Khurais HP Gas Compressor Swing Line Control Logic Modification Through Dynamic Simulation Modelling

Day 4 Thu, November 03, 2022

Zahrani

2022

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.

Facility Energy Strategy Development and Process Optimization: A Case Study from Saudi Aramco Khurais Facility

Day 4 Thu, November 03, 2022

Zahrani

2022

De-Salting Train Transformers Retrofitting and Optimization Study to Achieve Flexibility and Efficiency in Saudi Aramco

Day 2 Tue, November 01, 2022

Mutairi

et al. 2022

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

NGL Process Optimization at Khurais Producing Facility to Maximize NGL Recovery and Minimize H2S Content through HYSYS Simulations

Middle East Oil, Gas and Geosciences Show

Hawsawi

et al. 2023

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.