Engineering Procedure

SAEP-42 1 January 2018

Capital Project’s Energy Optimization Study
Document Responsibility: Energy Systems Optimization Standards Committee

Contents
1 Scope ............................................................2
2 Intended Users...............................................2
3 Conflicts and Deviations..................................2
4 Applicable Documents ....................................2
5 Definitions ......................................................3
6 Projects Energy Assessment...........................4
7 FEL2 Study Phase - EOS ...............................5
8 FEL2 DBSP Phase - EOS ...............................8
9 FEL3 - EOS Recommendations Follow-up ..... 11
Revision Summary.............................................. 11

Previous Issue: 29 February 2016 Next Planned Update: 15 October 2019

Revised paragraphs are indicated in the right margin Page 1 of 11
Contacts: Soliman Noureldin, Mahmoud Bahy Mahmoud (nourelmm) on +966-13-8809449
and Zeeshan Farooq (farooqzx) on phone +966-13-8809465

©Saudi Aramco 2018. All rights reserved.

Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

1 Scope

This procedure applies to all new facilities and expansion projects in the existing
facilities, where the overall energy consumption of the upcoming facility or new
expansion exceeds 100 MMBTu/hr of heating/cooling, or 10 MW of mechanical power.

This procedure provides a methodology to review project design from an energy

efficiency perspective. It provides guidelines to achieve energy efficient plant design
within the project phases by conducting an “Energy Optimization Study”.
This procedure is developed to ensure a high quality of “Energy Optimization Study”
by ensuring that every potential design improvement is captured during this study.

2 Intended Users

This standard procedure is intended to be used by project and process engineers in

Saudi Aramco, who are responsible for process and facilities planning, process
engineering and energy systems engineering. It can also be utilized as a guideline for
developing “Scope of Work” to conduct an Energy Optimization Study by an external
consultants (Energy Systems Optimization). This particular document will enable them
to conduct review of a new project design from an energy efficiency optimization
perspective. It will also ensure that new energy-efficient facilities in Saudi Aramco are
designed at the appropriate time.

3 Conflicts and Deviations

Any conflicts between this document and other applicable Mandatory Saudi Aramco
Engineering Requirements (MSAERs) shall be addressed to the EK&RD Coordinator.

Any deviation from the requirements herein shall follow internal company procedure
SAEP-302.

4 Applicable Documents
Note: This procedure is the main reference for the project deliverable “Energy Optimization
Study”, it provides details of the requirements for conducting the energy st udy during
relevant projects.

The following documents are referenced in this procedure:

4.1 Saudi Aramco Documents

Saudi Aramco Engineering Procedures

SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering
Requirement
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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

SAEP-341 Equipment Life Cycle Cost Procedure

SAEP-1350 Design Basis Scoping Paper (DBSP) Preparation
and Revision Procedure

Saudi Aramco Engineering Standard

SAES-A-502 Combined Heat and Power Systems Optimum
Design

Saudi Aramco Best Practices

SABP-A-058 Recommended Consultants for Industrial /
Non-Industrial Energy Assessment Studies
SABP-P-017 Grassroots Project Energy Assessment Study Scope
of Work

4.2 International Standard

EA-1G_2010 ASME: Process Heating

5 Definitions

5.1 General Definitions

Energy Assessment: Refers to the methodology of collecting and analyzing

available energy utilities related process data without losing the context of the
whole process needs. This is done in order to establish the “big picture” of the
energy requirements for a particular facility and identify component-based-
energy efficiency optimization opportunities of energy and process sub-systems
taking into account its operating and capital cost estimates.

Targeting: The process of setting targets of energy, cost, utility, area, etc.,
for process/plant or even for a whole facility ahead of design, knowing its
operational requirements, capabilities and limitations. Energy Targeting
provides the target for the Minimum Energy Requirement (MER) of a given
process.

Grand Composite Curve (GCC): A graphical representation of the excess

heat available to a process within each temperature interval. It indicates the
difference between the heat available from the process hot stream and the heat
required by the process cold stream, relative to the pinch at a given shifted
temperature.

5.2 Abbreviations
P&CSD – Process and Control Systems Department
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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

FPD – Facilities Planning Department

ESD – Energy Systems Division
IPMT – Integrated Project Management Team
FEL – Front End Loading
DBSP – Design Basis Scoping Paper
GCC – Grand Composite Curve
PFD – Process Flow Diagram
UFD – Utility Flow Diagram
H&MB – Heat & Material Balance
CHP – Combine Heat & Power
CCHP – Combined Cooling, Heat & Power
EOS – Energy Optimization Study
ORC – Organic Rankine Cycle

6 Projects Energy Assessment

This procedure mandates conducting energy optimization studies in the FEL2 project
phase and to review the design in FEL3 project phase (this is okay if the review is no
later than approximately the 60% PP stage, it would seem a little bit late otherwise.
These phases as per SAEP-1350 cover the “Study” phase, “Design Basis Scoping Paper
(DBSP)” phase and the “Project Proposal” phase, as shown in Figure 1.

Figure 1 - Phases of Projects

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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

The main objective of conducting an EOS is to develop the proposed facility design into
an Energy-Efficient Design. Involvement of P&CSD/ESD at the early stage of project,
i.e., FEL1 business case development, is highly recommended for the success of EOS.

The EOS shall be initiated in FEL2 Study phase and completed in FEL2 DBSP phase.
EOS is carried out in two stages as initial and final assessments. Initial assessment
consists of system level integration and shall be conducted by P&CSD/ESD.
Final assessment consists of optimizing the selected systems to achieve an energy
efficient design. The scope of the final assessment will vary from project to project,
depending on its nature. The scope of final assessment shall be developed by
P&CSD/ESD during initial assessment. The scope of work for the EOS should be
developed in accordance to SABP-P-017.

During FEL3 project proposal stage, the main task is to support design development of
the identified initiatives/recommendations of EOS and to resolve any issues/concerns
that arise due to proposed design modification.

The outcome of this analysis in the form of “Energy Optimization Study Report” shall be
considered in the DBSP. All unaccepted recommendations shall be submitted to Energy
Systems Optimization Standards Committee for approval with proper justification.

7 FEL2 Study Phase - EOS

The initial Energy Optimization Study shall be conducted in house by P&CSD/ESD

during FEL2 Study Phase. The scope of this initial study covers the overall systems
integration with the objective to identify the best utility configuration to fulfil all energy
requirements for a facility. In addition, it provides the foundation for EOS DBSP phase
study. The decision to conduct DBSP phase EOS by a 3rd party and/or in-house
consultant shall be decided by P&CSD/ESD during the initial EOS. The following
steps shall be applied to conduct Energy Assessment during the initial stage;

7.1 Establishment of energy consumption base-line

7.1.1 Select a project closely resembling the current project from the available
database. Criteria for resemblance is the process configuration, plant
geographical location; and/or previous experience.

7.1.2 Gather the selected project’s related information and capitalize on the
preliminary process design and similar projects if available to obtain the
PFD and UFD simulation models, data-sheets and economic data
necessary to define current project energy requirement.

7.1.3 Consider inter-plants integration during the establishment of the base

case design energy consumption level(s).
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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

7.1.4 Develop GCC for the project with base-line energy requirement and
consequently map utilities to the base case design, otherwise establish a
new base case design for approval by project’s owner.

7.2 Identification of Energy Utility Systems alternatives

7.2.1 Evaluate fulfilling energy requirement with all types of utility systems
commercially available. For example, flexible designs of Tri-generation
systems, furnaces, chilled water, cooling water, air cooling, refrigeration,
etc., should be considered, as well as cogeneration scheme(s).

7.2.2 Use utility system base case configuration or develop a new one with
some alternate utility system configurations.
Note: The design configuration of the utilities system shall be developed
according to SAES-A-502.

7.3 Inclusion of New Energy Optimization Technologies

7.3.1 Identify commercially available energy optimization technologies that

may be included in the new plant’s or project design, such as;
 ORC
 Absorption-Chillers and Adsorption Chillers
 Kalina-Cycle
 Turbo-expander
 Tube inserts
 High Efficiency Heat Exchangers and so on.
Note: FPD and PMOD to provide bases to establish cost estimation
correlations for these technologies.

7.3.2 Establish basis for selecting or rejecting technologies.

7.4 Define Process and Utilities Systems Integration Scenarios

7.4.1 Identify process-process, process-utility, and utility-utility interaction.

7.4.2 Study the possibilities for integration schemes with near-by facilities
and/or residential areas to optimize energy utilization.

7.4.3 Gather required data to establish facility’s Total Site Supply-Demand.

7.4.4 Propose alternative utility systems configurations to satisfy total Site

Supply-Demand changes. The proposed utilities systems shall be
appropriately defined to conduct proper economic evaluation.

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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

7.4.5 Obtain the latest energy values for primary utility (fuel, electricity,
water, cooling water, etc.)

7.4.6 Develop CHP model for the project and evaluate several utility systems
alternatives with comparisons to a base case design.

7.4.7 Conduct sensitivity analysis, utilizing CHP model for possible

integration scenarios.

7.4.8 Generate a priority list for evaluated configurations or alternatives based

on the NPV and overall system efficiency.
Note: NPV analysis shall consider equipment life cycle cost in accordance to
SAEP-341.

7.5 Initial Study Key Considerations

7.5.1 Define Energy Utility System configuration base case with all utility
appropriate details for future development.

7.5.2 Determine “marginal cost” for each energy utility of selected Energy
Utility System.

7.5.3 Discuss this assessment findings with the concerned project’s entities.

7.5.4 Develop a big picture opportunities list/modifications for base case

design (if available) via the identification and estimation of potential
energy savings opportunities. For example: Change in plot plan of the
plants relative to each others and/or to utilities plants.

7.5.5 Develop possible integrated design modifications strategies for realizing

energy and/or capital savings for the new facility mapped to the base-
case design.

7.5.6 Report all calculations and recommendations in “Energy Optimization

Initial Study Report” and submit to IPMT Leader.

In addition to analysis results, the “Energy Optimization Initial Study

Report” shall include a plan to conduct “Energy Optimization DBSP
Phase Study”. This plan consists of;
i. Decision to conduct EOS DBSP phase study either by a 3 rd party
consultant under ESD supervision or by P&CSD/ESD utilizing
in-house capabilities.
ii. Scope of work for the final assessment.
iii. Tentative schedule for the study with milestones.
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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

The decision to conduct in-house study by P&CSD/ESD or by a 3rd party

consultant under P&CSD/ESD supervision shall be made by the ESD in
consultation with the FPD based on available resources, project
complexity and schedule.
Note: For in-house study conducted by P&CSD/ESD, a formal scope of work
may not be required.

8 FEL2 DBSP Phase - EOS

Energy Optimization Study in FEL2 DBSP Phase is a continuation of FEL2 Study

phase. During this phase the selected alternatives are defined into project scope and
shall be evaluated and optimized as a result of EOS to achieve an energy-efficient
design. The objective of this study is to develop a Heat Exchanger Network and
identify any process modifications to minimize facility’s energy requirement as well as
optimizing any utility resources to fulfill facility’s energy demand. As the optimization
frame-work involve process-process, process-utility and utility-utility interaction along-
with community flexible requirement. The optimization of the design can be iterative in
order to ensure plant’s energy requirements is satisfied at minimum NPV, which is key
to success of the energy integration study. This Energy Optimization Study shall update
all the findings of FEL2 Initial Study report into a more rigorous evaluation. This effort
will produce design changes at HEN, distillation and utilities levels and evaluate all
changes in terms of NPV utilizing the updated optimized CHP model developed in the
study phase.

If a 3rd party consultant under ESD supervision is performs the energy optimization
study, then the study “Scope of Work” shall be prepared by FPD and reviewed as well
as confirmed by ESD before initiating the competitive bidding process. On other hand,
if the decision was to conduct the study in-house by ESD, then “Scope of Work”,
schedule and milestones shall be discussed and agreed between ESD and IPT leader.
Note: The recommended 3rd party consultants to conduct EOS is provided in SABP-A-058.

The following steps shall be applied to conduct the final Energy Optimization Study
during FEL2 DBSP stage;

8.1 Intra-plant Waste Heat Recovery

8.1.1 Review Process Description, PFD’s, H&MB, available simulation

models, energy consumption targets, prices and Saudi Aramco energy
efficiency measures/standards.

8.1.2 Extract stream(s) data from available documents and model for each
process, this data shall be used for energy targeting.

8.1.3 Establish base-case energy usage of each plant from the current heat
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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

exchanger network design, furnaces, pumps, compressors, CHP systems,

air/water coolers and refrigeration base case design.

8.1.4 Energy targets for each process/plants and all plants shall be calculated.
Utility targeting shall be conducted to identify minimum energy
demands for each plant.

8.1.5 The efficiency of the current HEN design and CHP system’s
configuration shall be assessed using an updated CHP model according
to SAES-A-502 and comparing the current utility consumption with the
energy targets identified.

8.1.6 Improvement opportunities shall be identified either as process

modification or HEN design improvement and produced for further
investigation.

8.1.7 Identified opportunities shall be assessed for practicality, safety and

flexibility. Opportunities fulfilling all considerations shall be evaluated
in terms of NPV.

8.2 Total Site Waste Heat Recovery

8.2.1 Each process/plant shall be investigated for optimum direct and/or

indirect interplants integration and all opportunities shall be identified.

8.2.2 Data shall be collected for the streams involving cross-process/plants

heat integration opportunities, to highlight any possible impact on the
plant safety, corrosion and operability.

8.2.3 Energy targeting for cross-process/plants heat recovery shall be

conducted. This could clash with earlier processes level matches and
must be evaluated in order to supercede earlier matches. Marginal utility
cost shall be derived from an updated CHP model and shall be utilized to
do the comparison.

8.2.4 The efficiency of the current HEN design and CHP, Cooling and
Refrigeration systems configuration shall be assessed using an updated
CHP model and comparing the current utility consumption with the
energy targets identified.

8.2.5 Identify and quantify opportunities for interplants heat recovery, and
assess them for practicality, safety and operability. Opportunities
fulfilling all considerations shall be evaluated in terms of NPV and listed
as potential improvement for the base case design.

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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

8.3 Utilities Systems Optimization

8.3.1 Operating philosophy, requirement of sparing philosophy, net heating

and cooling requirements of all process plants and adjacent industrial
community for potential integration shall be extracted.

8.3.2 Facility’s CHP or CCHP, air/water cooling, process heaters and

refrigeration systems models shall be updated, with all the newly
extracted data and shall be optimized to act as a final utilities systems.
This assessment shall include but not limited to the following:

8.3.2.1 Number and sizes of cogen units and boilers that meet energy
demand and satisfies all constraints.

8.3.2.2 Mechanical Drivers selection optimization including type size

and number of units.

8.3.2.3 Multiple furnace Integration with rest of the process and/or

utility system.

8.3.2.4 HEN area targeting and capital loss identification and

correction via HEN modification.

8.3.2.5 Distillation columns inter-heaters/coolers and feed condition

optimization.

8.3.3 All identified initiatives shall be evaluated one-by one in terms of NPV
with energy reduction due to its implementation.

8.4 Inclusion of New Energy Technologies

8.4.1 Quantify the available potential for deployment of new Energy

Technologies to the current project design.

8.4.2 Identify and evaluate all applicable technologies to capture the available
from base case design energy. Technologies fulfilling all considerations
shall be evaluated in terms of NPV and listed as potential improvement,
for the base case design now or in the future.

8.4.3 Develop selected energy technologies conceptual design and the

estimated impact on the project schedule.

8.5 Study Report Main Deliverables

8.5.1 Final design and configuration of plant’s energy utilities systems and its
major components with all appropriate level of details for design
development.
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Document Responsibility: Energy Systems Optimization Standards Committee SAEP-42
Issue Date: 1 January 2018
Next Planned Update: 15 October 2019 Capital Project’s Energy Optimization Study

8.5.2 Al the results and assessment study findings including energy

technologies conceptual design.

8.5.3 A comprehensive list of identified initiatives with its techno-economic

evaluation for potential energy savings or capital cost savings in NPV.

8.5.4 A list of the recommended initiatives with estimated potential impact on

engineering documents and project execution schedule (upon discussion
with licensors/contractors).
Note: All related activities, communication with licensors, contractors, etc.,
and all generated initiatives as well as the final recommendations shall
be included in the “Energy Optimization Study Final Report” and
submitted to IPMT Leader.

9 FEL3 - EOS Recommendations Follow-up

During FEL3 project proposal phase, any concerns/suggestions to the EOS

recommendations shall be addressed and resolved with P&CSD/ESD.

Revision Summary
15 October 2014 New Saudi Aramco Engineering Procedure.
29 February 2016 Minor revision for name change, scope clarity, roles and responsibility clarity, including some
improvements in procedure to conduct EOS.
1 January 2018 Editorial revision to delete paragraph 3.3.

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