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

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

Talk Overview

2

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.

Who is PES?

3

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 Pointby Pensky-Martens Closed Cup Tester

Primary test for “Jet/Kero” ASTM D56 – Flash Pointby Tag Closed Cup Tester

Background: What is Flash?

4

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.

Why Do We Care?

5

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

Plant Level Distillate Flash Team Work

6

Understanding Current State: Map the Process and Walk It!

Girard Point Distillate Map

StartCommunicate crude slate to

Operations

Bus. Pln.

Set tank line-ups and pump

rates

B&S/Ops

End

Crude goes into crude unit

Running for rate (A) or

recovery (B)?

Maximize F-1 Heater

FSS/Ops

A

B

Minimize AGO by increasing

HFO draw

FSS/Ops

Drop bottom of atmospheric

tower to allow rate increase

FSS/Ops

Excess LFO? N

Adjust temperature / pressure

/ reflux at 231

Y

Tech requests FSS to make 859

adjustments

859 rundown

Flash OK? SRTF Tanks Filled

FSS/Ops

Make 231 Stripper adjustment

To ULSK (1) or ULD2 (2)? 1

Adjust heavy naphtha draw at

137

FSS/Ops

LFO to 231

FSS/Ops

LFO to 250 TK (~1500 BPD)

FSS/Ops

231 Stripper Bottom Sampled

FSS/Ops

HFO to PB by DSL

FSS/Ops

Material to 835 TK

FSS/Ops

Flash OK? High (H) or Low (L)?

Y

N

Is there too much liquid

off 231 OH?

H

Y

N

L

Is there too much liquid

off 231 OH?N

Y

PB Tks (P) / SRTF (S) /

Cont (C)?

Sample taken at river crossing

P

2

High (H) or Low (L)?N H

Y

L

Consider 231 and 859 flash

results

Adjust 231 (A) or 859

(B)?

A

B 859 Process Map

Material to PB Tanks CoA Sample Pulled Flash OK?

Waiver Available?

Tank sampled at 50% Flash TooLow?

Tank certified and shipped

N

Y

Y

N

Is there room at 231?

Make adjustments at 231

Y

Y

Special sample at tank Flash OK?

N

N

Y

Rerun via 835 TankN

C

S

859 Distillate Process Map

StartCommunicate plan to

Operations

Bus. Pln.

End

Can you meet the plan?

Communicate adjustments to

Business Planning

FSS/Ops

Y

B

Business planning ratio used

FSS/Ops

Adjust stripper - remove heat

and steam

Material to SRTF

FSS/Ops

Take River Crossing Sample

859 Processes Material

FSS/Ops

Sample taken: 859 combined

feed

FSS/Ops

859 Stripper Bottom Sampled

FSS/Ops

Flash OK?High (H) or

Low (L)?

L

Y

N H

Flash OK?

N

Flash OK?

Adjust cold feed to 835 tank

from 210

Rerun via 835 TK

Tank sampled at 50%

Waiver Available?

N

CoA Sample Pulled

N

Y

Y

LCO pumped from LCO tanks

FSS/Ops

Material pumped from 835 TK

FSS/Ops

Stand-alone mode?

N

Room at stripper

Room at stripper

N

Y

Evaluate 865 Flash

Adjust stripper - add heat and

steam

231 Material

FSS/Ops

N

Tank certified and shipped

Y

Y

Y

Tech requests FSS to make

859 adjustments

High (H) or Low (L)? H

L

Consider 231 and 859 flash

results

Adjust 231 (A) or 859

(B)?

B

GP Process Map

Point Breeze Distillate Process Map

StartCommunicate crude slate to

Operations

Bus. Pln.

Set tank line-ups and pump

rates

B&S/Ops

End

Crude goes into crude unit

Material goes to cold tkg (835)

Feed is split

FSS/Ops

Sample taken at 82PH

82PH Ops

Adjust 210 Stripping SteamFlash OK?

N

Y

Product Shipped

Running for rate (A) or

recovery (B)?

Adjust top of atmospheric

tower for nap 95% pt

FSS/Ops

A

BAdjust bottom of atmospheric

tower for distillate recovery

FSS/Ops

Drop bottom of atmospheric

tower to allow rate increase

FSS/Ops

Need to send any LFO to

cold tkg?

Need to send any HFO to

cold tkg?

Y

N

A2 (A) or B2 (B)?

All material (A) or split

(B)?

N

B Material goes to 865

Material goes to 866

Material goes to 859

B

A

Y

A

865/866 Rundown Streams

Combine at 82PH

Review 210 Flash Results (A1,

B1, Lab vs. DMC, 95%)

FSS/Ops

N

Split streams(A) or adjust

distillation

Stripping Steam (A) or

Nap 95 (B)?B

B

A

Take Special Sample

A

Split Streams at 210

Final CoA Sample Pulled

FSS/Ops

On test?PB Product Tanks Filled

FSS/Ops

Waiver available?N N

Y Y

V1 to A3 (A) or V2 (B)? A

LCO to Tank 821

1232/868

137 DSL Line to TK835

V9/V22 to TK835?

B

Y

N

Continued on 859 Process Map

V9/V22 to FCC

Is there liquid return off

866?

Is there liquid return off

865?

Y

Y

Adjust termperature/pressure/

relfux at 866

FSS/Ops

Adjust termperature/pressure/

relfux at 865

FSS/Ops

N

N

Is there room on 865

liquid?Y

N

Evaluate 866 cold feed

FSS/Ops

Check 866 stripper operation

FSS/Ops

Check 866 flash data

FSS/Ops

Is 866 adjustment

required?

Adjust 865 stripper

FSS/Ops

Is the flash high (H) or

low (L)?

H

L

Adjust 866 stripper operation

and feed quality

FSS/Ops

Y

Lab / DMC issue?

Fix lab/DMC issue

FSS/Ops

Y

N

7

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

Test the Process/Generate Data - Flash Trial

All,

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 Notes / 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 Naphtha 95% on A1 325 ºF +/- 15

o   LIMS reference: 210A1, D3710 DIST 95%

         Target Naphtha 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 N/A N/A Constant

         Maximum flash N/A N/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 1FC1030A)) 0.05 #/gal minimum

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 430 - 440 ºF

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.

Quality Assurance Plan

Trial Guidelines/Setup

8

Issue Corrective Action Issue Corrective Action

1. Check Feed Flash at 865

·  Less than 100 F, Adjust 210 (A2/B2).

·  Greater than 100 F, Adjust 865 Stripper (Raise Temp then Decrease P).

1. Check Stripper Ovhd Liquid at 865

· If there is excess liquid (Lower Temp then Increase P.

2. Adjust 866 Stripper.2. Check flash results for 210 A2/B2

· If greater than 105, adjust A2 / B2.

3. Adjust Feed mix from 210.

1. Check 859 Feed Flash

· If less than 125 F, decrease Cold Feed if room on cloud.

· If greater than 125 F, adjust stripper (Raise Temp then Decrease P).

1. Check stripper overhead liquid at 859

· If there is excess liquid and sulfur is not a concern, consider lowering

temperature unless already near alarm point and then increase pressure.

2. Check cloud data

· If cloud is less than 13, increase LCO to 859.

2. Check cold feed balance

· 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

naphtha draw.

· Greater than 105 F, adjust 231 stripper operation (Raise Temp then

Decrease P).

1. Check stripper overhead liquid at 859

· If there is excess liquid and sulfur is not a concern, consider lowering

temperature unless already near alarm point and then increase pressure.

2. Check cloud data and whether there is room to export more jet

· If cloud is less than 13 and you have room, export additional jet.

· If cloud is less than 13 and there is no room to export additional jet,

increase LCO to 859.

2. Check cold feed balance

· Add more cold feed to 859 if available.

3. Check and adjust 859, per standalone mode guidance, above. 3. Adjust 231 rundown to a jet limit.

859/231 Split Mode: Flash at River

Crossing is less than 132 F

859/231 Split Mode: Flash at River

Crossing is greater than 138 F

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.

Flash at 82 Pumphouse is less

than 132 F

Flash at 82 Pumphouse is greater

than 138 F

859 Standalone Mode: Flash at

River Crossing is less than 132 F

859 Standalone Mode: Flash at

River Crossing is greater than 138

F

Check Your Data as You Go – Find Problems and Fix Them

9

A Simple Fix

10

Trial Results

82PH average flash decreased ~2 oF

during the trial.

Operational target of 135 oF is

sustainable without going below the

specification of 130 oF

11

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.

Trial included phases:

With and without steam to 210 A3/B3

HDS overhead product routed

0 distillate tanks off test

700 – 1300 bpd of distillate net gain is

achievable

Value of $ 2 -4 MM/YR

1 – 2 ºF lower flash

Pre-trial vs. Post-trial Summary

12

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 oF oF bpd

Pre-Trial 73 46 97.4 138.4 138.0 -

Entire Trial 43 21 +1.2 -2.1 -2.3 1340

Steam to A3/B3 28 20 +1.3 -2.2 -2.3 1400

Rerouted and Steam A3/B3 25 20 +1.3 -2.2 -2.3 1400

Rerouted without Steam to

A3/B314 14 +1.4 -2.6 -2.8 1470

New Tools for Monitoring and Control – Playbooks and Dashboard

13

Moving to VoC: What Do Our External Customers See?

The chances of being on-test for flash at the PES lab and off-test at a customer lab are minimal.

14

9/28/318/268/218/1 88/1 68/1 38/98/37/277/22

-1

-2

-3

-4

-5

-6

-7

-8

-9

-1 0

SAMPLE DATE

Sam

ple

Mean

__X=-5.451

UCL=-2.112

LCL=-8.791

1

1

Xbar Chart of Flash for PES Lab Result minus SXL Result

CustomerPES Average Result

Rounded (oF)

Pipeline Average Result

Rounded (oF)Delta (oF)

Primary Pipeline 138 144 -6

Secondary Pipeline* Inconclusive, due to limited data availability at this time (10 points).

1. Per ASTM D93-10 The Flash Analyzer Needs To Demonstrate:

• Variability Below ASTM Listed Reproducibility Criteria (7.94 ºF) *Diff. Operator & Lab

– Note: 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 No Additional Opportunities For Improvement.

3. Due to above work and QC program, Lab concludes there is not an opportunity here!

Lab Flash DOE and Gage R&R Studies?

15

What do you notice about the data above? Its running above the “Target” QC value even though its

within “Reproducibility”

137 PHL-D0093-04, OOS 5/11

142 PHL-D0093-04, OOS 8/27

120 LCL

127 TARGET

134 UCL

112

117

122

127

132

137

142

1/15 1/30 2/14 3/1 3/16 3/31 4/15 4/30 5/15 5/30 6/14 6/29 7/14 7/29 8/13 8/28 9/12 9/27

D93 F

lash

, F

QC ProgramASTM D93 PM Flash Performance, °F

PHL-D0093-04 (Tanaka APM-7) PHL-D0093-05 (Tanaka APM-6) PHL-D0093-06 (TANAKA APM-8)

PES lab participates in ASTM round robin for flash periodically

Since February 2013, PES lab flash results range from 1 - 5 oF 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.

Does Our Lab Have a Bias?: More to Come

16

Flash Contributor Check Work: D86 Initial Boiling Point

17

Flash Contributor Check Work: D86 5% Point

18

Flash Contributor Check Work: D86 10% Point

19

Flash Pt Regression vs IBP, 5% & 10% D86

20

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

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 oF

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

Plant Level Distillate Flash Team Work Summary

21

Going after the Bias Next!

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

What we learned about Flash at the Lab

22

Understanding Current State: Process Mapping

This is where you might earn a nickname!

Mapped and Walked

Setting a new daily QC

Doing the daily QC

How to do a “Flash” test

23

Temperature Conversion

• ASTM round robin reported in deg C

• Temperature conversion difference

QC Aging

• Material changes over time

Lab Tech Error

• Tech working area

• Incorrect method

• General error

Maintenance

• New tech spec needed

• Instrument maintenance

needed

Settings

• Instrument testing error

• Incorrect settings

• Use of reproducibility limits as

trigger

Calibrations

• Frequency

• Internally certified proto w/o CRM

calibration

• Where we calibrate

• Machine to machine bias

• Range of material calibrated

Exit Point Information

• Incomplete information about exit

point labs

Potential Bias Factors – Do Some Brain Storming

24

Bias Root Causes and Solutions

Root Cause Solution

Round Robin data evaluated as single points Visually evaluate round robin data over time

Calibrations performed annually as single

point

Perform 20 point calibrations weekly until

data support reduction in frequency

Calibration material used was not in flash

range of distillate materialUse n-decane as calibration material

No temperature calibrationsPerform temperature calibrations quarterly,

per Tanaka recommendation

No process for comparing PES to customers Obtain SXL data periodically and compare

No visual analytics Issue histograms for each calibration

QC Accepted Reference Value (ARV)

unknown

Provide QC material for ASTM round robin to

obtain ARV

25

Data Analysis: Temperature Calibration

Temperature calibrations cecks and adjustments are a critical part of machine performance

maintenance and monitoring.26

Create Visual Procedures

27

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

Data Analysis: ANOVA

ANOVA can also be used for Mean, but Histograms provide a better visual including data spread for

our Lab Technicians

29

Monthly Reporting

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.

n-Decane

Flash Results /

Instrument

Run#PHL-D0093-

06POS = +3.1

°F

1 129 Run on 06-09-15 BP = 29.73 in =755.14

2 127 EFP SET AT 127

3 125 ODD

4 127 752<odd<768

5 129

6 125 n-Decane - Alfa Aesar Lot# P31B030

7 125

8 125

9 127

10 127

11 127

12 129

13 125

14 127

15 127

16 127

17 127

18 127

19 127

20 127

**All tests were conducted in °F

30

PHL-D0093-04 (APM-7) bias at 130 F was -4.3 ºF

PHL-D0093-06 (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.

Lab Flash Summary

31

Questions?

32