Quality Every step of the way. Saeed Behnam Jey Oil Refining Co. Tehran,AUG 2016

Transcription

1 Quality Every step of the way Saeed Behnam Jey Oil Refining Co. Tehran,AUG

2 Introduction to Quality Quality Problem: Around 3 years ago we have received some reports about the Bitumen quality which has been export with the name of Jey. It was strange for us because quality control on products in refinery was checked carefully. After a while it was cleared that because of more benefit, some people got Jey products, mixed it with very cheap and low quality products like as: Vacuum residue, Gilsonite, even sand or other trash and finally export it with the name of Jey Co. Therefore at that time a system with the name of Quality Management system defined to monitor and control the quality to reduce any risk of low quality bitumen. Share our lesson learns and Best Practice with others 2

3 Introduction to Quality What is quality? Meeting Goals quality Refer to Product According to Standards %Q= No. of Fulfilled Requirements Total No. of Requirements.100 Delivery & Service Guaranty & Warranty logistic Documents Technical support 3

4 Raw Material (Feed) Production & Techniques Quality every step of the way Storage Loading & Packing Logistic Quality Management at different stages : Q.C + Q.C + Q.C + Q.C Consider the quality from 1 st step to final step 4

5 All Steps at a Glance Crude Q.C Distillation Tower Vacuum Distillation Tower VB Q.C Asphalt Reactors Crude Oil Step 1 Heavy Cuts Step 1 Vacuum Bottom (VB) PEN : Step 1 Step 2 Intermediate Tank Q.C Drum Packing Custom Q.C Storage Tank Final Product Quality Control Bulk Loading Step 4 Step 5 Step 3 Bag 5

6 Step 1 Quality Management in Raw Material 6

7 Step 1 Quality Management in Raw Material Crude quality and refining technology play a main role in final products (Feed of Asphalt Unit). Receiving crude oil from Marron Reservoir that is very famous in Iran + perfect process from a wellknown Brand like Fluor Group, in accordance to a perfect quality control in refinery will be result a perfect feed for asphalt unit. Lesson learn: High Quality Crude (from MAROON reservoir) with API 33 + Perfect process (Fluor, Golden refinery) In accordance to Perfect Q.C 7 Perfect Products As well as perfect Feed for Bitumen Unit

8 Step 1 Quality Management in Raw Material(VB) Vacuum Bottom Specifications & its Quality is another main factor affect directly on Quality of bitumen. Control % of Wax content during refining process will be done in Isfahan refinery. Level of Wax Content is not mentioned in standard but it is clear for specialist that too much wax content will cause defects on road pavement. Lessen learn: WAX content less than 2% 8

9 Step 1 Quality Management in Raw Material(VB) Viscosity of Vacuum Bottom Measuring the viscosity helps to adjust production Parameters to obtain high quality bitumen. It also improve utility or energy efficiency. Lesson Learn: I. Using on-line viscometer for feed II. VB with viscosity more than 650Cst is preferred for production Higher VB Viscosity Lower Reaction time 9

10 Step 1 Quality Management in Raw Material(VB) VB Sampling & Off-line control Sampling of VB for Measuring both Viscosity and Penetration in laboratory is highly recommended. sampling & Lab test VB in each shift It helps to have precision VB Viscosity for Jey Lesson Learn: VB sampling at least once per production shift. Production On-Line viscometer calibration for Quality Assurance 10

11 Step 2 Quality Management in production 11

12 Step 2 Quality Management in production Technology Conventional Method old method Biturox Technology high quality & more energy saving Using modern technology to obtain high quality product Providing at least 2 technologies I. Biturox Technology II. Conventional Method Help to produce different type of bitumen: Penetration Grade Performance Grade Viscosity Grade Australian and Chinese standard 12 Mixing & spraying water

13 Step 2 Quality Management in production Quality Control (Tools & Techniques) Using different quality tools and techniques to measure, monitor, analysis and action, are very useful. Our experience says using control chart to control upper and lower limits of main specifications and Fishbone diagram for cause of any deviations is practical. Best Practice: Using Q.C Tools like as: I. Fish bone diagram (Cause and effect) II. Control Chart (control Viscosity changes over time). اجتناب ناپذیر اجتناب ناپذیر تعمدی 13

14 Step 2 Quality Management in production Pilot Plant to get the best results Using Pilot plant to obtain best production conditions such as : Air consumption, temperature, pressure and other parameters is vey helpful. on one hand,it helps, producer to adjust all factors base on technology. On the other hand it can be used for R & D activities. Jey Oil Co. Pilot Plant Provide compatible pilot plant like as: Biturox Pilot Plant Supply any special bitumen according to 14 customer need

15 Step 2 Quality Management in production Oxidation process will maximize the risk of making coke. Therefore cleaning reactors, heat exchangers, piping and all related equipment is necessary. Jey Lesson learns says: Annual cleaning all equipment to guaranty operational efficiency Periodic overhaul (every 2 years)for all equipment including Reactors, Pumps, piping, in order to maintain equipment and produce high quality products, recommend. 15

16 Step 3 Quality Management during transferring and storage 16

17 Step 3 Quality Management during transferring and storage To be sure about quality products, sampling from each storage tank will be done and sent to LAB for test report. If quality meet standard, certificate from quality control Dep. Will issue and tank will be sealed. Lesson Learn: Sampling & Testing Sampling from output line of reactor and intermediate tanks Sampling from Different levels of storage tanks Tanks are sealed only if the product meet standard requirements 17

18 Step 3 Quality Management during transferring and storage Lesson learns and Best Practice: I. Avoid loading & Unloading at a same time. II. Suitable temperature of bitumen in storage tank is 150 o c ~ 180 o c. Loading & Unloading at a same time 18

19 Step 4 Quality Management in Loading & Packing 19

20 Step 4 Quality Management in Loading & Packing Using Batch No. for production tracing Assigning a Batch No. to each storage tank helps Bill of Lading producer to Trace the products( in the case of any Claim) Batch. No. consist of all required information Such as:: Product type 60/70,PG64-22,VG Production Date Production Time Storage tank No. Detail technical data 5M/95 20

21 Step 4 Quality Management in Loading & Packing Bulk It will be recorded on Bill of Lading Batch. No. Drum or Bag It will be recorded on Bill of Lading and also on body of bag or drum 21

22 Step 4 Quality Management in Loading & Packing Jey Best Practice: Sealing bitumen tankers to eliminate any risk of changing quality This Sealing device has a serial No.,that will be recorded on Docs. Loading lid at the top and Unloading valves at the rear side of bitumen Tanker should be sealed with an special sealing system top Jey recommendation: Serial No. of sealing device with documentations should be checked by End user. 22 rear

23 Step 4 Quality Management in Loading & Packing Quality and concern on Bitumen Drum packing Protect Bitumen drums from rain water and dust by using special cap seal. Special Cap and Dies Special Hemming Tool Lesson Learn: Using Sealing drum caps with special Hemming machine is recommend. 23

24 Step 4 Quality Management in Loading & Packing Bitumen Bags quality Because of some environmental factors in many European countries using of drum for bitumen is forbidden, therefore new bitumen bags developed. 1. Outer layer for keeping bitumen firmly This bags has two layers 2. Inner layer with special Modified material for Benefit of Bitumen bags: Improving quality Easy transport Keeping quality during handling Improving some characteristic of Bitumen after melting 24

25 Step 5 Quality Management During logistic 25

26 Step 5 Quality Management During logistic Insolated bitumen tankers keeping the bitumen temperature from refinery to end user storage tank is one of the main factors for maintaining quality. Why? No need to Heat it again Other Benefits: Energy saving Increase safety Reduce environmental pollution Re-heating reduces Bitumen quality 26

27 Step 5 Quality Management During logistic Design Fabrication Service Lesson learns & Best Practice: According to Road Ministry and Jey oil Co. Standard I. Use Insulated Tankers for distance more than 150 Km (specially in winter season). II. Fabrication of Bitumen Tankers should be done according to approved standard of (Road Ministry and Jey Co.) III. Acceptable drop Tem. should be less than 0.6 O C /hour. 27

28 Step 5 Quality Management During logistic Using Bitutainer Using Bitutainer for Bulk bitumen is a good idea. It will eliminate all unnecessary loading/unloading and heating accordingly. Its heating systems is designed some how to prevent any quality changing. No need to heat keeping Quality 28

29 Step 5 Quality Management During logistic generally random sampling from bitumen drum has been done from top of it. sampling from Top of Drum Old sampling Methods of drum content, could not guaranty 100% of quality Destructive Sampling from TOP, MIDDLE and BOTTOM of drums was being done. But not practical. 29

30 Step 5 Quality Management During logistic Disadvantages of destructive sampling: I. Time consuming II. III. Wasting bitumen More staff requirement Jey Best Practice : Design, fabricate and using a special tool for sampling from different levels of each Bitumen drum. 30

31 Step 5 Quality Management During logistic Final quality control in customs and export terminals for quality assurance is necessary Jey Lesson Learns says: Establish a new laboratory in Terminal port (like Bandar Abass) to check quality and Identify any defects. ( in the terms of FOB) It will perform quality Assurance 31

32 Quality every step of the way CE Standard qualification certificate in the production process and product quality several Certificates and awards ISO17025 the competence of testing IMS Certification Quality and calibration laboratories 32 Auditing by third party can help each organization to find its gaps and improve it. Try to get different certificates from qualification organization is a vey good chance to be excellent.

33 Conclusion and Suggestions : Jey co. has been started its quality management system which is ongoing and will improve it in future. : We propose to trade directly with Jey to be sure about quality. : Jey Quality control Team is ready to help,all the customers who Purchase Jey Bitumen indirectly. 33

34 Thanks for your attention با تشکر از توجه شما Nous vous remercions de votre attention 感谢您的关注 Cảm ơn bạn đã quan tâm của bạn 여러분의관심에감사드립니다 Terima kasih atas perhatian Anda شكرا لكم على اهتمامكم आपक ध य न क ल ए धन यव द 34