standards at thebeginning could bemeans high costduring the operation,maintenance or andanticipate prematurelyequipment replaces.


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Scope of the work: Good Practices

The above concepts require to apply a set of a Good Practices. The kind of matters depends ofindustries types. The Pasantia goal is to take practical reviews during technical interviews withmanager of assets in those mentioned stages. To take a review of their practices verifying in ownscenarios its achievements of assets management integral vision.

For to undertake this work is necessary the most complete information that the professionals andthe time available allow to have. To get the information, an strategic interviews plan must beconsidered.

During the interviews shall be taken different kind of evidence and register of those practices.

To get that goal it had been considered interviews with the followings enterprises:

1. STF S.p.A. / Magenta - LombardiaSector: Desing, manufacturing and built-up equipments for energy plants and high pressure andtemperature vessels.

2. Rina S.p.A. / Genova - LiguriaSector: Naval register, Industrial Certificated and Technical training.

3. Ansaldo Energy / Genova - LiguriaSector : Italian energy generator.

4. Instituto Italiano de Soldadura / Genova - LiguriaSector: Research, development and training on metallurgy manufacturing techniques, inspection,and procurement certification.

Schedulling : Visit Program

The visits program will take about 20 days long during September 2007.

Resume : Final Report

A complete report of the good practices found at interviews shall be prepared to discuss with tutorand coordinator of this program.

SYD/syd - sep. 2007


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Visit Report

Enterprise : STF S.p.A.Contact : Ing. Michele del VeccioPosition : Quality manager.

STF S.p.A. Resume

HistoryMain products and servicesMain marketsOrganisationAssets referenceBest Practices


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History

The STF group was founded in xxxx, actually it has an industrial complex with 160.000 m2 of totalcovered areas and 32.000 m2 of covered manufacturing area., located in Magenta town, 25 kmsnear to Milano, Lombardie Region.

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Main products and services

STF offer a complete set of services from design, development solution, up grades, modifications.In this stage there are a close approach between client, STF and technical reference advisor.

STF has related agreement with different entities, ASME, Foster Wheeler (American Boilermanufacture licence). Its agreement allows to STF to have under control the main conceptstandards for different applications.

Those standards provide useful criteria about performance equipment and know-how for operationand maintenance activities.

Under any circumstance of changes, to up grade capacity or efficiency this standard give thereference for make decision, in order to choice the right new materials, new security advices ornew dimension or equipments capacity .

Main markets

The STF target markets are industrial boilers, gas turbine, heat recovery and steam generator. Inorder to reach this target they are owner of specific technology and license for design, develop,manufacturing, erection and start up specific equipment and whole installation for energy plantsproject.

Organisation

In plant STF has about 200 professionals and technicians whose working directly. In the differentsite where STF has their project, is working about 1.000 employees.

The headquarters has a complete installation to satisfy all client requirements.

STF has an engineering department for study new proposal. But their main objective is to solvemanufacturing and construction problems to the production line inside STF and to the team projecton client site.

Purchasing and project management provides materials delivery control in accordance withspecifications. They make the first control for workshop order traceability.

Production department involves different process into the site :- Machinery shop : here works qualified welders. Their obtain and maintain its qualification

up-grade and related exclusively for specific process. Even some qualifications are validatedfor a specific project life only in order to guarantee full quality achievement. Normally thewelders doing the first steps into the join parts.

- Pressure Parts manufacturing: The prepared parts are assembly and doing the last weldssteps.

- Heat Transfer manufacturing : As previously described for the thermal equipments in thiscase.

- Surface treatment : Last one manufacturing process to get certain hardness in specificparts.


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- Storage: Place to keep stand by intermediate parts o finals pieces to be delivered.- Quality control: This function across the entire organisation to get specific control inside the

process and take corrective tasks immediately when they happen. The main function is totake all register in each step of the process, each shift, including all workers that made anytasks on the pieces. These kinds of information allow guarantee the equipment under thedesign specifications. In addition, Quality Control Department is an internal controller, butalso is the entity who gives response any questions of the client controller. In some cases,

the project the participation of expert considers, such as an ASME inspector.

Best Practices

StandardsFor design process STF use ASME, API and UNI EN its allows keep safety standards.To control the manufacturing process, STF apply ISO 9000 standards, its allows keep undercontrol all design parameters

Quality PlanTo keep under control all design parameters and task registers STF use a master plan PCQ(Plan of Control Quality) where its belongs all necessary reference for planning works,verified welders qualifications and procedure certifications. Its systems allows to know inany moments all data concern to the original material source, workers, humidity control andother parameters for traceability.

Fabrication DrawingsEngineering department provide all specification for complete the standards. Its includereference for each welding and assembly procedure into the unassembled drawings.

Procedure Certifications

Its belong to PCQ as Quality Control and provide specification and testing for weldingprocedure in order to guarantee to keep design parameters.

Welders Qualifications

Also belongs to PCQ as Quality Control and verify the welders ability for doing specific task,find the root into the join pieces or finish the last step in different position.

Non Destructive testNDT allows to keep under control all job development, doing Ultrasonic Test, MagneticParticles, Penetrate Liquid, Ionized Radiation and Hardness Measurement. Have a specialconsideration to affected zone area (AZT) because is the critical point and a wrong job willproduced high failure risk.

Traceability / stampillado

All the single parts and components of the equipment in manufacturing process areidentified by metal mark, from the material reception to the each one of process step.Thesystem allows guaranteeing for the clients the materials quality used for built up theequipments are under engineering specifications.


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Assets reference

STF have concern into the earliest age of assets. Since that their final client has the project inconceptual terms gives a first input to develop specific equipment under their own standardrequirement.

Those standards are defined by authority requirements, environmental request or business needs.In some case the state-of-art made a contribution to determinate this kinds of matters.

In this age (project & development) technical-economical evaluation are made in order todeterminate the return investment and the asset life expectancy. This period must be keeping onthe cycle life.

For that reason many important details must be controlled in order to get all design parametersduring the manufacturing equipments.

This is possible to obtain if is apply a strict quality control systems.

If all control are been applied then is possible reduced de risk of failure for assembly or erectionreasons, given more capital payback of the investment because the asset will be keep on service.


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Fig. 1 : Nuclear plant reactor body in France site. Top view.

Fig. 2. Nuclear plant reactor body in France site. Side view.


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Fig. 3. : Reactor shell machining.

Fig. 4. : Reactor cup under the quality process control.


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Fig. 7. : Multi welding machine. It registervoltage variation in order to get all theinformation about the task doing out ofthe range allowed during the each step.

Fig. 8. Metal markapplication for later

recognize task duringthe trace applications.


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Visit Report

Enterprise Rina S.p.A.Contact : Ing. Danielle Giorgi /

Ing. Andrea BombardiIng. Alfredo Traverso.

HistoryMain products and servicesMain marketsOrganisationBest PracticesAssets reference


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Visit Report

Enterprise : Istituto Italiano SaldaturaContact : Ing. Stefano Pinca

Ing. Giancarlo Canale

HistoryMain products and servicesMain marketsOrganisationBest PracticesAssets reference

Microsoft Word - Report Pasantia MAM SYD 2007 - English

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