Md Hisam, Muhammad Fuad (2025) DMAIC - Based Measurement System Analysis (MSA) for optimizing high purity propylene in Propylene Recovery Unit. Masters thesis, Universiti Teknikal Malaysia Melaka.
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DMAIC - Based Measurement System Analysis (MSA) for optimizing high purity propylene in Propylene Recovery Unit - 24 pages.pdf - Submitted Version Download (780kB) |
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Abstract
It is important to achieve and to keep the purity of propylene at ≥99.5%, in order to meet the high-quality specifications needed in downstream petrochemical uses. Nevertheless, a significant number of refineries still face the problems of repeatability and reliability of their measurement systems that affects the quality of product and the efficiency of plant operation and long-term integrity. One of such cases was witnessed at a Malaysian refinery located in Johor, where the PRU (Propylene Recovery Unit) unit performance was found to be repetitively disturbed/limited by inaccuracy in measurement because of calibration inconsistencies, operator differences, environment variations and non-standard maintenance practices. There were significant issues with unstable process control, frequent purity excursions, excessive energy consumption, and expensive rework of product. Incorrect data from the measurement system could lead to bad decisions and nonoptimal process adjustment in the likes of pressure, temperature and flow, that adding unnecessary complexity and cost to what was meant to be a well controlled process. To fill this void, the case study applied a DMAIC type methodology, a structured approach to process problem solving commonly used in six sigma projects, using Measurement System Analysis (MSA). The framework was applied to systematically identify, assess, and minimize the variables in PRU measurement systems. The work was centered on actual operating conditions and employed statistical Analyzes like Nested Gage R&R (ANOVA) to quantify the repeatability and reproducibility for a group of gas measurements made at the hands of various operators. This integrated approach resulted in measurable achievements. After the enhancement, the refinery experienced improved purity readings repeatability, lower process variability and less off-spec reprocessing. The standardization of processes has significantly increased the efficiency of the workflow process and decreased material waste, very much in line with the company's environmental and workflow optimization company goals. Finally, this work has shown that MSA and DMAIC methods can be successfully applied together based on industrial experiences of the authors. And by making data integrity a cornerstone of process control, the refinery not only increased its production of propylene, but it also inched one step closer toward attaining strategic goals for quality, cost optimization and sustainability. The approach and outputs detailed here could potentially provide a useful model for other organizations in refining or process industries who are dealing with the same issues.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Propene, Propene industry |
| Subjects: | T Technology > T Technology (General) T Technology > TP Chemical technology |
| Divisions: | Library > Tesis > FTKIP |
| Depositing User: | Norhairol Khalid |
| Date Deposited: | 18 Aug 2026 08:28 |
| Last Modified: | 18 Aug 2026 08:28 |
| URI: | http://eprints.utem.edu.my/id/eprint/30370 |
| Statistic Details: | View Download Statistic |
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