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Content
1. Introduction............................................................................. 2
1.1 Definition ............................................................................................. 2
1.2 Purpose and Scope ............................................................................ 2
1.3 Intended Users ................................................................................... 2
1.4 Initial Assessment Objectives ............................................................. 3
3. Methodology ........................................................................... 4
3.1 Energy Flow Diagrams Overview ....................................................... 6
3.2 Steam and Power Diagram ................................................................ 7
3.3 Fuel Diagram ...................................................................................... 8
3.4 Energy Saving Housekeeping list .................................................... 8
3.5 Energy Saving Generic Checklist ................................................... 10
1. Introduction
Energy conservation in Saudi Aramco has become everyones business. It is mandatory
for each process facility to find cost effective solutions to save energy and achieve more
with less. Saudi Aramco has constituted a committee called Energy Management Steering
Committee (EMSC) to direct and manage a sustainable process for energy conservation.
A vital contribution towards the success of the company wide energy conservation policy
comes through documenting the company best practices in methodology, tools and
applications in the field of energy conservation and distributing such knowledge among
our facilities. Hence, a consistent effort has been exerted in Saudi Aramco to produce
Best Practices to help Saudi Aramco plants achieve their energy conservation targets and
disseminate energy conservation knowledge. This particular Best Practice document for
initial energy assessment is a contribution towards this goal. It is expected to draw the
line in conducting energy assessments through a user-friendly methodology.
The theme of this quick energy assessment methodology for energy efficiency
optimization is, Big Picture First, Details Later.
Energy assessments, also called energy audits, may be primitive or comprehensive and
detailed. A variety of approaches, methods and tools are available to conduct such
energy assessments to improve the energy efficiency of industrial processes.
1.1 Definition
This Best Practice manual is intended for use by the energy engineers working
in Saudi Aramco plants, who are responsible for efficient operation of their
facility. This particular document will enable them to conduct quick energy
assessments systematically.
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
The best practice document does not only help plants energy groups conduct a quick
energy assessment for both short and long term energy savings opportunities but also
establish the procedures and checklists that can enable process engineers and operators
make intelligent choices on hour-to-hour basis.
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
For simplicity and timely results, Decomposition Techniques will be used in lieu
of the time-consuming Mathematical Programming/Optimization Techniques.
The plants energy utility needs will be defined with reasonable level of
flexibility and the energy utility system; electricity, fuel, steam and other
energy-related utilities will be scrutinized one by one to find the near- optimal
consumption of such utilities that guarantee minimum deficiency in the utility
supply to plant processes.
On the macro level the energy system components are generation, distribution
and utilization. The objective will be to minimize waste in energy fresh
resources and capital (de-bottlenecking) in these three components. This can be
done via the continuous upgrade of the efficiency of energy system components
in generation, distribution and utilization. However, the utilization component
has a unique feature, where its boundaries are not completely dictated by the
process. Therefore, the room of improvement in this component is much wider
than the others.
3. Methodology
There are four essential tasks that can be conducted by a small energy focus group of
three engineers:
Data, Models and Targets
Insights, Opportunities and Estimated savings potential
Screen and Formulate Strategy
Document, Report and Present
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
H2, steam, water, nitrogen and air. Preliminary purpose of these models will be to
locate the energy consumption elephants (ECEs) in both process and utility
plants and generate insights for energy saving opportunities
4. Add more depth in the level of details of the energy utility model for each ECE
and/or other criterion of focus
5. Define the effect of disturbances and uncertainty on the energy utility system
models
a. Sources of disturbances
b. Site energy utility balance under disturbances
c. Nominal and dynamic targeting of energy utility systems
d. (Check that the big picture depicted for the process and the utility plants is
correct with enough degree of confidence before you proceed)
6. Target (order of magnitude targeting)
a. Identify main processing issues that affect utility utilization
b. Link utility-utility interactions
c. Integrate and qualitatively optimize site utilities
7. Integrate core processes among themselves and with utilities
8. Develop a comprehensive initiatives list via identifying and estimating energy
utility savings opportunities
a. Housekeeping list
b. Checklists (generic and process specific)
c. Waste energy recovery (pinch method and others)
d. In-process Modification (pinch method and others)
9. Champion a cross-fertilizing discussion among plant disciplines to prioritize,
screen the initiatives and writing a project sheet, for each initiative, including a
description of the opportunity and energy utility savings estimate
10. Develop word strategies for realizing savings from facility goals, analysis of the
results, and mapping of the opportunities onto the facility strategy. Then, report
and present results.
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
The energy flow diagrams will enable the Energy Engineer to find the
Elephants to focus his efforts and decide where to start and insist on accurate
data collection to further proceed with the analysis. A simple overall energy
flow diagram is shown in Figure 1, while typical Oil Refinery and Gas Plant
overall energy flow diagrams are represented in Appendices 1 & 2 respectively.
Fuel
Energy Sources
Energy
Generation
Steam Energy
Electricity
Distribution
Energy
Buildings & Others Process
Utilization
Energy
Byproducts
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
Steam big picture shall exhibit at least steam sources, pressure levels, mass
balance, let down valves and turbines, main users and losses such as vents, let
downs and condensate. These information can be used in the way as shown in
Figure 2 below to generate ideas and opportunities for saving under the main
theme of Big picture first, and details later.
Steam Targets
103 t/h
Consider replacing turbines with motors Enhance the recovery of
Steam from condensate
6.28 MW
Reduce it via HP Process
operating at Proc. #2 Condensate
lower pressure
1 t/h
4 t/h
MP Boiler 68 t/h 0.0 t/h
chemicals
MP
Eliminate vent 27 t/h 13 t/h
Vent 30 t/h
MP Process
2 t/h Proc. #4 Condensate
Proc. #1 2 t/h
18 t/h
0.0 t/h Vent
40 t/h
Deaerator 1 t/h 0.0 t/h
30 t/h 0.0 t/h
BFW LP
49 t/h 7 t/h 4 t/h
Raw water Effluent 5 t/h LP Process
Make-up Treatment Plant Proc. #1
Proc. #3
Condensate
Process Condensate
Reduce and make use of boiler blow-down
Est. 50 % Returned
Page 7 of 15
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
Fuel big picture shall exhibit at least fuel sources, pressure levels, mass balance,
let down valves and compressors and main users. Hydrogen composition should
also be considered to define the opportunities for recycles. Typical fuel diagram
is shown in Figure 3 below.
400 psig
380 psig
PSA
350 psig
180 psig
NG
52 psig
50 psig
boilers furnaces
15 psig
5 psig
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
3.4.3. Retrofits
Consider the use of Economizers and Pre-heater in Furnaces/Boilers
Utilize boiler blow-down for heat integration (BFW preheating)
Consider the reuse of turbo-expander to generate power in the HP/LP
pressure control valves
Upgrade sluggish response control valves since the delay might
result in extra flaring
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
Recover condensate
Better control for dispersion steam to flare stacks
Eliminate steam venting
Optimize steam use in strippers
Minimize live steam utilization and optimize the amount used
through pressure manipulation
Eliminate live steam used for re-boiling and stripping where it is only
used for BTU value
Minimize or eliminate live steam consumption in sour water strippers
by replacing it with re-boilers
Page 11 of 15
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
Page 12 of 15
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
Revision Summary
6 March 2011 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with minor changes.
21 July 2013 Editorial revision to change document responsibility name from P&CSD/Energy Systems Unit
to P&CSD/Energy Systems Division.
20 January 2016 Reaffirmed the content of the document with major changes, text reformat, and change the
document responsibility name from P&CSD/Energy Systems Division to Energy Systems
Optimization Standards Committee.
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Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
Appendix I
$ 0.5 MM
$ 0.9 MM
Other users
Process
Purchase
$ 52.4 MM $ 0.8 MM Machine
$ 24.4 MM Drive
$ 21.5 MM $ 0.4 MM
Flare
$ 20.70 MM
Fuel $ 51.2 MM
furnaces
$ 73.1 MM
$ 0.0 MM
$ 0.3 MM
refrigeration
$ 16.9 MM $ 2.2 MM
power $ 18.4 MM
Motors
$ 19.1 MM
$ 0.40 MM Other users
Total Purchased $ 37.6 MM $ 0.0 MM
Export
Page 14 of 15
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-005
Issue Date: 20 January 2016
Next Planned Update: TBD Quick Energy Assessment Methodology for Energy Efficiency Optimization
Appendix II
Export
SA Fuel
Purchase Gas
$ 20.018 MM/yr Flare Area
$ 0.0 MM/yr
2.54 MM Ib/hr
$ 0.0 MM/yr $0.11MM/yr
Steam $19.618 MM/yr Inlet Area
$0.27 MM/yr
$ 19.618 MM/yr $1.72MM/yr
$2.8 MM/yr Utility Area
$ 0.0 MM/yr $0.244MM/yr
$ 20.018MM/yr
Fuel $ 0.4 MM/yr Sulfur Recovery
Area
$0.221MM/yr
$ 0.0 MM/yr $16.6MM/yr Gas Treat
$ 0.0 MM/yr $3.25 MM/yr Area
$ 56.1 MM/yr
power $ 56.1 MM/yr $0.335MM/yr
Gas Comp.
$18.08 MM/yrArea
Total Purchased $ 56.1 MM/yr
$0.609MM/yrLiquid Recovery
200 MW
$29.04 MM/yr Area
Note: These Data are Shedgums
Gas Plant
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