PRECISION MACHINING & MANUFACTURING SERVICES

Transcription

1 PRECISION MACHINING & MANUFACTURING SERVICES

2 03 The complete solution Proserv s Coatbridge facility is our Global Centre of Excellence (CoE) for the design, engineer, manufacture, repair and refurbishment of critical components and assemblies. We specialise in asset new build and lifecycle solutions for clients in a range of industries, including; oil and gas, aerospace, defence, marine, renewables and food. Our fully integrated service offering means we can provide clients with a one stop shop solution for their complete precision engineering and manufacturing needs, resulting in greater operational and cost efficiencies. Proserv has a long and well established track record dating back almost 40 years and we continue to invest in our fleet of equipment to provide the highest standards of quality and service our clients have come to expect. Precision engineering and manufacturing Special purpose machining Non destructive testing (NDT) Welding, cladding and heat treatment Coordinate measuring machine (CMM) and quality management Surface treatments Assemblies and testing Refurbishment and upgrade

3 05 Special purpose machining We engineer and manufacture special purpose machines according to our clients exact project requirements and specifications. At Proserv, we have delivered numerous unique machine solutions to clients worldwide, which is a testament to our specialist capabilities, skills and expertise. line equipment for a leading food manufacturer, the engineering and build of staking rigs for computer chassis, the manufacture of crystal growing machines used in transatlantic fibre optic communications, and the manufacture of specialist aluminium extrusions to the cosmetics industry. Examples of past projects have included the design and manufacture of production Precision engineering and manufacturing At Proserv, we offer a fully integrated, turnkey service for our clients precision engineering and manufacturing needs. We take responsibility for every aspect of an engineering project, from design through to machining and assembly, to ensure products and systems are delivered efficiently and cost effectively. Our clients benefit from the dedicated support of design and engineering teams who optimise manufacturing processes, solve problems and identify ways to improve end product functionality.

4 07 Welding, cladding and heat treatment Non destructive testing (NDT) Welding procedures are instrumental in the provision of corrosion resistant overlays in both the manufacture of quality new parts and the reclamation of worn or damaged components. Proserv holds over 80 welding procedure specifications (WPS) and supporting procedure qualification records (PQR) by certifying authorities. This enables us to fulfill repairs to the highest quality standards, even on high pressure systems. With a total of five Fronius cladding stations, we have worked with major testing houses to ensure chemical, mechanical and radiography tests are approved to ASME IX, API, NACE, AWS D1.1, ISO 15156, BS EN287/8, Norsok and other international standards. Proserv offers highly effective NDT systems and services for examining the integrity, safety and reliability or critical and complex component parts. Carried out by our trained PCN II inspectors, our range of services provides clients with the confidence to make informed decisions about the life of their assets. Our capabilities include: Liquid penetrant inspection (LPI) Magnetic particle inspection (MPI) Positive material inspection (PMI) Weld clad thickness (WCT) Ultrasonic testing (UT) Phased array equipment and testing Mobile services

5 09 CMM and quality management Surface treatments To further enhance our quality assurance and increase our inspection capacity, Proserv has invested in leading coordinate measuring machines (CMM) and software. In line with our ongoing efforts for operational excellence and to provide the highest standards of quality and service to clients, ongoing investment in our equipment and services is essential. We use continuous improvement initiatives such as Lean, 5S, Visual Management, and Key Performance Indicators (KPIs) to support our efficiency and quality targets and ensure we meet all compliance criteria. Our highly skilled in-house personnel are trained to the following qualifications: CSWIP, NDT PCN Level II and NACE Coating Applicators & Inspectors. Proserv offers a range of high performance surface treatments. Our coating and painting processes protect and preserve to increase the life of critical components and assets and optimise their performance. Within our dedicated coating facility, we have blast rooms, curing ovens, paint spray booths and a paint store. Based on the size of our facilities, we can accommodate mass batches as well as large sized and small volume, high value components. The range of coatings we can provide include xinc phosphate, xylan, molycote and everslik, all applied using Norsok approved high build paint systems by NACE level I applicators and NACE level II inspectors.

6 11 Refurbishment and upgrade Proserv offers a complete aftermarket service for our clients assets ranging from planned maintenance programmes through to refurbishment projects, equipment repair and certification. Once used parts have been removed from service, we can either repair or upgrade these parts then re-machine them back to their original state and exact specification for final testing and service. We can manage projects of any size ranging from single spare parts through to the most complex assemblies across a variety of different industry sectors. As our after-market services are all under one roof, we have the capability and capacity to reliably process work within tight turnarounds, helping to minimise project downtime. Assemblies and testing Proserv has extensive experience in providing testing services for client equipment. Tests can be conducted to national, international or industry standards or to the client s own enhanced test specification. Using our purpose-built test facilities we can undertake various types of testing including hydrostatic testing, gas testing, high pressure testing, site integration testing (SITs) and factory acceptance testing (FATs). skids that contain pressure containing components such as valves or pipework. All test pits are covered by high capacity overhead cranes. All tests are conducted using purposebuilt facilities that have been designed such that testing can be conducted safely with remote monitoring facilities. Our test pits can accommodate large items and this allows us to undertake testing of larger frames or

7 13 CAPABILITY AND CAPACITY Our precision engineering and manufacturing facilities throughout the UK are equipped with a modern fleet of high specification equipment. This is an area we continue to invest in to ensure projects are delivered safely, efficiently, and to the highest quality standards. FACILITY HIGHLIGHTS 10 CNC lathes (2 x VTLs) 3600m 2 coating space 14 cranes (max 5-20t lifting weight) 17,678m 2 manufacturing space 3657m 2 test and assembly space 6 machining centres (3 x horizontal twin pallets & 3 x vertical) 4 horizontal boring machines full C axis

8 15 Project Management Our teams leverage their years of expertise to manage the risks, costs and safety of our clients projects. No typical project is the same. We provide a tailored and integrated set of project management processes and systems for consistent and rigorous project delivery. OUR ASSURANCE We appoint an experienced person to be the single point of contact for each client project; this individual is then responsible for ensuring the project is completed on time, on budget and to the agreed quality. Supply Chain At Proserv, we have developed strategic relationships with many suppliers to ensure we provide exceptional supply chain integration and service. We believe the capability and reliability of our supply chain integration is as important as the in-house facilities, and we monitor the service and business levels of key suppliers to ensure that excellent service is delivered to our customers, always. Quality Quality management is at the heart of what we do and we have earned an excellent reputation over the years for our commitment to the very highest standards. It is an essential component of Proserv s continuous improvement efforts. Quality control is achieved by an extensive array of measurement equipment, with several coordinate measuring machines located throughout the facilities. We operate in line with international quality standards recognised under the following registrations: ISO Quality Management System ISO Environmental Management System ISO Welding Process AS Quality Management System

9 17 Aftermarket Repair Case Study As a result of the technological solutions provided by Proserv, our client has further prolonged the life of their assets while bringing the well back into full production. Christmas Tree Spool Body Client: OEM Location: Troll Field, Norway Equipment: Christmas tree spool Background The client required a solution that would allow them to refurbish Christmas tree spools that had been in operation for over 20 years in the Troll Field, Norway. Due to the age of the equipment, several repairs, material certification and quality assurance documentation was required as part of the overall work scope. Project Description The overall age of the equipment was a challenge faced by the team and various procedures were required to carry out the material certification and quality assurance documentation. The collaboration between Proserv and the client was key to the success of the project, which ultimately provided significant cost savings and reduced lead times by choosing a refurbishment solution of existing equipment over new component parts. Scope Proserv worked with the client to first understand the original material composition as this would aid in the repair process. In order to achieve this, sacrificial test pieces trepanned from the base material were taken and additional outlets were machined that could later be capped off. A Positive Material Identification (PMI) was taken of the cores and the results from further mechanical testing. This provided the necessary details to make revision changes to existing weld procedure specifications and procedure qualification records (WPS & PQR). These were then simulated during the second and third stress relieves. The repair welds were witnessed by DNV and undertaken by Proserv and NS 477 welding inspectors under strict ISO 3834 standards. Checks to the heat affected zones (HAV) and the hardness were also collected for analysis. Conclusion As a result of the technological solutions provided by Proserv, our client has further prolonged the life of their assets while bringing the well back into full production. The client is also looking to roll out the procedure for all tree spools within the Troll Field.

10 19 New Equipment Manufacture Case Study By implementing an ingeniously simple design that complemented an existing system, Proserv has manufactured and delivered an efficient state of the art system for the client. Station Depositor and Conveyor Client: Leading biscuit manufacturer Location: Uddingston, UK Requirement: Enhance the station depositor and conveyor system output method Background Proserv was approached by a leading biscuit manufacturer to provide a solution for their tea cake biscuit product line. The current depositor and conveyer system offered eight production units per row and suffered reliability issues, low production performance and high waste output. Project Description The client s current system required an upgrade and Proserv designed and manufactured a wider conveyer and a new 16 station mallow depositor head with state of the art Siemens touch screen control and new compact Mitsubishi drive technology. The new design seamlessly integrated with the existing automation system and the manufacturer has seen a vastly increased volume and improved throughput figures for the product in a significantly reduced amount of time. The system now produces 480 tea cakes per minute, 28,800 per hour and 691,200 per day, almost five million per week. The machine runs 24 hours a day and product waste has been reduced to less than one percent of total production, an increase of over 300% on products produced on a weekly basis. Conclusion By implementing an ingeniously simple design that complemented an existing system, Proserv has manufactured and delivered an efficient state of the art system for the client at their manufacturing plant in Uddingston. Benefits Increased productivity outputs and less waste State of the art touch screen Siemens controls and compact Mitsubishi drive technology for ease of operation Less risk of downtime due to the availability of real time data Significant reduction in maintenance due to the new design features I am delighted with the increase in productivity and reduction in waste since the installation of the new system. Proserv has delivered a reliable and seamless design that we are all thrilled with, and we look forward to working with them in future product line improvements.

11 Proserv Coatbridge Russel Colt Street Coatbridge Lanarkshire ML5 2BN T: +44 (0)