This paper covers and evaluates a retrofit work for desalting trains grids in Saudi Aramco Khurais facility to accommodate water cut increases due to field maturity. The main objective of this retrofit work is to accommodate the increase in water cut (emulsified and free water) while enhancing the de-salting process with minimum modification scope and cost effective approach. This Paper is intended to: Presents the retrofit basis and compare old and new grids design. Presents the results of this optimization study along graphical representations. Highlights how this initiative increased the desalting trains efficiency and redundancy. The basic concept of the retrofit work is to change the grids in electrostatic separation vessels from the conventional tapered configuration to straight configuration. The original configuration was tapered configuration that is intended to maximize separation and balance the load on all transformers however the limitations of this configuration is in case of one grid shorted all other transformers will be shorted. Despite the available transformers capacity, however as the water cut increases the chances of water carry-over increases as well as emulsions which results in multiple outages of de-salting trains. Straightening the grids will help avoiding total outages of the transformer, so in case of one grid shorted, other two grids will be running with a higher load which provides redundancy, reliability and guaranteeing the quality targets. This modifications were evaluated from safety, process, electrical and cost life cycle point of view and assessed post retrofitting for 1 year against there pre-defined success majors that includes: Outage hours of dehydrator and/ or de-salter (Target less than 5 hours per quarter). Demulsifer chemical consumptions (Target reduction by 10% or more annually) Quality specification (Target maintaining BS&W and Salts within crude specifications of 0.2% and 10 PTB respectively even in case of 1 or 2 transformers shorted. This modifications succeeded in achieving the predefined targets in addition to a cost saving equivalent to US$ 120,000 due to demulsifer injection reductions (i.e Regular and emergency dosage). Figure 1 shows the change in grids configurations before and after retrofit work

This paper covers an optimization study at Aramco's Khurais processing facility to maximize NGL yield and minimize H2S content through HYSYS simulation. Model validation and identifying the confidence level of the model (prior optimization) approach and results are covered along with the realized results of the optimized operating envelope in simulation compared to field trial results. The optimization approach focused on flashing more light ends due to a pressure drop in both the condensate feed drum and condensate stripper column while reducing NGL heating to maximize C3+ yield while maintain H2S below 30 PPMv. The identified optimized operating enveloped was implemented and benefits were realized. The main conclusions and realized benefits of adjusting the operating parameters to the optimized operating envelope includes maximizing NGL recovery in the facility by more than 900 BPD while maintaining quality parameters within limits, reduced the steam consumption by more than 150,000 lb/day and creating more tolerance to process upsets and normal fluctuations. The novelty of this paper is that it describes a process to define the confidence level of the model prior to commencing the optimization on a pre-existing model. In addition, it highlighted a simple approach to maximize C3+ recovery while minimizing H2S content and energy consumption, which creates room for optimization opportunities in any gas plant with no gas sweeting system.

This paper covers practical demulsifer and wash water approach followed by Saudi Aramco Khurais producing facility to optimize the chemical and water consumption. This Paper is intended to: Share practical demulsifer and wash water optimization approach. Highlight how this approach enhanced the separation process and how it already helped Saudi Aramco to meet the product quality with minimal operating costs by optimizing operating parameters in the field. The basic idea of the optimization is to relax the oil - emulsified water separation in HPPT by allowing water carry over to the downstream equipment and vessels through minimizing the demulsifer dosage on the production header to increase the retention time. The optimization process includes manipulating different key parameters (controlled variables) which are demulsifer dosing rate (on production header and dehydrator), wash water dosing rate, de-salting train mixing valves differential pressure and transformers voltage with continues monitoring and corrective actions based on the export specification of BS&W and salts within pre-defined internal limits to avoid having off-spec product (Trial and Error) This approach resulted in decreasing the operating costs by reducing overall demulsifer dosage by 50%, and allowing the overall separation efficiency to be increased contributing towards enhanced separation. Various graphs included showing the full impact of optimizing the operating parameters on improved separation in dehydrator. From the water conservation, this process resulted in reducing non-potable wash water consumption for crude washing purposes by more than 20,000 gallon/day without compromising the crude specification. This optimization resulted in cost saving equivalent to around US$ 650,000 due to significant demulsifer reduction. Sustaining such an optimum performance proves to be a challenge and in this regard, the team is focusing heavily on the monitoring efforts that are equipped with the advisory features on what to do should the deviation exist from the stipulated target. This includes, among others, the alerting feature for immediate corrective actions by the team. Overall, this initiative succeeded in maintaining the facility crude quality specifications of BS&W and salts while reducing chemical operating costs, creating positive environmental impacts by saving non-potable wash water while increasing the assets utilization and reliability effectively.

Khurais central processing Facility is a hydrocarbon plant consists of 5 GOSPs with a stabilizer (i.e oil train), 3 gas plants and power plant with their associated utilities. Each oil train has one HP gas compressor to send the gas from oil trains to gas plant. These compressors is oversized and running each compressor alone results in excessive recycling and wasting energy. In 2018 Khurais introduced a new energy optimization initiative which is swing line that is a common header connects all HP compressors together with the objective of maximizing operating loads in each gas compressor. In doing so, the last compressor can be shut down for as long as the capacity of the other compressors is still adequate to accommodate the extra gas rate from the shutdown compressor.[1] (Refer to Figure 2) Although this approach resulted in maximizing energy efficiency of the facility it introduced a new challenge to the facility which is in case of any trip to a compressor connected to swing line all other connected compressors will trip. Recently Khurais introduce a new philosophy to shift the load from tripped compressors to other compressors through modifying swing line and compressors DCS control logics. This paper covers the swing-line control logic modifications and enhancement followed by Saudi Aramco Khurais producing facility to overcome multiple compressor outages challenge. This paper is aimed to: Share the challenge of multiple compressors trips with swing line operations that occurs if one of the compressors connected to swing line is tripped resulting in 100% of gas flaring. Present dynamic simulation modelling results and new logic modifications implemented for compressor controls to avoid such multiple trips scenario. Present Compressor trips cases before and after implementing the control logic enhancements. Highlight how this approach enhanced compressor's reliability and helped Saudi Aramco to reduce its carbon footprint. In this paper various dynamic simulation modelling graphs that showed the root cause for multiple compressor trips will be presented, evaluation of several control logic and their consequences. This topic will also cover the new proposed logic with zero investment to avoid multiple compressors trip scenario with operations of swing line. Details about behavior of compressor before and after the modification including the reaction of newly implemented control logic in flare control valves is included part of this paper. After the implementation of this logic the following results have been realized: No incident of multiple compressor trips happened due to proper functioning of logic. Eliminated 60-100 MMSCF/year of flaring due to multiple compressors trips scenario through having "quickest" handle to restoring flow to the swing line and stop flaring. Reducing carbon footprints due to flaring compared to old setup. Realized Recovered revenue worth approximately US$ 500,000/year The novelty in this paper is describing an approach of gradual load shifting from a tripped compressor to other running compressors to avoid multiple compressors trips which can be utilized in any facility that has a common suction header connects all its compressors. Such logics can be implemented in-house with no modification in compressors or swing lines or other equipment.

This paper covers an energy optimization study conducted by Saudi Aramco to maximize energy efficiency and minimize GHG emissions via onion peeling method to analyze the system from outside to inside by segregating the system to three essential layers in Khurais hydrocarbon facility to achieve operational efficiency and environmental sustainability. This paper is intended to: Share the optimization strategy and how it can be replicated. Presents the results of this optimization study along with operating modes energy and emissions data and graphical representations. Highlights how this approach enhanced the overall facility operating efficiency. The onion peeling approach allows to achieve maximum efficiency by conducting sensitivity analysis on each layer's parameters to achieve the optimum operating mode for minimizing power bill (i.e., maximizing power generation), minimizing scope 1 and 2 emissions, minimizing sales gas consumptions. The aforementioned approach was done based on the following strategies: Maximize power generation in facility whenever reaching the threshold that makes power generation better than importing from grids in term of GHG emissions and EI. Maximize waste heat recovery for power and steam generations. Minimize recycling in major energy consuming equipment in the facility. Maximize major energy consuming equipment efficiencies through load management optimizations. Follow operating levels concept rather than optimum mode concept by ranking all possible modes in hierarchy and challenge the system to achieve better operating level (i.e., lower level number) Figure 1 Shows the model's layer and summary Post-Implementation of the defined strategies and following operating level concept, several initiatives introduced to achieve lower operating levels with energy savings and GHG (scope 1 and 2) reductions realized. Finally, this study concluded that to achieve better operational mode environmentally and economically, it is recommended to analyze the overall system from outside to inside as multiple layers, to capture opportunities in the system. Such an approach shall be followed after defining the needed strategies, depending on the facility's design, demand and operating conditions.