Asbuilt documentation Experiences and development

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As-built documentationExperiences and development
Herman Baets Manager Technical Governance
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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

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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 equipments15.000
• (vessels, heat exchangers,storage tank,)
• Amount of control loops....35.000
• Energy consumption
• Electrical ca. 370 MW ca. 5 Belgian consumption
• Steam ca. 500t/h heating of 10.000 houses

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The Belgium-Netherlands Chemical cluster
R'dam-Botlek
R'dam-Pernis
Exxon Mobil Lyondell Chemie Shin-Etsu
Shell Shin_Etsu
Netherlands
Basell Polyolefins
Dow
Moerdijk
Europoort-Terminal
Exxon Mobil
Shell
ELLBA
Rozenburg
Huntsman-ICI Basell Polyolefins
Meerhout
Geel
Exxon Mobil
Geleen
BP Chemical
DSM
Germany
Antwerp
Ostend
Terneuzen
BASF Atofina Antwerp Bayer/Lanxess Solvay/Solvin E
xxon Mobil Ineos-Phenol Borealis Degussa-Hüls
Zwijndrecht
Dow
Beringen
Bayer/Lanxess Borealis Ineos-Oxide
Borealis
Beek
Tessenderlo
LVM
Tessenderlo Chemie/LVM Dow
Feluy
Atofina BASF BP Chemical Polimeri
Steam Cracker
Jemeppe
Ethylene Pipeline
Solvay/ Solvin
Propylene Pipeline
Belgium
lt 2 Mil. t/y
2-6 Mil. t/y
6-10 Mil. t/y
France
gt 10 Mil. t/y
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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)

BP Chembel BF Goodrich Chemical Exxon Chemical
Belgium Kaneka Belgium Oleon ICI Belgium Janssen
Pharmaceutica Phillips Petroleum Soudal Sanico Te
ssenderlo Chemie- LVM Praxair Trans Furans
Chemicals Borealis Polymers DOW Belgium

• 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

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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 ?
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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 ?
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BASF AntwerpenWhy As-built is an issue ?

• Analyze of the document/data strategy
• Create the process to keep it up to date
• Intelligent and pragmatic
• Criticality according to the European regulations
• Risk management
• 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

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As-built BP Who ?20 Plant Owners have
contributed
NL ENERGIE
CHEMBEL
EP
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The As-built BPHow ?

• 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

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As-built BP Synthesis of the workshopsTopics

• Process
• Hazard/Risk
• Operations/maintenance
• Spatial Plant lay-out 3D
• Equipment
• Physical data
• Logical data
• Specifications

Total 23
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Synthesis of the workshopsProcess

• 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
• Alarm and trip settings list
• Piping isometric drawing (according PED)

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Synthesis of the workshopsHazard/Risk

• Emergency equipment and exits layout
• Hazard and effects register
• register of safety devices
• Risk analysis
• ATEX-certificate

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Synthesis of the workshopsOperations/maintenance

• Maintenance and inspection plan
• Maintenance manual
• Operating manual

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Synthesis of the workshopsSpatial Plant lay-out
3D

• 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

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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

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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

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Synthesis of the workshops Specifications

• Insulation specification
• Material specification
• Piping specification

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The As-built BPNext 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

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• Thanks for listening
• Questions ?

E-mail herman.baets_at_basf.com Tony.houthaeve_at_basf.
com