BASF chemical production
BASF is a company of superlatives. The world's largest chemical group was incorporated as "Badische Anilin- und Soda-Fabrik" in Mannheim in 1865 and is now headquartered in Ludwigshafen/Rhein. The BASF city with its 200 chemical production plants, several hundred laboratories, technical centres, workshops and offices is the largest industrial complex in Europe and the world's largest integrated chemical site. Over an area of more than 10 square kilometres, some 34,000 employees work on the development, testing, manufacture and sale of thousands of different products. The safety standards are also among the best in the world, both in respect of the people in the Rhine-Neckar metropolitan area and the company's own employees. As part of the chemical industry's international "Responsible Care" programme, BASF has not only committed itself to acting in a responsible manner towards people and the environment, but also to the continuous improvement of plant and industrial safety. One practical implementation of this for years in the area of fluid handling has been the routine use of fittings and safety technology from the "RS brand".
Another example can be seen in the Deka factory, where dry disconnect and breakaway couplings from RS Roman Seliger have been in use for ten years. The Deka factory is one of the oldest buildings in the BASF complex, but has nothing in common anymore with the old production facility apart from its traditional name. Its old walls now house an ultra-modern plant for manufacturing intermediate products for the pharmaceuticals industry, construction chemistry and pest management. Preliminary products for paints, disinfectants and additives for polyurethane production are also produced here.
Increased process efficiency: From ten minutes to ten seconds
Modern multi-purpose plants often manufacture several different products and product varieties. Flexible media flow adjustment/conduction is needed for this, along with regular adjustment of pipework and fittings. Hose lines between individual plant parts create "flexible" connections where it is impossible for valves to do so. This results in a lot of coupling, as all the different kinds of media accessing the various hoses, pipework and fittings are in constant flux. Every coupling procedure means an interruption to the process. This presented a major challenge as flange connections were still prevailing in the Deka factory instead of quick coupling systems. Having to loosen and reconnect flanges meant an interruption of at least ten minutes, even with employees who were well used to the work. This had to be reduced in the interests of an integrated process.
System safety
According to the plant manager at the Deka factory, there was a lot of learning the hard way before this was achieved. After months of testing using various alternatives, the decision was taken in the Deka factory to switch from flanges to a quick coupling system. A dry disconnect coupling was chosen in particular for safety reasons and a TR from RS for reasons of quality. And the employees have seen excellent results from this! What previously took ten minutes is now a ten-second job - an instant change in media.
Added value: Increased safety
The safe quick coupling function is just one feature of the TR, which has been principally developed as a safety coupling. Decoupled hose lines form closed systems thanks to the dry disconnect coupling mechanism. At the moment of decoupling, the valves in both the male and female sides close "automatically". Therefore, there is no need for additional closing of taps as with open flange connections, nor residue disposal. Coupling practically takes place during operation, providing the maximum safety from leaks and evaporation. This not only makes work easier for employees but also protects them from health risks. Following this initial step towards increased safety from leaks, there was a second step towards greater safety from incorrect connections. The challenge: critical media, such as highly odorous amines, are sometimes stored in the tanks and flow through the pipe and hose lines. However, the (unintentional) mixing of amines and non-amines is a particular problem. Adding different colours to the amines (green) and non-amines (blue) was the first right step. But only the mechanical coding of the male and female parts of the TR, i.e. the use of the key/keyhole principle, has ultimately made the mixing impossible. This is another significant safety advantage for employees as well as the work process and plant.
Added value: Less maintenance costs
There has also been a significant increase in safety in the loading area. A range of pipelines (now all equipped with TR male parts) open out into the tank wagon station on the external east wall of the Deka factory. Hose lines via which chemical products are pumped from the Deka factory to the road or rail tankers are connected here. Previously, damage was always occurring in the area where fluids were transferred, e.g. from tankers being moved while fluids were still being loaded. Tired of the repeated need for repairs and increased maintenance costs and given higher safety requirements, solutions were looked for and the prin-ciple of breakaway couplings found. The company opted for the ABV breakaway coupling from RS in various nominal widths. It functions according to the "predetermined breaking point" principle. Therefore, if there is a tensile load during loading, e.g. from a tanker moving during shunting while the loading hose is still connected, the ABV effects a controlled separation of the line. The open ends are safely sealed at the same time. This protects the pipe/hose line and its fittings from damage and the service staff and the environment from unwanted media leaks which might arise if a hose ruptured, for example. The division concerned has been successfully using ABVs at the tanker station for a long time now. Along with the tangible reduction in maintenance costs, there has also been a considerable "incidental" increase in safety for people, the environment and the plant.
Added value: Longer main-tenance cycles
Using the SGA hose loading arm at different loading stations on the complex has had the same effect on maintenance costs and safety. The multi-section, horizontally pivotable arm supports the weight of the hose when the hose lines (media hose, gas hose, possible power cable) are placed on the arm. This takes the burden off employees during loading, while simultaneously protecting the hose line from mechanical loads such as torsion, axial distension, bends, cover abrasion and being driven over. This also increases the product life, thereby extend-ing maintenance cycles. At a company of superlatives like BASF, this adds up to significant savings across all applications.
Leak-free coupling
Some of the pipes in the Deka factory carry problematic chemicals, such as amines. This is another reason for achieving the highest coupling safety standards. The sophisticated valve technology of the
TR dry disconnect coupling ensures that problematic media are consistently blocked off at the moment of decoupling, thereby preventing leaks.
Decoupling in emergencies
Rail and road tankers are filled using hose lines at the Deka factory's loading stations.
ABV series breakaway couplings at the interface between plant and logistics ensure that shunting mistakes like "driving off too hastily" cannot end in catastrophe. At a defined tensile load - long before the hose tears - the ABV cuts the connection and safely closes the separation points.
Effortless tanking
The
SGA hose loading arm bears the weight of the spiral hoses with the heavy flange coupling at various points in the plant. This minimises the physical burden on the employees. As it can be moved horizontally, no effort is required to connect it precisely e.g. to a truck. At the same time, the hose line is thereby protected from tensile stress, torsion and mechanical loading of the hose cover, significantly extending the maintenance cycles.
Facts and Figures
BASF SE – The Chemical Company
With business partners in more than 200 countries, six affiliated facilities, some 385 production sites worldwide and approx. 105,000 employees, BASF is the world's leading chemical company and active in all important global markets. BASF operates the world's largest integrated chemical complex at Ludwigshafen am Rhein. It is the headquarters of the BASF Group, which consists of more than 320 subsidiaries and associates. Its portfolio covers the five business areas of chemicals, plastics, performance products, agricultural pesticides and nutrition as well as oil and gas. he BASF Group posted a turnover of €50.7 billion in 2009 and achieved operating profit before special items of approx. €4.9 billion. Intelligent system solutions and high-quality products help its customers to be more successful. BASF acts in accordance with the principles of sustainable development. Dr. Jürgen Hambrecht is the Chairman of the Board of Executive Directors.
Copyright of images: RS / BASF SE
