“Meeting deadlines allows results to become possible”.
Index
The CompanyHistoryFacts and FiguresWorkshopsAll over the world
Engineering
EquipmentFormingDrilling and machiningWeldingFurnacesLogistics and sea front workshopIncoming projects and new investments
ProductsReactor overhead condenserLPG Storage TankHeat ExchangerCoke DrumHP AbsorberMild Hydrocracking ReactorsDemethaniserStacked Heat Exchanger
Certificates and Qualifications
References
Respect our clients
Respect our people
Responsibly grow our business
Our Vision
The Company
1960The first tank
1980
Zinc-plated tanks for drinking water
1996
UNI EN ISO 9001Certification
2000
Sea-frontWorkshop
2002
UNI EN ISO 14001Certification
2003
BOSCO Industrie Meccaniche
2007
Walter Tosto Group
2008 Ortona Yard: Covered areaexpansion 2011
Stamp N
1970
Tanks for diesel oil and wine
1994
Plant and process gas tanks
2214Employees 56 160 236 356340320 440 460420
2010- 50th years anniversary- first nuclear job
2013New workshop in Ortona
2012New workshop in Romania
2014New Nuclear Workshop
450 486475 500
Company > HistoryThe Company > HistoryThe Company
Walter Tosto Spa is a worldwide leader for the produc-tion of heavy wall static and heat transfer equipment for Oil&Gas, Petrochemical, Power and Energy markets. Founded in 1960 by Mr. Walter Tosto, the company is man-aged by Walter Tosto’s son, MD - Luca, who widened the business to the overseas areas. Today our company operates in international markets, be-ing characterized and supported by advanced manufactur-ing technologies, more than 500 qualified employees and 9 relevant facilities: seven in Chieti Scalo, one in Romania (WTB), and one placed in the Ortona Port, on the Adriatic Sea, directly connected to main international ports and routes. Our position in the worldwide scenery has also been streghtened by an advanced, ongoing investments plan, thanks to which 60 million euros have been invested in R&D, logistics and new capabilities over the last 5 years. In particular, within the second quarter of 2010 one of our highest technological achievements was reached, since a new bending machine completed (the biggest in the world), capable of cold rolling plates up to 300 mm in thickness, completely engineered and assembled by our internal staff. Another important step in the company’s history is the acquisition of Bosco Industrie Meccaniche in 2003, that has improved Walter Tosto skills in the pro-
Founded in 1960 by Walter Tosto
Today
Average Turnover
Investments in the last 5 yearsAverage Production
Export in 55 Nations WorldwideSeafront workshop for direct loading350.000 Sqm workshop area85.000 Sqm covered
14 employees
over 500 employees
100 mln Euro
60 mln Euro
14.000 Tons per year
14.000 Tons per year
cess of fabrication and heat transfer equipment. All above investments and plans are completely in line with the com-pany strategy to be mainly focused on the critical and very long lead items such as reactors, heavy wall pressure ves-sels and high pressure heat exchangers, in order to proceed with being considered as customers’ point of reference for the development of many important international projects. In this way, our company aims at gaining customers’ confi-dence and developing large international projects.
The Company > Facts and figuresThe Company
Worldwide areas where Walter Tosto exported its products.
Worldwide Walter Tosto Office/Agents.
The Company > All over the worldThe Company
Engineering
Engineering & Materials
ASME-III ASME-VIII Div. 1 ASME-VIII Div. 2 PD5500 AD 2000-Merkblatt
Computer Aided Design System
Some of the Applicable Design Codes and standards
System Name
FinglowCATIA V5Pro EngineerSolid EdgeAutoCADANSYSAspen Suite
Sant’AmbrogioPAAC
Purpose
Calculation software3D drawing software3D drawing software 3D drawing software2D drawingFinite Elements AnalisysHeat Exchangers Mec. DesignShell & Tube Exchanger Design Rating SoftwareMechanical calculation softwareFeedwater Heater and surfacecondenser thermal design
Developer
Finglow LtdDassault SystemesPTS USGAutodeskANSYSAspentech
Sant’AmbrogioBosco Spa
AD Merk Blatter 2000 Stoomwelzen SQL/SELO API CODAP
CODRES HTRI HEI GOST IBR
RCC-M RCC-MR
Carbon Steel (CS)Fine - grain Steel / NormalizedHigh strenght - CS (QH)
Cr - Mo alloys0,5 Mo1 Cr - 0,5 Mo2,25 Cr - 1 Mo2,25 Cr - 1 Mo - 0,25 V
Stainless SteelFerriticAusteniticAlloy claddedAustenitic steel duplex
Ni - Alloyed Steel0,5 Ni3,5 Ni
Non Ferr. MaterialsTi-Gr. I / Gr. IICopper AlloyHigh Nickel Alloy
Engineering& Materials
Walter Tosto develops contracts specification in full compliance with Design Codes and custom-er’s requirements. More than 20 skilled engineers, draftsmen and design managers are able to satisfy contracts requirements through the application of ad-vanced software both for thermal and mechanical de-sign (ASPENTECH/HTFS/TASC+, SANT’AMBROGIO, ANSYS, AUTOCAD, SOLID EDGE etc). The full knowl-edge and familiarity with all the exsisting Design Codes as ASME, PD 5500, CODAP, STOOMWELZEN, AD 2000-Merkblattand GOST, allow Walter Tosto peo-ple to perform the most sophisticated mechanical designs according to the most advanced technical requirements. Furthermore the in-house presence of FEM experts together with the several ANSYS licenc-es, make the Finite Element Analisys a powerful in-strument in our hands, for the design of critical parts of the equipment like the forged connection between shell, head and skirt or the thin tubesheet of a Waste Heat Boiler, even 3-dimensional complete FEA mod-els have been developed in-house for particular criti-cal applications. Beside the Mechanical Design, Wal-ter Tosto has strong skillness to develop the Thermal and Fluid dynamic design of Heat Exchanger giving to our Clients all the required guarantees.
Incoming projects > ITER
Nuclear reactor ITER project
ITER is the most advanced fusion projects ever done worldwide thanks to the support and financing of the EU, Russia, India, China, South Korea and USA. ITER is based on the ‘tokamak’ concept of magnetic con-finement, in which the plasma is contained in a doughnut-shaped vacu-um vessel. The fuel - a mixture of Deuterium and Tritium, two isotopes of Hydrogen - is heated to temperatures in excess of 150 million°C, forming a hot plasma. Strong magnetic fields are used to keep the plasma away from the walls; these are produced by superconducting coils surround-ing the vessel, and by an electrical current driven through the plasma. The Vacuum Vessel is a hermetically-sealed steel container inside the Cryostat that houses the fusion reaction and acts as a first safety con-tainment barrier. In its doughnut-shaped chamber, or torus, the plasma particles spiral around continuously without touching the walls. The size of the Vacuum Vessel dictates the volume of the fusion plasma; the larger the vessel, the greater the amount of power that can be pro-duced. The ITER Vacuum Vessel will be twice as large and sixteen times as heavy as any previous tokamak, with an internal diameter of 6 metres. It will measure a little over 19 metres across by 11 metres high, and weigh in excess of 5.000 tons. The Vacuum Vessel will have double steel walls, with passages for Cool-ing Water to circulate between them. The inner surfaces of the Vessel will be covered with Blanket Modules that will provide shielding from the high-energy neutrons produced by the fusion reactions. Some of the Blanket Modules will also be used at later stages to test materials for Tritium Breeding concepts.Forty-four ports will provide access to the Vacuum Vessel for Remote Handling operations, Diagnostic systems, Heating, and Vacuumsystems: 18 upper ports, 17 equatorial ports, and 9 lower ports.
Incoming projects and investments
“To look ahead” is Walter Tosto’s leitmotiv: inno-vation and new challenges characterize the company.
In 2010 WT started facing the nuclear market, signing a contract, in consortium with Ansaldo Nucleare and Mangiarotti, for the supply of the Vacuum Vessel of the fusion reactor of the ITER project.
Thanks to this experience, the company will shortly further improve knowledge, processes and quality of the performance in all the markets.
a new workshop for special process and sophisticated mechanical machining
tailor made robotic UT testing equipment
measuring 3D laser tracker
CNC 5 axes portal milling machine
design and engineering of customized industrial manipulators, positioners and handling systems
Narrow GAP welding machine
Furthermore, Walter Tosto started and successfully concluded at the end of 2011 the procedure for the certification Stamp N and NPT.
Equipment
Equipment > Forming
Pressing Machinepressing force: 9.000 Tons
Plate bending roller diagraminternal diameter: 3500 mmplate material: SA 542D 4a
460
440
420
400
380
360
340
320
300
280
260
240
220
200
0
0 1000
thick. mm rolling thickness prebending thickness
Width mm1500 2000 2500 3000 3500
Equipment
Heavy rolled plates represent the best solu-tion for long lead items merging the excellent quality of plates from ingot, the potential cost saving and the possibility of having extra large shell courses with reduction of circumferential welds.
Equipment > Drilling and machining
1 Galbiati Drilling MachineAxis X: 5.000 mm; Axis Y: 3.840 mm; AxisZ: 1.100 mm; Axis W: 600 mmMax Drilling Dia: 51.7 mm – STS drilling systemDouble head drilling machineCNC: Siemens 840D
3 Pama Boring Milling MachineAxis X: 6.000 mm; Axis Y: 3.100 mm; Axis Z: 700mmIntermittent rotating table dim.: 2.000x2.500 mm x 30 tonClearance: 1.200 mmCapacity: 30 TonsCNC: Siemens 840 D
4 Innse Boring MachineAxis X: 11.500 mm; Axis Y: 4.320 mm; Axis Z: 1.100 mmContinuous rotating table dim.: 3.000x3.000 mm x 60 tonClearance: 1.560 mmCNC: Siemens 840 D
2 Sant’Eustacchio Lathe/Drilling MachinePlatform Diameter: 8.000 mmMaximum turning platform diameter: 8.300 mm x 4.000mmPlatform Capacity: 100 Tons, p y, Adjustable up to 200 tonsMachine featuring C axis and Double Z axis, one featuringelectric boring and milling device Capto C8, 24 KwCNC: Siemens 840 D
2 3
4
Equipment
Example of state-of-the-art equipment re-cently acquired are the INNSE boring machine and GALBIATI drilling machine.
1
4 Double Welding head ESW-SAW with 90mm/60mm strip 0.5mm in thk.Power Source Welding: n°6 “Generator 1250” Miller (n°3 per welding head)(Manipulator) column and boom 3m*7m; maximum load at end of arm kg 300
2 Internal Bore WeldingThis particular welding is performed using a gun inserted in the tubesheet hole with a rotating head. With special tools is possible to re-build the seat when is necessary to cut the tube already welded.
1 SAW Narrow Gap head up to 300mm (single wire and tandem technique) for longitudinal, circumferential jointPower Source Welding:n°2 Power Wave AC/DC 1000 Lincoln
3 Face welding of tubes/tubesheet for a tubular reactor
Equipment > Welding
2 4
3
Equipment
1 The large amount of material welded, thick-nesses and processes has driven Walter Tosto to the recording of more than 1.500 PQRs.
Equipment > Furnaces
2 Dimension: 10 x 11 x 28 (Mt) Max Temperature: 750°C Q: 800T, Thermocouples: 30
1 Dimension: 5 x 2 x 5 (Mt)Max Temperature: 1100 °CQ: 40T, Thermocouples: 4
5 Dimension: 6 x 6 x 24 (Mt)Max Temperature: 1100°CQ: 250TThermocouples: 24
3 Dimension: 6 x 3 x 12 (Mt)Max Temperature: 1100 °CQ: 110T, Thermocouples: 16
4 Dimension: 6 x 6 x 22 (Mt)Max Temperature: 750°CQ: 250T, Thermocouples: 12
2 3
4 5
Equipment
Walter Tosto owns five furnaces able to per-form any kind of heat treatment. Some of them are placed next to the bending and forming machines in order to optimize the operations and to perform different activities such as hot intermediate heat treatment, water quenching and solution annealing.
1
Ortona Yard
Over 9.000 sqm of covered area 3 spans + 1 under construction
dedicated to the new milling machine Waldrich
indoor painting and surface treatment facility (about 400 mq2)
furnace for post weld heat treatment (29mt x 11mt x 10mt)
3 quays: RIVA: Height: 1.60 mt, Water Depth: 6.00 mt RIVA NUOVA:Height: 2.00 mt, Water Depth: 6.00 mt NORD NUOVA: Height: 2.00 mt, Water Depth: 7.00 mt
Logistics/Seafront Workshop
Walter Tosto Spa owns a sea front work-shop in the Ortona Port (Adriatic Sea).This allows the shipping in one piece of items with noteworthy dimensions:- diameters up to 15 mt; - lengths up to 100 mt;- weights over 1500 tons.
Handling and lifting operations are carried out with equipment owned by the company.
Logistics
8 self propelled modular COMETTO, featuring 6 axes2 self propelled modular COMETTO, featuring 4 axesTotal Capacity: about 1.400 Tons
Krupp mobile crane, maximum capacity of 1.000 tons.
Products
Plant
CustomerCapacityMaterialPressure
Petredec LPG Terminal
Port Luis – Mauritius
Lloyd Jones Construction
9.403 m3
DILLIMAX 500ML
10.8 bar
Products > LPG Storage Tank
Length Diameter ThicknessWeight
54.906 mm
15.430 mm
35 mm
880.000 kgProducts > Reactor overhead condenserPlantEPCCustomerLocation
Polypropylene Plant
Linde Engineering
Tobolsk Polymer
Russia
ItemMaterial
Weight
Reactor 220-R2
SA 516 gr. 60 N, SA 789 UNS
S 32 205, SA 516 Gr. 60 N
65.400 kg
Products > Coke Drum
PlantCustomer
EPCMaterialPressure
Coking Unit Reficar Refinery
Reficar Cartagena Refinery
Expansion Proj.
CB& I Lummus
SA 387 Gr.11 Cl.1 + 410 S
5,17/ 7,69 bar
TemperatureLength DiameterThicknessWeight
463/ 504°C
24.130 mm
7.925 mm
32 + 3 mm
285.400 kg
Products >Heat Exchanger (Breech Lock Type)
PlantEPCCustomer
Material
UHDT Complex
UTC Engenharia S.A.
Petrobras Petroleo
Brasileiro S.A.
Shell: SA 387 Gr.22 + 3 mm
Clad SS 321
Tube: SA 213 TP 321
Channel: SA 336 F 22 Cl.3 + 3 mm
W.O. SS 347
Pressure
Temperature
DiameterTubes
Weight
Shell Side: 106 bar
Tube Side: 92 bar
Shell Side: 410°C
Tube Side: 430°C
1.450 mm
Nr: 711
Dia: 25,4 mm
Thk: 3,05 mm
61.500 kg
Plant EPCCustomerLicensorItem:
Mild Hydrocracking Unit
(Romania)
S.C. Rominserv S.A.
Petromidia
Axens
Hot and Cold Separators and
HP Amine Absorber
Products > Mild Hydrocracking ReactorsProducts > HP AbsorberPlant typeEPCCustomer
MaterialPressure
Refinery
Saipem SpA
Abu Dhabi Gas Development
Company Ltd.
SA 516 Gr.65 + W.O. SA 240 316 L
82/HV at 150°c
TemperatureTL-TL length DiameterThicknessWeight
125°C
35.000 mm
6.109 mm
181 + 4.5 mm
1.400.000 kg
Products > Stacked Heat Exchanger
Plant EPCCustomerItem:
EB/ SM
Shaw Energy & Chemicals Group
Tianjin Dagu Chemical Co.
Items are part of the Stacked Heat
Exchanger: Feed Vaporizer, Feed/
Effluent Exchanger, HP Steam Generator
LocationWeight
China
473.000 kgPlant EPCCustomerItemLocation
3rd Expansion Proj
Shaw Stone & Webster
Sharq Sabic
HP Demethaniser
Saudi Arabia
DiameterThickness Length Weight
5.700 mm
76 mm
71.300 mm
653.000 kgProducts > Demethaniser
Approvals > Qualifications
Walter Tosto SpA operates according to a quality management system pursuant to ISO 9001 standard since 1995.Thanks to the relevant attention paid for improving the quality of the activities performed, Walter Tosto SpA has always been focused on obtaining further certifica-tions. Qualifications like ISO 3834 “Quality requirements for fusion welding of metallic materials“ as well as ASME stamp U, U2, U3, S, R, N and NPT.Our Quality department is also specialized for obtaining international credits like SELO for operating in China or GOST, for Russian and CIS countries. Moreover, our company highly cares about possible im-pacts of its activities on environment and population. ISO 14001 certifies and formalizes our strong will to re-spect environmental resources by lowering emissions. At the end of 2011 Walter Tosto has obtained the ASME N and NPT Stamp related to the “Rules for construction of nuclear facility components”.
Quality Certificate
Walter Tosto S.p.A. - Via Erasmo Piaggio, 72 66100 Chieti Scalo (CH) - Italy, Europe.phone: +39.0871.5801 fax: [email protected] design: Dispenser
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