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DOCUMENTATION TOOLS SMART TOOLS FOR DIGITAL DOCUMENTATION


Rösberg details how its ProDOK and LiveDOK documentation tools are helping INEOS Group manage consistent documentation for plant operation, safety and audits


available for maintenance and operations and future projects. However, consistent documentation needs maintaining and continuous updating with suitable tools – especially where maintenance activities, modifications and extensions are concerned. Only then does plant reality (as-built) reliably match with the documentation at all times. Consistently adopting this approach makes it possible to digitally create documents that comply with formal requirements, for instance for audits and safety inspections. For some time now, the chemical


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companies in the INEOS Group have been optimising and harmonising processes across locations in their Smart Manufacturing Initiative. This also involves making plant documentation as consistent as possible and using uniform tools for planning and operative support (Fig. 1). In this example INEOS Styrolution, a global leader in manufacturing of styrenics, has benefited for a long time now at its locations of Antwerp, Ludwigshafen and Schwarzheide from the documentation tools ProDOK and LiveDOK (Fig. 2) by Rösberg. LiveDOK helps INEOS generate completely


paperless documentation that is accessible across the site. The tool includes redlining functions, package administration on the four-eyes principle (i.e. the two-person rule) for especially critical workflows – and also a web- based version. The practical tool is now an essential part of daily operations, providing support for engineers and technicians in everything to do with plant documentation. INEOS Styrolution uses ProDOK for the


planning and operations and maintenance support of its process plants. Using this tool, all I&C operations can be digitalised, because data and documentation from external sources in any format can be integrated and centrally managed. In 2019 all three locations migrated to the newest version of the software. As the most recent site, INEOS Phenol in Gladbeck is now benefiting from the unified project data and master data, which is already being used by several other plant operators at the chemical location Marl. With the support of the automation specialists, importing the data from various different systems into the I&C platform at the Gladbeck site was accomplished in a short time. Christian Nadolski, Head of Project


Development & CAPEX Management said: 8


n modern process plants efficiency is essential, and it can only be achieved if the data from the project is continuously


“One very important thing when deciding on tools for digitalisation is that they should not be too powerful – otherwise, too many specialist competences and administrative personnel are required. Here, ProDOK is pretty well self- explanatory, an out-of-the-box solution that meets the needs of our planning and maintenance staff 100%.” The CAE-I&C system ensures an integrated planning process with consistent rules, and uses software technology that opens up many possibilities above and beyond planning. For example, a production plant is being built


by INEOS in Chemiepark Marl for cumene, an important raw material in the production of phenol and acetone. Here, too, both software tools from Karlsruhe are in use. Work on the new plant in Marl began in


December 2020. At present, manufacturers’ information on sensors, actuators etc. installed in the plant is being imported into the I&C system using NE100 or eCl@ss. As a cross- sectoral, ISO- and IEC-compliant standard, eCl@ss is ideally suited for a consistent description of technical process data. This creates a clear overview and enables comparisons and analysis to be made throughout the plant and also across multiple sites, for I&C planners, I&C planning maintenance teams and production staff. It was also possible to import the complete I/O configuration of the Honeywell process control system including wiring, so a large number of instrument loop diagrams can be generated from the imported data. “In the end more than 3,000 I/O points, approximately 9,000 instruments and around 100 safety functions (SIFs) will be documented in ProDOK,” Nadolski explained. “We will then have consistent, modern documentation for the plant owner that includes all necessary documents for


Fig. 1: The chemical enterprises in the


INEOS Group have been optimising and harmonising processes across locations


in their Smart Manufacturing Initiative for some time now (Copyright: INEOS)


operations, recurring inspections and audits.” This means that official requirements regarding plant safety and hazardous incidents, as well as periodic safety and standards inspections for functional safety and explosion protection can be conducted much more simply and efficiently, and involve fewer personnel. Changes that are made during the


operations can also be comfortably recorded and added to the documentation, thanks to the LiveDOK documentation software. The system makes it possible to administer, search and correct all the documents and plans of industrial plants digitally, in real time. Changes, additions and new documents are imported straight away and are visible to all project participants. “It is so much easier to meet the requirements of proof, for instance in periodic inspections,” Nadolski said. “All servicing activities relating to safe operation and the useful lifetime of field devices and system components are documented. Some of the devices’ operating life can be extended and they would not need to be replaced every time around. The proof for this is available pretty well at the touch of a button.” As part of the project, Rösberg’s automation


specialists trained both the company staff and the contractors – who will also now benefit from the consistent documentation. Planning folders can be transferred digitally, and feedback is also securely documented. “We are now optimally equipped for the future,” Nadolski added. “ProDOK and LiveDOK are established systems in process engineering – and they are continuously developed and enhanced, meaning that they adapt to relevant standards and customers’ requirements.”


LiveDOK helps to generate completely paperless as-built documentation that is accessible to everyone concerned (Copyright: Rösberg)


5 JULY/AUGUST 2022 | PROCESS & CONTROL


Rösberg Engineering roesberg.com/en/


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