SMART

MANUFACTURING
Stretching borders of the 21st Century Industries

Unlocking the Brilliance in an Organization

2nd Aug 2014

India Poised….
 SPECIFIC

TIMELY MEASURABLE

RELEVANT E
ABL
H IEV
AC

En-route to S M A R T
Contents

Smartening the Manufacturin

Size of the Opportunities in S

Leverage technologies…..

Enablers and Barriers……

Road map….. The Smartest rou

Redefining factories of the future….

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 Smartening The
Manufacturing……....
Tenets that distinguish….
1. Zero Incident… wrt safety, environment and reliability ……. including Zero injury

2. Habituated to perform at ‘Potential BIC Limits’ – Energy, Inventory, Cat Chem, Maint., etc.

3. Best In Class in each Asset, Process & Product Stewardship……… Global Competitive Edge

4. Ability to process ‘Different Feeds/ Raw materials’ with confidence..

5. Zero ‘Missed opportunity’ across supply chain, Agility to swing between products..

6. Focused Collaborative New Initiatives ……..…. Reduces Time to Market

7. Responsive care to all stakeholders…

8. Strong culture of Curiosity and Commitment (e.g. no. of IP institutionalized, speed of PIP, etc.)

9. Employer of Choice
10. Repository on tacit knowledge
Collaboration is the key…… amongst Industry – Academia – Government
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 Notable impediments en-route …..

Turn adversities into opportunities.... A few India specific

Within Tamil Nadu: Pan India: Global:

a. Talent Creation a. Diversity State Vs Centre a. Skewed energy price
b. Competency gap b. Cont. technology dependence b. 7T $ impact on “AoKW”
c. Tracking ‘Turnback’ incidents c. Fixed mindset c. Small & smart (Industries)

New Impending Emerging

Challenges..
Hidden:
1. Industry friendly ambience?
2. Δ & incr. cost- prdts/ grades
3. Time to track efficiency of
critical processes…
Tempest?…. Threats…...
Manage Boundaries:
1.Subsidies – Leveler or Killer Environment:
2.Entry tax, multiple agencies 1. Thrust on sustainable
growth
3.RTI misuse as IP invasion
2. Solar making inroads
4.Declining job opportunities
3. Food security

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Size of Opportunities - “SMART”
Manufacturing
Sl. No Attributes Function ¢/bbl
1 Zero incident… Zero injuries (with HSE, Engg & Tech) Operation 4
3
2 Optimize energy use ‘live’ (NG, C3, CSO, H2, CSP, etc.) Operation

3 Alternative use of Sulphur (with lab and R&D) Technology 20

4 Molecular mgt sply of C7s to C10s (with R&D) Technology 10
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5 Time to Cash on “Idea to Market / Implementation” Tech / MPC

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6 Leverage technology for EED (Early Event Detection) Engineering
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7 Induct new crude (why 5% each time?) with confidence Technology

8 Optimize HC inventory (~51mm bbl at given time) Business 20

3
9 Integrate Human factors into plant optimization Operation

Illustrations …… based on a refinery work up..

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 Leverage
technologies…..…
Technologies that impact manufacturing industries

GPS
Artificial intelligence
Big Data Analytic
Robotics Cloud Computing Disruptive Innovation
Advanced Materials Process Intensification
Energy Storage Adv. Oil & gas recovery
Solar Roadways Smart Sensor Renewable Energy
Pattern Recognition
Smart Grids
Advanced QMIs

Courtesy
1. http://www.mckinsey.com/insights/business_technology/disruptive_technologies
2. An uncommonly Cohesive Conglomerate, by Booz & co .
https://smart-process-manufacturing.ucla.edu/about/news/Smart%20Manufacturing%206_24_11.pdf
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 Leverage technologies…..…
Contd..
Broad Classification of “Technology Impact Areas” of any industry: -

1. Assets Performance Measurements

2. Automation of Knowledge Work & People empowerment
3. Advanced Materials / Robotics in I&M value services
4. Process Intensifications & Disruptive Innovations
5. Energy Storage & Harnessing Renewable Resources

Process Envisaged in SMART Manufacturing: -

Deliberate asset wise List Enablers / Barriers

Shortlist
potential opportunities (Tech. maturity, policy, etc.)
thru ball park ROI

Implement & Prioritize – Returns &

Conduct Post Audit Implementation ease Carry out detailing
(ROI, Sch. Risk, Changes, etc.)
Align people (Competency),
processes & policies
Set up dedicated teams in the above Five Areas and explore newer options..
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Disruptive
technology….. Wrt devices
Notable ones
1. FSM –Corrosion monitoring
2. Field Bus
3. Hand held device
4. NIR
5. Barcode / bio metric
6. Lubricity test for Jet / Diesel
7. HT - SIMDIS
8. Coking propensity of HC
9. Low lux Camera, etc.

Need Advanced Sensors to forecast / forewarn on asset performance….

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Disruptive
Innovations ……

Examples: -
EPDM
Carbon Fibre
Isoprene

Examples: - Examples: -
C3= ex FCC CSP
DSO (alt DMDS) GM Food
grains
TAN removal by resin
Reactive distillation, etc.

Production of 2,6 DMN, NDA, etc. can become a game changer……

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 Smartest route Opportunities

For a highly optimized and competitive business enterprise

 Smartest
Routes……………………
A. Assets Performance Measurement
1. Revisit sensors / measurements needs from past incidents
2. Assess missing measurements in new crudes / feed processing & update
3. Build intelligence in tracking site wide performance of Fuel & Steam network
4. Build intelligence in tracking site wide performance of H2 & NG network
5. Build intelligence in tracking site wide performance of water mgt
6. Build intelligence in tracking site wide performance of ETP
7. Build intelligence in tracking potential yield of key products
8. Laser induced ultrasonic for contactless investigations of weld defects
9. SMART Fasteners with detection of residual bolt stress by remote monitoring
10. Build intelligence to manage Cl, Amine, Na, CN, Nap acid, etc.

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 Smartest
Routes……………………
B. Automation of Knowledge Work & People Empowerment
1. Automate exception reports for each asset and make available at corporate
2. Forecast & set BOZ & track deviations on 24 x 7 basis for each asset
3. Thru "What If" live tools and take plant to BOZ (wrt E&L, Q, Y, C, etc.)
4. Set up EED (Quality, Safety, Reliability, Cat life, etc.) & close with OperGuide
5. Standardize, establish and link to Corporate memory for lessons learnt
6. Raise confidence level in processing new crude / feed induction
7. Develop in-house kinetic models and ensure seamless output from assay
8. Inventory Optimization – tracking decisions & implications
9. Track knowledge element in “Idea to implementation” and reduce time
10. Update planning automatically post implementation of MOC (mgt of change)

Contd……..

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 Smartest
Routes……………………
B. Automation of Knowledge Work & People Empowerment Contd..
11. Update OMPro, SOPs, SMPs, etc. automatically post approval of RCA
12. Facilitate QMI release of all products
13. Use model based APC / OPT including global optimization
14. Automate start up and shutdown for normal plan
15. Automate PM, PdM schedule thru advanced diagnostic techniques
16. Automate materials mgt thru Intelligent maint. / operation 'live' update
17. Seamless interphase of manufacturing across SCM
18. Automate routing / loading sequences during grades change overs
19. Develop virtual plant simulator for staff training and ‘what if’ scenarios
20. Information push to Mobile by exception

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 Smartest
Routes……………………
C. Advanced Materials / Robotics in I&M value services
1. Conduct high risk activity with robotics incl. repeat routine tasks
2. Design and deploy Flexi platform to eliminate scaffolding
3. Development and deployment of "Smart" gaskets
4. Self lubricating bearing / non metallic type / wear rings
5. Mist lubrication System for rotary equipment with no manual lube oil top-up
6. Solid state power & control devices
7. Wireless technology / advanced instrumentation in process control
8. Smart Hook up
9. Anti-fouling coatings for high temp. (>350 deg C) applications in exchangers
10. Orbital machine for external painting of pipe lines without scaffolding
11. Advanced materials / Nano technology to prevent corrosion / failures
12. Friction stir welding for elimination PWHT requirement.
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 Smartest
Routes……………………
D. Process Intensification & Disruptive Innovations
1. Right molecules at right destination (C7s to C10s) - A holistic view
2. Reduce undesired chemical reactions – Alky, HTs, HCU, Pt, FCC & Coker
3. Oil Chemical interphase & mastery on Δ value analysis/ decision support system
4. Adopt adsorptive options and lower energy need – nP, H2, ETP and C3=/C3
5. Oxidative desulphurization an alt to hydrodesulphurization
6. Reduce OPEX by half in production of Px
7. Holistic integration of Utilities of DESAL / CPP / IGCC / CB with rest units
E. Energy Storage & Harnessing Renewable Resources
1. Assess & Deploy Energy storage, Smart Grid, CSP, etc
2. WiTricity technology
3. Static convertors for converting one form of energy to electricity.
4. Convert Shale gas to granules for transportation & reconvert at destination
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Smartest
Routes……………………
Choose the route…

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Smartest
Routes……………………
Choose the route…

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Smartest
Routes……………………
Choose the route…

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 Enablers and
Barriers…..…
D1. “Molecular Management of C7s to C10s Components”…….. an illustration
Enablers:
1. Availability of advanced monitoring tools
2. Better understanding of reaction kinetics and ability to characterize feed components
3. Pooled resources drawn from Technology & Research
4. Drive to reduce the OPEX in Px production cost

Variables:
5. Sources - CDU, FCC, LCO HCU / HTs, Coker and Imported naphtha
6. Quality and quantity vary with feed type to respective units and operating severity
7. End destinations - Px, Gasoline, PCN, Jet, LABFS and Diesel which are based on: - N+2A, i/n
ratio, tP, type of aromatics (incl. EB, TMB, Di-aromatics, etc.) and nP apart from extent of other
impurities present that impact processing cost
8. Complexity is still higher as there are several isomers….. each may convert differently in d/s
reaction units ending up undesired products like gas, C3 and light ends

Out of the box thinking helps…

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 Enablers and Barriers
Contd…..…
Assessment Mol. Mgt Contd..
Barriers:
a. Measurements
 Inadequate model wrt PIONA (Carbon wise) / DHA ex Coker, HTs, LCO HCU & FCC ,
 Need for On-line QMIs (for key components in stream) to support plant wide Opt
b. Tools
 Absence of integrated scheduling tool to handle variable cost & make delta moves
 Missing inhouse kinetic model to depict all variables specially wrt delta variable cost
c. System
 In sufficient lab / R&D support
 Need for front line peer meeting thru forums like TN atleast once a quarter
 The compromise on many occasions is crude mix restrictions….

Time to challenge young minds…

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 Road
map……………………
.
Sl. # Activity Action by Sch

1 List potential opportunities / ideas

2 Sort Ideas and classify into say 4 to 5 key result areas (by support team)

3 Define objective, Scope, Deliverables & Time schedule wrt KRAs

4 Set up task force (incl. members from R&D) one for each key result area

5 Conduct scoping study & present business plan , ROI & Change mgt
6 List the collaborative needs with outside institutes / universities
7 Review & approve / prioritize business plan & direct action on barriers
8 Resolve barriers – Competency, JDs, Policy, Change mgt..
9 Mitigate external barriers wrt feed & product handling, if any
10 Raise MOCs with clear definition on acceptability criteria of end state
11 Implement and align stakeholders thru involvement / trg and document

12 Post audit & Close out with well defined governance to sustain benefits
Every thing starts with a small & smart step…
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