HIMA Smart Safety Test Enhances Efficiency at BASF Zhanjiang Verbund Site Project
BASF's Zhanjiang Verbund Site Project (ZVSP), BASF's largest greenfield venture in China, has faced considerable complexity in implementing rigorous test procedures such as Factory Acceptance Tests (FAT), Integration FAT (IFAT), and loop testing. These tests traditionally involve huge time and manpower requirements. Therefore, BASF has integrated the HIMA Smart Safety Test as part of the SILworX® engineering and diagnostics platform to simplify and automate the safety lifecycle test procedure.
The FAT and IFAT at initial project stages were originally performed manually. As much effort was required, particularly in testing intricate start-up and shutdown sequences, BASF sought better alternatives. Introduction of HIMA Smart Safety Test allowed for automated static and sequential functional tests by BASF. Automated tests brought automatic documentation and also test evidence generation with it, so compliance and traceability were very easy.
Joint cooperation of HIMA and BASF engineering staff led to a custom testing and verification solution, developed specifically to the needs of the Zhanjiang site. The new solution ensured not only strict conformity with safety norms but also greater test accuracy and reproducibility. In the process, small but crucial defects were detected and eliminated early on—leading to overall process acceleration of the FAT and IFAT cycles.
Regarding tangible benefits, the Smart Safety Test facilitated time reduction, cost reduction, and lighter manual documentation load. Computer reports generated according to project specifications avoided the inefficiencies associated with manual reporting and minimized human error. Such savings were essential in achieving the aggressive project timeline while maintaining the highest attainable standards of functional safety.
BASF staff were highly satisfied with the outcome, particularly relating to project quality and speed of delivery. Going forward, the companies are looking at the application of Smart Safety Test capabilities in loop testing and automated proof testing for incorporation into plant operations, driving the value of the solution into the operating phase after commissioning.
Peter Sieber, HIMA Group Vice President Strategic Marketing, commented: "This project is a fine demonstration of the value which close collaboration between user and solution provider can generate. It also indicates that HIMA really means business when it comes to simplifying functional safety for customers."
