New requirements in the chemical and process industry

The chemical industry is undergoing far-reaching changes as complex process systems, global sourcing and modern materials are introduced. TÜV SÜD Chemie Service offers integrated sourcing strategies, active risk prevention and dependable life assessment aimed at ensuring safe, reliable and cost-effective systems and installations. At ACHEMA 2012, held in Frankfurt am Main from 18 to 22 June 2012, TÜV SÜD's experts will showcase their comprehensive service portfolio for the chemical and process industry (Hall 9.1, Stand C39).

Manufacturers from the Asia Pacific region play an increasingly important role in global sourcing in the chemical and process industry. They offer plant components, including process engineering equipment and pressure vessels, at attractive prices and progressively improved quality. "However, thorough supplier selection and evaluation, 'watertight' specification of product characteristics and detailed quality assurance are imperative in global sourcing", says Kurt Schumacher, global sourcing expert and member of the management team of Plant & Equipment Integrity at TÜV SÜD Chemie Service GmbH. These aspects must be considered to ensure that initial cost savings will not be used up by expensive rework or delays in delivery later on. Compliance with the relevant laws, codes and standards of the country of destination is a particularly important consideration. Kurt Schumacher warns, "Since it's often the little things that cause problems later on, statutory testing alone is not sufficient." Examples of particularly critical aspects include traceability of materials and completeness of the required documents such as drawings, plans and documentation.

Improving safety with hazard and operability studies (HAZOP)

The hazard potential inherent in process systems and the physical properties of materials is becoming increasingly complex. New approaches to risk qualification and failure-probability classification have been developed in recent years. "HAZOP studies offer the possibility of systematically and actively improving plant safety", explains Klaus-Dieter Peschel, Head of Plant Safety & Inspection at TÜV SÜD Chemie Service's location in Dormagen. These studies are conducted by a multi-disciplinary team of internal and external experts led by an experienced TÜV SÜD facilitator. Possible hazards associated with the operation and modification of the plant or installation are identified, their causes and consequences evaluated and corrective actions developed. The multi-stage approach considers technical and organizational hazards, potential human error and external influences, permitting targeted differentiation between safety measures that are actually necessary and those that are less useful, as well as identification of the best solution for the functional safety of process control components. "This approach improves the level of safety, reduces downtime and avoids unnecessary investments", explains Peschel. Effectively implemented, a HAZOP study also impacts favourably on the overall approval procedure and the insurance terms applicable to a process-engineering or chemical plant.

Using plastics reliably and permanently

In the chemical and process industry, high-performance plastics are increasingly replacing steel components. These innovative plastics are lightweight, highly resistant to chemical and mechanical stresses and cost-efficient. "Both the quality of the base material per se and the quality of the joining and welding of, say, plastic pipes and tanks are steadily improving", says Franz Hingott, who works in the Materials Technology department of TÜV SÜD Chemie Service. As high-performance plastics or FRP systems resist higher pressures and temperatures over longer periods of times, the requirements made on life assessment and testing are also changing accordingly. "For reliable determination of long-term performance, components must be assessed in the overall context of manufacturing, processing and subsequent operating conditions", says the TÜV SÜD expert. By applying this approach, the experts can select the test process that best fits the relevant code or standard.

The experts at TÜV SÜD Chemie Service operate at international level and are familiar with the various markets from their long experience and work on numerous projects. Clients benefit from their one-stop on-site services. The accredited testing organization is also recognized as Notified Body and Approved Body, which ultimately facilitates the placing on the market and putting into service of systems and components. TÜV SÜD's testing laboratory offers test stations with heating ovens and pressure equipment that are also suitable for the testing of higher-strength plastics.

Technical talks by TÜV SÜD at ACHEMA 2012

-          Monday, 18 June, 2 pm: HAZOP – A review on 40 years of application, trends and challenges in a changing community and legal environment (Rainer Semmler, Harmonie 2, CMF)

-          Wednesday, 20 June, 12:30 pm: Global sourcing of pressure vessels for chemical and petrochemical plants (Kurt Schumacher, Illusion 1, CMF)

-          Thursday, 21 June, 11:00 am: Damages of PTFE expansion joints (Franz Hingott, Illusion 2, CMF)

Further information about our services is available at www.tuev-sued.de/chemieservice.