Case Study on Reduction of Flash Point Giveaway; from Process to the Lab

Transcription

1 Case Study on Reduction of Flash Point Giveaway; from Process to the Lab Jeffrey Lawrence Business Process Improvement Manager and BB Minitab Insights Conference September 12, 2016

2 Talk Overview Who is PES? Background What is Flash? Why we care? What was done Plant level Distillate Flash Team work What we learned about Flash at the Lab Open Questions 2

3 Who is PES? Headquartered in Philadelphia, PA, PES owns the largest oil refining complex on the East Coast. We operate two domestic refineries Girard Point and Point Breeze in South Philadelphia. We process approximately 335,000 barrels of crude oil per day (42 U.S. gallons per barrel), making it the largest oil refining complex on the U.S. Eastern seaboard. Among our various products are gasoline, low-sulfur diesel, jet fuel, kerosene, butane, propane, home heating oil and the petrochemical cumene. 3

4 Background: What is Flash? The Flash point temperature is a measure of the tendency to form a flammable mixture with air under controlled laboratory conditions. It is one of a number of properties which must be considered in assessing the overall flammability hazard of a material. Flash point is used in shipping and safety regulations to define flammable and combustible materials. A key product specification on Distillate products such as jet fuel, kerosene, home heating oil, and road diesel. Is a one-sided Minimum specification. Primary test for Diesels ASTM D93 Flash Point by Pensky-Martens Closed Cup Tester Primary test for Jet/Kero ASTM D56 Flash Point by Tag Closed Cup Tester 4

5 Why Do We Care? Key product specification Difficult to correct off-spec Complex system of units and tanks Dilution is not a good solution Rerunning is expensive and wasteful We sell by volume Flash is controlled mainly by the amount of light boiling material in the mix. Lower Flashes yield more volume. 5

6 Plant Level Distillate Flash Team Work Purpose To evaluate, develop and implement a strategy that reduces distillate product stream flash point giveaway through measurement evaluation and contributing stream operating improvements. Importance By reducing flash point giveaway, we increased the opportunity to upgrade lower value heavy naphtha into distillate at a then $10/bbl margin. Maximum opportunity with a target change was estimated at ~$13MM/year. How? Assemble a cross functional team DMAIC Six Sigma approach Define Purpose and Importance listed above Measure Collect data to identify gaps Analyze Use data and team knowledge to identify opportunities Implement Test theories Control Put in measure to monitor and maintain 6

7 Flash OK? High (H) or Low (L)? Adjust 231 (A) or 859 (B)? Running for rate (A) or recovery (B)? Excess LFO? Flash OK? To ULSK (1) V1 to A3 (A) or V2 (B)? V9/V22 to TK835? High (H) or Low (L)? Is there too much liquid off 231 OH? Flash Too Low? Is there too much liquid off 231 OH? PB Tks (P) / SRTF (S) / Cont (C)? Waiver Available? Is there room at 231? Flash OK? Is the flash high (H) or low (L)? Is there liquid return off 866? Is there liquid return off 865? Running for rate (A) or recovery (B)? Flash OK? Is there room on 865 liquid? eed to send any LFO to cold tkg? Lab / DMC issue? On test? eed to send any HFO to cold tkg? A2 (A) or B2 (B)? Waiver available? All material (A) or split (B)? Split streams (A) or adjust distillation Is 866 adjustment required? Stripping Steam (A) or ap 95 (B)? Understanding Current State: Map the Process and Walk It! Girard Point Distillate Map Start Communicate crude slate to Operations A Drop bottom of atmospheric tower to allow rate increase Bus. Pln. Set tank line-ups and pump rates B B&S/Ops 859 Distillate Process Map Crude goes into crude unit Maximize F-1 Heater LFO to 250 TK (~1500 BPD) LFO to Stripper Bottom Sampled H Adjust temperature / pressure / reflux at 231 Minimize AGO by increasing HFO draw HFO to PB by DSL Material to 835 TK L Adjust heavy naphtha draw at 137 Business planning ratio used Material pumped from 835 TK 859 rundown Make 231 Stripper adjustment Flash OK? High (H) or Low (L)? L H Room at stripper Adjust stripper - remove heat and steam Start Communicate plan to Operations Can you meet the plan? Sample taken: 859 combined or ULD2 (2)? 1 feed 859 Processes Material 859 Stripper Bottom Sampled Sample taken at river crossing Stand-alone mode? Evaluate 865 Flash Adjust cold feed to 835 tank from 210 Bus. Pln. B Communicate adjustments to Business Planning LCO pumped from LCO tanks C 2 Point Breeze Distillate Process Map LCO to Tank 821 P S Make adjustments at 231 Special sample at tank Room at stripper Adjust stripper - add heat and steam L Tech requests FSS to make 859 H adjustments Consider 231 and 859 flash results A SRTF Tanks Filled B 859 Process Map Start Tank sampled at 50% 1232/868 Communicate crude slate to Operations Bus. Pln. Set tank line-ups and pump rates B&S/Ops Material to PB Tanks CoA Sample Pulled Flash OK? Tank certified and shipped Crude goes into crude unit 231 Material End Take River Crossing Sample A Flash OK? Drop bottom of atmospheric tower to allow rate increase Adjust bottom of atmospheric B tower for distillate recovery Adjust top of atmospheric tower for nap 95% pt High (H) or Low (L)? H L Tech requests FSS to make 859 adjustments B B A A B Feed is split Material goes to 865 Material goes to 866 Material goes to cold tkg (835) Material goes to 859 Material to SRTF Tank sampled at 50% CoA Sample Pulled Flash OK? Rerun via 835 Tank Tank certified and shipped End Consider 231 and 859 flash results Adjust 231 (A) or 859 (B)? GP Process Map Continued on 859 Process Map A B 137 DSL Line to TK835 Waiver Available? Adjust termperature/pressure/ relfux at 866 Evaluate 866 cold feed Adjust 865 stripper Check 866 stripper operation Adjust 866 stripper operation and feed quality V9/V22 to FCC H Rerun via 835 TK Adjust termperature/pressure/ relfux at 865 Check 866 flash data Split Streams at 210 L Fix lab/dmc issue A B 865/866 Rundown Streams Combine at 82PH Sample taken at 82PH Review 210 Flash Results (A1, B1, Lab vs. DMC, 95%) B A Adjust 210 Stripping Steam 82PH Ops Take Special Sample PB Product Tanks Filled Final CoA Sample Pulled Product Shipped End 7

8 Test the Process/Generate Data - Flash Trial Purpose To determine capability and optimal targets in order to reduce distillate product stream flash giveaway. Achieved by coordinated moves between operating units to stay within desired operating targets as set forth General Guidelines Unit moves made by console operators Questions should be directed to FSS LIMS results monitoring is critical to the success of this trial. LIMS references are included with the guidelines for each unit PI Overview monitoring page created to assist in monitoring Quality assurance plan guidelines provided Current product targets are being maintained during trial Suggested corrective action levels and sequence of moves provided Trial Guidelines/Setup All, The refinery will perform a trial to minimize distillate flash giveaway from 9/10/2014 to 10/3/2014. The goal of the trial is to determine capability and optimal operating targets in order to reduce distillate product stream flash giveaway. This will be achieved by coordinated moves between operating units to stay within desired operating targets as set below. General Guidelines: Unit moves should be made by console operators. Questions should be directed to FSS. LIMS result monitoring is critical to the success of this trial. All LIMS reference numbers are included with the guidelines for each unit. 210 Unit Guidelines: Target Range otes / Comments Target flash on A2 100 ºF +/- 5 o LIMS reference: 210A2 Target flash on B2 100 ºF +/- 5 o LIMS reference: 210B2 Minimum flash on A3 100 ºF minimum o LIMS reference: 210A3 Minimum flash on B3 100 ºF minimum o LIMS reference: 210B3 Target aphtha 95% on A1 325 ºF +/- 15 o LIMS reference: 210A1, D3710 DIST 95% Target aphtha 95% on B1 325 ºF +/- 15 o LIMS reference: 210B1, D3710 DIST 95% Product Stripper steams A2 (PI Tag AA2STMRATIO) 12.6 #/Bbl maximum adjust per sample results B2 (PI Tag BB2STMRATIO) 12.6 #/Bbl maximum adjust per sample results A3 (PI Tag AA3STMRATIO) 12.6 #/Bbl maximum if in use Steam out for the first week. Add in for week of 9/15 B3 (PI Tag BB2STMRATIO) 12.6 #/Bbl maximum if in use Steam out for the first week. Add in for week of 9/15 Main Tower Stripping steam A (PI Tag AFRC118) 2 M#/hr minimum adjust for Tower dp, Lightends B (PI Tag BRFC218) 2 M#/hr minimum adjust for Tower dp, Lightends 137 Unit Guidelines: LFO to remain on lower draw Maximize LFO to 231 prior to placing on DSL Target flash for the LFO stream 105 ºF +/- 5 o LIMS reference: 137LFO If 2 pump operation is required to send maximum distillate to 231, use both pumps 865 Unit Guidelines: Set overhead naphtha to 864 Minimum feed flash 100 ºF minimum Check with FSS to have 210 adjust A2/B2 or adjust feed mix o LIMS reference: 865CHG Operate stripper at targets 340 ºF max 360ºF Adjust temperature as primary handle 40 psig min 35 psig Adjust pressure as secondary handle to temperature 866 Unit Guidelines: Set overhead naphtha to 865 charge Steam ratio /A /A Constant Maximum flash /A /A - only adjust based on 82 Pump House 859 Unit Guidelines: Set overhead naphtha to 865 charge Minimum feed flash 125 ºF minimum o LIMS reference: 859CHG Minimum Steam Ratio (PI Tag 0.05 #/gal minimum 1FC1030A)) 231 Unit Guidelines: Target flash for ULSD 135 ºF minimum o LIMS reference: 231ULK Target flash for 15MV1 133 ºF minimum o LIMS reference: 231ULK Stripper Reflux 2.5 MBPD minimum Stripper Pressure 15 PSIG Stripper Bottom T ºF Quality Assurance Plan Product Quality Assurance Plan Below is a list of specific issues. To the right of each issue are possible corrective actions, organized in order of recommendation. Issue Corrective Action Issue Corrective Action 1. Check Feed Flash at Check Stripper Ovhd Liquid at 865 Less than 100 F, Adjust 210 (A2/B2). If there is excess liquid (Lower Temp then Increase P. Greater than 100 F, Adjust 865 Stripper (Raise Temp then Decrease P). Flash at 82 Pumphouse is less Flash at 82 Pumphouse is greater than 132 F than 138 F 2. Check flash results for 210 A2/B2 2. Adjust 866 Stripper. If greater than 105, adjust A2 / B2. 3. Adjust Feed mix from Check stripper overhead liquid at Check 859 Feed Flash If there is excess liquid and sulfur is not a concern, consider lowering If less than 125 F, decrease Cold Feed if room on cloud. temperature unless already near alarm point and then increase pressure. If greater than 125 F, adjust stripper (Raise Temp then Decrease P). 859 Standalone Mode: Flash at 859 Standalone Mode: Flash at River Crossing is greater than 138 River Crossing is less than 132 F 2. Check cloud data F 2. Check cold feed balance If cloud is less than 13, increase LCO to 859. Add more cold feed to 859 if available. 3. Make adjustments at 210 A2/B2 and A3/B3. 1. Check Flash at 137 LFO Less than 105 F, adjust 137 LFO by increasing stripping steam or heavy 1. Check stripper overhead liquid at 859 naphtha draw. If there is excess liquid and sulfur is not a concern, consider lowering Greater than 105 F, adjust 231 stripper operation (Raise Temp then temperature unless already near alarm point and then increase pressure. Decrease P). 859/231 Split Mode: Flash at River 859/231 Split Mode: Flash at River 2. Check cloud data and whether there is room to export more jet Crossing is less than 132 F Crossing is greater than 138 F If cloud is less than 13 and you have room, export additional jet. 2. Check cold feed balance If cloud is less than 13 and there is no room to export additional jet, Add more cold feed to 859 if available. increase LCO to Check and adjust 859, per standalone mode guidance, above. 3. Adjust 231 rundown to a jet limit. 8

9 Check our Data as ou Go Find Problems and Fix Them 9

10 A Simple Fix 10

11 Trial Results 82PH average flash decreased ~2 o F during the trial. Operational target of 135 o F is sustainable without going below the specification of 130 o F Boiling Point Distillations of one of the HDS unit overhead liquids shows 30-40% distillate range material. Overhead can be routed to increase ability to capture lighter material directly into the distillate pool and eliminate recycling to front of process. 11

12 Pre-trial vs. Post-trial Summary Trial included phases: With and without steam to 210 A3/B3 HDS overhead product routed 0 distillate tanks off test bpd of distillate net gain is achievable Value of $ 2-4 MM/R 1 2 ºF lower flash Phase Trial time Valid data collection time HDS Product per bbl of Feed Flash Flash (CoA) Product Increase (109 Mbpd Basis) Description # of days # of days % of feed o F o F bpd Pre-Trial Entire Trial Steam to A3/B Rerouted and Steam A3/B Rerouted without Steam to A3/B

13 ew Tools for Monitoring and Control Playbooks and Dashboard 13

14 Sample Mean Moving to VoC: What Do Our External Customers See? Xbar Chart of Flash for PES Lab Result minus SXL Result UCL= _ X= LCL= /22 7/27 8/3 8/9 1 8/1 3 8/1 6 8/1 8 SAMPLE DATE 8/21 8/26 8/31 9/2 Customer PES Average Result Rounded ( o F) Pipeline Average Result Rounded ( o F) Delta ( o F) Primary Pipeline Secondary Pipeline* Inconclusive, due to limited data availability at this time (10 points). The chances of being on-test for flash at the PES lab and off-test at a customer lab are minimal. 14

15 D93 Flash, F Lab Flash DOE and Gage R&R Studies? 1. Per ASTM D93-10 The Flash Analyzer eeds To Demonstrate: Variability Below ASTM Listed Reproducibility Criteria (7.94 ºF) *Diff. Operator & Lab ote: ASTM Listed Repeatability (3.24 ºF) *Same Operator & Same Analyzer 2. A Prior Gage Repeatability And Reproducibility (GR&R) Study & A Designed Experiment (DOE) Demonstrated The Flash Analyzer To Be Capable With o Additional Opportunities For Improvement. 3. Due to above work and QC program, Lab concludes there is not an opportunity here! 142 QC Program ASTM D93 PM Flash Performance, F 142 PHL-D , OOS 8/ PHL-D , OOS 5/ UCL TARGET LCL 112 1/15 1/30 2/14 3/1 3/16 3/31 4/15 4/30 PHL-D (Tanaka APM-7) 5/15 5/30 6/14 6/29 PHL-D (Tanaka APM-6) 7/14 7/29 8/13 8/28 PHL-D (TAAKA APM-8) 9/12 9/27 What do you notice about the data above? Its running above the Target QC value even though its within Reproducibility 15

16 Does Our Lab Have a Bias?: More to Come PES lab participates in ASTM round robin for flash periodically Since February 2013, PES lab flash results range from 1-5 o F less than ASTM RR mean. Current PES lab practices do not Flag a problem. Using Z-score probability on the data plotted, there is only a 0.28% chance that there is not a bias. 16

17 Flash Contributor Check Work: D86 Initial Boiling Point 17

18 Flash Contributor Check Work: D86 5% Point 18

19 Flash Contributor Check Work: D86 10% Point 19

20 Flash Pt Regression vs IBP, 5% & 10% D86 Flash Point can be reasonably estimated using only the IBP and %5 point. Using 10% didn t add any additional value and resulted in unacceptable VIFs 20

21 Plant Level Distillate Flash Team Work Summary Operating targets changes, process monitoring tools, and communication resulted in significant savings for PES Found keys to maximum opportunity to realize savings Demonstrated ability to successfully operate at a lower rundown target of 135 o F Expect to continue trend of 0 distillate tanks off-test for Flash Demonstrated a Total distillate net gain of 1100 bpd, valued at the time $4 MM / year Identified Potential Future State Value: $7.2 MM / year If there is a Lab Bias, worth > $4 MM / year Going after the Bias ext! 21

22 What we learned about Flash at the Lab How? Assemble a new smaller cross functional team Use DMAIC Six Sigma approach again Define Purpose and Importance listed above Measure Collect data to identify gaps Analyze Use data and team knowledge to identify opportunities Implement Test theories Control Put in measure to monitor and maintain 22

23 Understanding Current State: Process Mapping Mapped and Walked Setting a new daily QC Doing the daily QC How to do a Flash test This is where you might earn a nickname! 23

24 Potential Bias Factors Do Some Brain Storming Exit Point Information Incomplete information about exit point labs QC Aging Material changes over time Lab Tech Error Tech working area Incorrect method General error Temperature Conversion ASTM round robin reported in deg C Temperature conversion difference Calibrations Frequency Internally certified proto w/o CRM calibration Where we calibrate Machine to machine bias Range of material calibrated Maintenance ew tech spec needed Instrument maintenance needed Settings Instrument testing error Incorrect settings Use of reproducibility limits as trigger 24

25 Bias Root Causes and Solutions Root Cause Round Robin data evaluated as single points Calibrations performed annually as single point Calibration material used was not in flash range of distillate material o temperature calibrations o process for comparing PES to customers o visual analytics QC Accepted Reference Value (ARV) unknown Solution Visually evaluate round robin data over time Perform 20 point calibrations weekly until data support reduction in frequency Use n-decane as calibration material Perform temperature calibrations quarterly, per Tanaka recommendation Obtain SXL data periodically and compare Issue histograms for each calibration Provide QC material for ASTM round robin to obtain ARV 25

26 Data Analysis: Temperature Calibration Temperature calibrations cecks and adjustments are a critical part of machine performance maintenance and monitoring. 26

27 Create Visual Procedures 27

28 Data Analysis: n-decane CRM Testing Histogram analysis allows us to check and track each machine s performance and capability relative to a standard and each other. 28

29 Data Analysis: AOVA AOVA can also be used for Mean, but Histograms provide a better visual including data spread for our Lab Technicians 29

30 Monthly Reporting n-decane Flash Results / Instrument Run# PHL-D POS = +3.1 F Run on BP = in = EFP SET AT ODD <odd< n-decane - Alfa Aesar Lot# P31B **All tests were conducted in F Repeat runs now done monthly by same technician on all machines. Data save in Excel and copied to Minitab where technician has been trained to create Histograms. 30

31 Lab Flash Summary PHL-D (APM-7) bias at 130 F was -4.3 ºF PHL-D (APM-8) bias at 130 F is -2.0 ºF Lab Team identified up to $6 MM / year of value. Improved calibration process and monitoring has been put in place to ensure a bias does not reform and last. 31

32 Questions? 32