Manufacturing Asset Assessment & Planning (MA2P) for Surface Finishing Facilities
Manufacturing Asset Assessment & Planning (MA2P) is a comprehensive process and strategy to optimize the life cycle costs and improve the reliability of manufacturing assets. MA2P is a unique tool developed by Integrated Technologies Inc. to assess the physical condition, operational efficiency, impact of failure, and relative risk of failure for process equipment, physical plant, and plant systems. Life cycle costs and risk can be managed with effective planning. MA2P deliverables include a quantitative assessment of condition and risk and recommendations to reduce operational life cycle costs and mitigate risk. Investments in MA2P can extend the life of manufacturing assets, reduce the risk of business interruption and EH&S system failures, and dramatically improve operational efficiency.
A detailed audit report is generated for the wet process lines and wastewater treatment systems (as applicable). Each piece of equipment and the system is identified with a written description of the defect and rated. The risk table above is utilized to categorize the various components and system defects to establish a level of risk or importance based on the ratings and level of impact. The final report summary provides specific recommendations for corrective action and associated estimated costs.
Typical Report Segment:
Tank T-400 Deoxidier liner is constructed of 316L stainless steel material and is not compatible with the mixed acid bath chemistry which includes HF. The liner (which replaced an earlier FRP liner) is expected to fail prematurely.
Level of Importance: Extremely High
Condition Rating: 3
Application Rating: 0
Impact Rating: I
Areas of Impact: P, S, M. H
A flexible PVC drop-in liner (1/8″ thick) should be installed over the existing stanless steel liner. The saddle clips to hold the flight bar will require redesign. The drop shields and channel moats will require redesign and are coverd as a separate problem. A leak detector shoudl be installed between the PVC and stainless steel liners. A spare liner can be purchased for use in this tank or others for emergency for cost of approximately $13,000. Note: A more rebust solution would be to install a Koroseal liner but this would increase cost.
Estimated Cost (ROM): $35,000 (includes installation of drop-in liner, shipping and leak detection plus rental of temporary storage for five days.
ITI is a global consulting, engineering, and design-build firm based in Burlington, Vermont. We specialize in manufacturing processes, water and wastewater treatment, recycling, and ventilation applications for the metal and surface finishing industry.