TQM Case Study

1. TQM Case Study TQM Case Study By: Bader Ba-Hammam

2. Problem Statement • There is high sulfur in Propane (C3) & Butane (C4) products coming from JGP to the customers in Jubail such as Ibn Sina & Sadaf. • Generally, JGP practice to maintain sulfur below 20ppm or well below the 30ppm specification, to allow for possible process upset or errors in reading or measurements that could produce off-spec products • JGP management takes the responsibility and the commitment to reduce sulfur to be on specification and gain customer satisfaction. • A team was assembled to review the problem with the objective of determining if the modification can be made to increase the reliability and operation performance of the MEROX unit.

3. Study Methodology • Define the problem. • Identify and evaluate possible causes. • Find solutions and identify recommendations. • Implement the changes.

4. Define The Problem • Identify the big problem • Using the “Three Actual” rule to understand the problem before solving it by collecting data from the right sources • Go to actual place • See the actual process • Talk to the people (operation & maintenance)

5. Define The Problem • Describe the process • JGP has 3 existing fractionation modules and a new module in construction phase. • In each module, there is a MEROX Unit that reduce the Sulfur concentration on the products. • Fractionation Unit Overview • MEROX Introduction • Measure the process performance

6. Fractionation Unit Overview

7. MEROX Introduction • MEROX: Mercaptan Oxidation. • MEROX unit reduces LPG sulfur content to meet customers product specifications.

8. MEROX Introduction What does MEROX process consist of? Mercaptan Sulfur Extraction Section Utilization of caustic solution to extract mercaptans sulfur from LPG products as they are converted to mercaptides. Caustic Regeneration Section Utilization of catalyst and air to regenerate caustic solution as the mercaptides are converted furthermore to insoluble disulfides.

9. SulfurExtraction Regenerated Caustic Extractor Caustic Settler Sand Filter Prewash Drum Treated Product LPG Contaminated Caustic

10. SulfurExtraction Blockage of Merox unit equipment due to salt formation H2S Mr. LPG

11. SulfurExtraction Extractor Caustic Settler Sand Filter Prewash Drum

12. SulfurExtraction H2S + 2NaOH  Na2S + 2H2O NaOH(Caustic)

13. SulfurExtraction Extractor Caustic Settler Sand Filter Prewash Drum

14. SulfurExtraction Off specification LPG products RSH(Mercaptans) NaOH

15. SulfurExtraction Extractor Caustic Settler Sand Filter Prewash Drum

16. Legend Mercaptans NaOH Solution Hydrocarbon SulfurExtraction

17. SulfurExtraction RSH + NaOH NaSR + H2O RSH(Mercaptans) NaSR(Mercaptide)

18. SulfurExtraction Extractor Caustic Settler Sand Filter Prewash Drum

19. SulfurExtraction Extractor Caustic Settler Sand Filter Prewash Drum Treated Product Contaminated Caustic

20. O X I D I Z E R VentTank Disulfide Separator Caustic Regeneration To atmosphere 60 PSIG Steam Contaminated Air Process Air Disulfide Oil To Crude CausticHeater Catalyst Add. Pot Contaminated Caustic Regenerated Caustic

21. Caustic Regeneration O X I D I Z E R O X I D I Z E R Process Air VentTank Disulfide Separator CausticHeater

22. Caustic Regeneration Catalyst NaSR+ + ½ H2O ½ RSSR + NaOH O2 RSSR(Disulfides) NaSR(Mercaptides) Merox Catalyst

23. Regeneration O X I D I Z E R Depleted Air VentTank Disulfide Separator CausticHeater To Crude Regenerated Caustic

24. SulfurExtraction Extractor Caustic Settler Sand Filter Prewash Drum Treated Product Contaminated Caustic

25. Regeneration Process Air O X I D I Z E R Depleted Air VentTank Disulfide Separator CausticHeater To Crude Regenerated Caustic

26. Define The Problem • Measure the process performance • The two figures show product sulfur as determined by laboratory analysis in C3 and C4 products, respectively, between February 2005 and February 2006. • During this period, as can be seen from the figures, there has been total of only 2 periods where off-spec product (>30ppm) was actually produced from one of the three Modules; Mod II in February 05 and Mod I in early November 05. During these incidences, the other modules were producing on-spec product. • Note that the off-spec readings obtained in January 05 for C4 and C3 are accounted for by problems at RT lab. • In addition, there were 16 days in which C3 product sulfur exceeded 20ppm but were still on-spec. • Also, there have been a total of 46 incidences where C4 product sulfur ranges between 20ppm and 30ppm. (32 periods between 20-25ppm & 14 periods between 25-30ppm) • To have off-spec C3 while having on-spec C4 would mean that the process is not functioning properly.

27. Define The Problem • Measure the process performance

28. Define The Problem • Measure the process performance

29. Identify & Evaluate Possible Causes • JGP formed a team consisting of 2 process engineers, 1 instrument engineer, 1 maintenance engineer, 2 area operation foremen and 1 maintenance foreman. • Brainstorming session was conducted to list all the possible root causes that could lead to high sulfur in the C3/C4 products. • The team was able to identify approximately 20 conditions or causes that could either lead to off-spec product or give the perception that off-spec product was being produced. • Cause and Effect diagram was identified as follow:

30. Identify& Evaluate Possible Causes Operation/ People procedure High Quantity of Inlet Sulfur High HC Feed Rates Low Caustic Strength Sulfur not removed by MEROX Low HC Flow Low MEROX Cat Strength Low Caustic Flow High MEROX Catalyst Strength Carryover Re Entry Sulfur High Sulfur in C3/C4 Products Extractor Level Tx Faulty Lab Results Low Temp Inlet to Oxidizer Low O2 Flow Analyzer Wrong O2 Analyzer C4 From RT Level Control Interface Level Control On-line Analyzer Valve Plugging problem RT Lab Equipment

31. Identify & Evaluate Possible Causes • After listing all the causes, the team outlined tools available for plant personnel to detect the conditions and outlined the actions that should be taken. • Moreover, the frequency of the event occurring and a severity index were assigned to each cause. this severity index is meant to be an estimate of the amount of time before the condition, if left unnoticed or if no action was taken to eliminate the cause, may lead to off-spec product. • In addition, safeguards were identified to list all the tools in place to alert personnel that such conditions or causes were occurring.

32. Identify& Evaluate Possible Causes

33. Identify& Evaluate Possible Causes

34. Find Solutions & Identify Recommendations • Brainstorming session was conducted to list all the possible solutions and proposed recommendations. • Although the unavailability of reliable analysis of the product from RT lab is one of the primary cause of the problem, this specific issue is not addressed because the laboratory has already taken steps to correct matters. • As a result, the team has identified 17 recommendations to overcome the problems currently being experienced in the MEROX unit.

35. Find Solutions & Identify Recommendations • The affinity diagram was conducted to sub-divide the recommendations into sections as per following: Section 1)Most Important; reduce the possibility of high sulfur products by providing operation/engineering with timely and needed information about the unit. 1) On-line GC 2) Create poster to hang outside showing procedure for shake test 3) Log results of shake test in DCS 4) Create MEROX dashboard: DCS/PI schematic to show overview of important parameter for MEROX performance as per decision tree in JIM 1504.33-1 5) Evaluate available and proven disulfide-caustic interface detection instrument 6) EJR to install water flush line to remove plugs from LCV-650

36. Find Solutions & Identify Recommendations Section 2)General Items; to provide the operator with better information when sulfur begins to rise as well as reemphasizing instruments PMs. 7) Consider increasing O2 alarm to 10% 8) Add ΔT reading & alarm in DCS for all oxidizers 9) Make On-line GC schematic in PI containing all sulfur information 10) Install seal pot on O2 analyzer 11) Replace F&PS analyzer installed to measure sulfur in RT C4 because it is not reliable due to manufacturer's defect 12) Monthly PM for level & interface instruments

37. Find Solutions & Identify Recommendations Section 3)Long-Term; for evaluation & studies. 13) Check Mod III inlet analyzer for accuracy 14) Evaluate “rate of change” alarm for level in Extractor 15) Evaluate installing flow transmitter on Disulfide oil flow 16) Evaluate enlarging DS oil line from 1 to 2 17) Consider adding balance calculation to alert operations when TR C4 combined with JGP C4 approached off-spec.

38. Implement The Changes • Each proposed recommendation was assigned to the right employee depending on his specialty to ensure the fulfillment of the recommendation by eliminating the cause of high sulfur product and following-up by evaluating and measuring the performance after the change. • My role was to evaluate the existing interface level transmitter for all the Modules and then search and evaluate new technologies. • It is found that the displacement type installed in JGP Mods is not suitable to detect interface level and it is not recommended by ARAMCO consultants. • There are many interface level detectors methods used around the world for different applications. These instruments should be studied very carefully from all aspects to have the right one for JGP application.

39. NaOH H2S Merox Catalyst Mr. LPG

40. Thank You Thank You