Application of Data Analytics in Manufacturing

Safia AL SUQRI Sr. Engineer – Process Optimization Services

Outline

Introduction

The Power of Data Analytics.

Analytics Application.

Case Study

Orpic – the journey so far

Our Products

Polypropylene

Our Plants

Our Business Model

Growth Strategy

Sohar Refinery Improvement Project The USD 2.6 billion capital investment will increase Orpic’s refining capacity and significantly improve our environmental performance. The project will enable Orpic to

change the nature of crude oil and elevate our production capacity by 70%. The commissioning phase is schedule to 2017.

Muscat Sohar Product Pipeline

The 280 kms two-way multi-product pipeline will connect our Mina Al Fahal Refinery to our plants in Sohar and an intermediate distribution and storage facility at Jifnain, as well as a new storage facility at Muscat International Airport, which will receive aviation fuel directly from the pipeline. The project is due to be commissioned in 2017.

Liwa Plastics Industries Complex

The USD 3.6 billion transformational project will improve Orpic’s product mix and business model, double its profit and support the development of a downstream plastics industry in Oman. It is a steam cracker project which will process light ends produced in Orpic’s Sohar Refinery and its Aromatics Plants as well as optimize Natural Gas Liquids extracted from the currently available natural gas supplies. Upon completion, the plastics production will have increased by 1 million tonnes, giving Orpic a total of 1.4 million tonnes of polyethylene and polypropylene production by 2020.

Outline

Introduction

The Power of Data Analytics.

Analytics Application.

Case Study

•Qualitative and quantitative techniques and

processes used to enhance productivity and business

gains.

•Different Applications used:

o Data Historian System, (LIMS and PI)

o Planning and Scheduling applications (PIMS & Aspen)

o Controlling applications (APC, AAM, CPM)

o Reconciliation and Performance Record Systems (Sigma

fine)

o Reliability and Asset management (RCM, RBI, xOW)

o Capabilities Development (OTS, simulation, Petro-Sim, Hyses)

Application of Data Analytics in Orpic

The Power of Data Analytics

Application of Data Analytics in Orpic

Raw Data

Analysis

Planning

Optimization

Troubleshooting

Implementing

Monitoring

Supply Chain/

Process Optimization

Operations

Process Optimization

Operations

Process Optimization

Supply Chain/ Oil

Accounting

LP Modeling

•Feedstock Data

•Process Data

•Market Status

DCS & Lab

•LIMS Data

•Process Data

PI & Lab

•LIMS Data

•Process Data

•Process Control

•Simulation

DCS & Lab

•LIMS Data

•Process Data

PI & Lab

•LIMS Data

•Process Data

•Performance Review

LP Modeling & Sigma Fine

•Products Data

•Process Data

Analytics Application

Outline

Introduction

The Power of Data Analytics.

Analytics Application.

Case Study

Success Story - APC

•Advanced Process Control

•Predict the unit performance

•Predict the product qualities.

•Stabilize the operation.

•Results:

o Stable Operation

o Reduce Quality giveaway.

o Increase Production.

o Saving Million$$

Specification or Limit

Average

Average

Current Operation

Variations Reduced with

Advanced Control

Move Average Closer to

Specification or Limit

Minimize process variances Stabilizes process operation

Success Story – Simulation

Processing New Crude

Thanks