The following thesis aims to explain a complex topic, namely an industrial plant shutdown to perform maintenance, as clearly and simply as possible. To enhance readability and understanding from a possible reader, a real case has been reported: the shutdown of three production lines located in the Chemical Hub of Ferrara. The term “Turnaround” refers to a planned and coordinated event where a production unit or an entire facility is taken offline temporarily to perform maintenance, repair, inspection, and upgrade activities. The primary goal of a Turnaround is to optimize maintenance activities, ensure equipment reliability, and minimize the impact on production by efficiently and effectively managing the shutdown and outage period. In this last sentence, a term such as reliability has been used which may be unknown to many; for this reason, the beginning of this thesis is guided by two chapters focused on the basics of maintenance and on the figure of the "maintenance engineer", and then continue with a detailed and in-depth chapter on "Turnaround Shutdown", exploring its purposes, alternatives, fields of application, advantages and disadvantages. This thesis has been developed thanks to the contribution of the company Pansoinco S.r.l. which successfully secured a contract for managing the mentioned shutdown. For this purpose, an appropriate in-house software (SDman – ShutDown Management) has been developed and adapted according to customer requirements, namely Eni Versalis. The contributions of this thesis extend beyond theoretical implications by offering practical recommendations for Turnaround Shutdown and Outage practitioners and industrial managers. By implementing the proposed software usage, organizations can reduce downtime, enhance maintenance effectiveness, improve safety performance, and achieve cost savings, ultimately leading to increased operational efficiency and competitiveness. The shutdown of the industrial plant in Ferrara has presented several difficulties such as the fusion of an engine that fed a compressor, which led to an earlier-than- anticipated shutdown, and especially the flood that hit the Emilia Romagna region in mid-May. Despite these obstacles and delivery delays, all required activities were successfully completed within the scheduled shutdown timeframe. By leveraging the lessons learned from this field experience and utilizing the proposed software, industrial managers and practitioners can optimize future shutdowns, ensuring continued reliability and success even in the face of challenges.
La presente tesi di laurea ha come obiettivo l'analisi e la gestione delle fermate di impianti industriali per eseguire manutenzione, con particolare enfasi sul concetto di "Turnaround". Tale termine si riferisce a un evento pianificato in cui una specifica unità di produzione o l'intero impianto vengono temporaneamente fermati per condurre attività di manutenzione. Lo studio si basa su un caso reale: la fermata di tre linee di produzione nel Polo Chimico di Ferrara. Il principale obiettivo di un Turnaround è ottimizzare le attività di manutenzione, garantire la "reliability" degli impianti e minimizzare l'impatto sulla produzione, attraverso una gestione efficiente ed efficace del periodo di fermata. Per garantire una migliore comprensione, la tesi inizia con due capitoli introduttivi sui fondamenti della manutenzione e sul ruolo dell'ingegnere di manutenzione, per poi approfondire il concetto di Turnaround in un capitolo dedicato chiamato "Turnaround Shutdown", che analizza i suoi scopi, alternative, campi di applicazione, vantaggi e svantaggi. La ricerca è stata condotta in collaborazione con l'azienda Pansoinco S.r.l., che ha ottenuto un contratto per gestire la fermata dell'impianto industriale in questione. È stato sviluppato un software interno chiamato SDman (ShutDown Management), adattato alle specifiche richieste del cliente, l'azienda Eni Versalis. Oltre agli aspetti teorici, la tesi fornisce raccomandazioni pratiche per operatori e responsabili delle fermate di impianti industriali, nonché per i manager del settore industriale. L'implementazione del software proposto consente di ridurre i tempi di fermo, migliorare l'efficacia della manutenzione, incrementare la sicurezza operativa e ottenere risparmi economici, contribuendo all'aumento dell'efficienza operativa e della competitività complessiva. Nonostante le difficoltà incontrate durante la fermata dell'impianto a Ferrara, come la fusione di un motore e un'alluvione nella regione dell'Emilia-Romagna, la maggior parte delle attività è stata completata con successo entro la tempistica prevista. Attraverso l'analisi delle esperienze acquisite sul campo e l'utilizzo del software proposto, i responsabili e gli operatori del settore industriale saranno in grado di ottimizzare le future fermate, garantendo continuità operativa, affidabilità e successo, nonostante le sfide e le difficoltà che potrebbero presentarsi.
turnaround shutdown and outage management of an industrial plant in ferrara
Bettazzi, Pietro
2022/2023
Abstract
The following thesis aims to explain a complex topic, namely an industrial plant shutdown to perform maintenance, as clearly and simply as possible. To enhance readability and understanding from a possible reader, a real case has been reported: the shutdown of three production lines located in the Chemical Hub of Ferrara. The term “Turnaround” refers to a planned and coordinated event where a production unit or an entire facility is taken offline temporarily to perform maintenance, repair, inspection, and upgrade activities. The primary goal of a Turnaround is to optimize maintenance activities, ensure equipment reliability, and minimize the impact on production by efficiently and effectively managing the shutdown and outage period. In this last sentence, a term such as reliability has been used which may be unknown to many; for this reason, the beginning of this thesis is guided by two chapters focused on the basics of maintenance and on the figure of the "maintenance engineer", and then continue with a detailed and in-depth chapter on "Turnaround Shutdown", exploring its purposes, alternatives, fields of application, advantages and disadvantages. This thesis has been developed thanks to the contribution of the company Pansoinco S.r.l. which successfully secured a contract for managing the mentioned shutdown. For this purpose, an appropriate in-house software (SDman – ShutDown Management) has been developed and adapted according to customer requirements, namely Eni Versalis. The contributions of this thesis extend beyond theoretical implications by offering practical recommendations for Turnaround Shutdown and Outage practitioners and industrial managers. By implementing the proposed software usage, organizations can reduce downtime, enhance maintenance effectiveness, improve safety performance, and achieve cost savings, ultimately leading to increased operational efficiency and competitiveness. The shutdown of the industrial plant in Ferrara has presented several difficulties such as the fusion of an engine that fed a compressor, which led to an earlier-than- anticipated shutdown, and especially the flood that hit the Emilia Romagna region in mid-May. Despite these obstacles and delivery delays, all required activities were successfully completed within the scheduled shutdown timeframe. By leveraging the lessons learned from this field experience and utilizing the proposed software, industrial managers and practitioners can optimize future shutdowns, ensuring continued reliability and success even in the face of challenges.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/206612