Transcript Document
As-built documentation Experiences and development
07/06/2006 Herman Baets Manager Technical Governance PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Infrastructure
Total site area ....................................................................598 ha Number of plants .....................................................................54
Capacity tank farm ....................................................... 446.000 t Quay length .....................................................................4.551 m Roads .............................................................................. 152 km Railtracks ............................................................................41 km Overground pipes .............................................................290 km Underground pressure pipes ……………………………. 230 km 07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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BASF Antwerpen N.V.
Some technical figures
Replacement value……………………………………..+/- 6,4 bn € Amount of dynamic equipments……………………………..19.000
(pump, motor, turbines, fans,…) Amount of static equipments…………………………………15.000
(vessels, heat exchangers,storage tank,…) Amount of control loops…..…………………………………..35.000
Energy consumption Electrical Steam 07/06/2006 ca. 370 MW=ca. 5% Belgian consumption ca. 500t/h = heating of 10.000 houses PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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The Belgium-Netherlands R'dam-Botlek Chemical cluster
Exxon Mobil Shell Lyondell Chemie Shin_Etsu Shin-Etsu Basell Polyolefins Dow
Europoort-Terminal Netherlands Moerdijk
Exxon Mobil Shell ELLBA
Rozenburg
Huntsman-ICI Basell Polyolefins
Ostend Terneuzen
Dow
Zwijndrecht
Bayer/Lanxess Borealis Ineos-Oxide
Feluy Geel
BP Chemical
Meerhout
Exxon Mobil
Geleen
DSM
Antwerp
BASF Atofina Antwerp Bayer/Lanxess Solvay/ Solvin Exxon Mobil Ineos-Phenol Borealis Degussa Hüls
Beringen
Borealis
Tessenderlo Beek
Tessenderlo Chemie/LVM LVM Dow Steam Cracker Ethylene Pipeline Propylene Pipeline Atofina BASF BP Chemical Polimeri
Jemeppe
Solvay/ Solvin
Belgium
< 2 Mil. t/y 2-6 Mil. t/y 6-10 Mil. t/y > 10 Mil. t/y
France
07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
Germany
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Chemical companies in the Antwerp Harbour and the Campine
1/3 of the Belgian Chemical Industry In both these regions
Antwerpen
Air Liquide Industries Belgium ARCH Chemicals Atofina Chemicals BASF Antwerpen Bayer Antwerpen / Lanxess BP Chemical BF Goodrich BP Solvay PE Europe Borealis Degussa Antwerpen Eval Europe Exxon Chemical Belgium Ferro Fina Antwerp Olefins Haltermann (DOW) Hercules Belgium Indaver INEOS-Phenol INEOS-Oxide Lanxess Rubber 3M Belgium Monsanto Europe Nippon Shokubai NSP Olefins Phillips Petroleum Chemicals Praxair Production Solvay / SolVin Reilly Union Carbide Benelux Witco Benelux BP Chembel BF Goodrich Chemical Exxon Chemical Belgium Kaneka Belgium Oleon ICI Belgium Janssen Pharmaceutica Phillips Petroleum Soudal Sanico Tessenderlo Chemie- LVM Praxair Trans Furans Chemicals Borealis Polymers DOW Belgium 07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Why As-Built is a general issue ?
Do laws exist, where “keeping douments/data as built” is required ?
NO !
Why this is an issue ?
07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Why As-Built is a general issue ?
Risk management
Government forces nothing !
The society moves to risk management European regulations follow this idea Economical Social The local government as representant of the society are adapting this ideas in their laws
Our objective:
Be prepared so that we can prove that we manage our risks.
Which data/documentation do we need to fulfill the requirements ?
07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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BASF Antwerpen Why “As-built” is an issue ?
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Analyze of the document/data strategy 2.
Create the process to keep it up to date Intelligent and pragmatic Criticality according to the European regulations Risk management 3.
Design of the document/data management system
The Ibanx initiative As-built Best Practice
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General Objectives of As-built BP ?
Facilitation of the agreement in the different companies about the content of as-built technical documentation/data how far good quality and availability pushes company business results.
Agreement leads to optimal decisions about technical documentation/data About the necessary resources (men, money, system) The required quality The necessary availability.
The drive for realisation and maintenance 07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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As-built BP Who ?
20 Plant Owners have contributed NL ENERGIE CHEMBEL E&P
07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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The As-built BP
How ?
Mapping methodology supported by typical examplary documents Evaluation of the criteria Engineering, operations/maintenance Legal requirements (ATEX, PED, AREI, ARBO, Seveso, BRZO,. ) -
Result: As-Built data base
99 document types according to STEP LIB 83 elektronical examples 105 related documenttypes by the participants) 4713 data as-built (yes/no) and why PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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As-built BP
Synthesis of the workshops Topics
Process Hazard/Risk Operations/maintenance Spatial Plant lay-out: 3D Equipment Physical data Logical data Specifications
Total: 23
PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Synthesis of the workshops Process
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Process flow diagram (PFD)
•process data sheet •
Piping and instrumentation diagram (PID)
•electrical load list •equipment list •line list •instrument list •
Functional control and logic diagram
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Alarm and trip settings list
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Piping isometric drawing (according PED)
PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Synthesis of the workshops Hazard/Risk
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Emergency equipment and exits layout
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Hazard and effects register
•register of safety devices •
Risk analysis
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ATEX-certificate
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Synthesis of the workshops Operations/maintenance
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Maintenance and inspection plan
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Maintenance manual
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Operating manual
07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Synthesis of the workshops Spatial Plant lay-out: 3D
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Plot plan
•lightning and grounding layout •fire and gas protection equipment location drawing •road and drainage layout •civil and structures general arrangement drawing •equipment location plan •building layout sections and elevations •instrument location layout •area classification layout •
Underground services layout
PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Synthesis of the workshops Equipment: physical data
Assembly drawing
•equipment data sheet •general arrangement drawing •construction drawing •certificate of conformance
Instrument data sheet Spare parts list
•parts list
Valve data sheet
PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Synthesis of the workshops Equipment: logical data
I/O list Loop diagram
•control logic diagram •cause and effect chart •single line diagram •connection diagram •cable list •isometrics overall electrical tracing •lighting and power layout •plc configuration diagram •control schematic diagram PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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Synthesis of the workshops Specifications
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Insulation specification
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Material specification
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Piping specification
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The As-built BP Next steps
Presentation on the PELC A Working group (AB-BP) creates the publication Objective: Text ready 9/2006 Participants: Members of the companies who participated Facilitation/coördination: IBANX Brainstorming further actions Keep the BP up to date E.g.: What is document/data, linked to the procedure ?
Publication on the USPI-website 07/06/2006 PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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07/06/2006 Thanks for listening Questions ?
E-mail: [email protected]
PELC conference 2006 - Herman Baets BASF Antwerpen N.V.
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