Best Practice

SABP-A-005 20 January 2016

Quick Energy Assessment Methodology for Energy Efficiency Optimization
Document Responsibility: Energy Systems Optimization Standards Committee

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

2. Quick Energy Assessment Overview ..................................... 3

2.1 Energy Efficiency Optimization Task Description ............................... 3
2.2 Solution Method Using Decomposition Approach .............................. 4

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

4. Reference Detailed Energy Assessment Studies ................. 13

Appendices
Appendix I - Typical Oil Refinery Overall Energy Flow Diagram....... 14

Appendix II - Typical Gas Plant Overall Energy Flow Diagram....... 15

Previous Issue: 21 July 2013 Next Planned Update: TBD

Revised paragraphs are indicated in the right margin Page 1 of 15
Contact: Soliman Nour Eldin, Mahmoud Bahy Mahmoud (nourelmm) on +966-3-8809449

CopyrightSaudi Aramco 2016. All rights reserved.

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

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

The term Energy Assessment refers to the methodology of collecting and

analyzing available energy utilities related data in order to establish the big
picture of the breakdown of energy consumption for a particular facility and
identify component-based-energy saving opportunities within the facility.

1.2 Purpose and Scope

The purpose of this best practice document is to describe a methodology and

introduce short cut tools by which quick assessment for energy efficiency
improvement can be conducted faster, cheaper and better. Its scope include
quick energy assessment methodology in a step-by-step manner, simple models
for data representation, checklists for identifying areas for energy savings and
short cut tools for creating and evaluating process initiatives for energy saving
for common use in Saudi Aramco plants.

1.3 Intended Users

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

1.4 Initial Assessment Objectives

Preliminary review of plant process, system drawings and data gathering
Understand the Big Picture of the plant-wide operations
Understand process energy and utility systems
From the available data, establish your current reality
Establish your desired result Targeting
Identify all opportunities for energy savings
Propose Quick-hit savings
Propose scope for definitive assessment with some economic analysis
Propose plant-wide energy-utility strategy or Total Energy Management

2. Quick Energy Assessment Overview

The first priority in any plant initial energy assessment effort is to define the quick
hits for energy cost savings that can be achieved with minimum/no investment.

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.

2.1 Energy Efficiency Optimization Task Description

Energy Efficiency Optimization Task aims to specify the near-optimal operation

targets/modes that minimize the plants energy consumption while avoiding
deficiency in energy supply of the utility systems to the plants process.
Following that, the task will be to list all possible operational and design
modifications necessary to achieve the specified/desired target(s). This includes
identification of all related engineering activities in a minimum possible time
using uncertain plant data and without any interruption to the plants normal
production. This task shall achieve the following two objectives:
1. Minimum disruption in the energy utility supply
2. Minimum consumption of energy utility.
Given an industrial facility that consists of several processes and utility plants, define;
at minimum deficiency in energy utility systems supply to the process; near-optimal
targets for energy consumption minimization, find a list of possible operational and
design modifications to achieve desired target(s) and conduct the engineered solutions

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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

2.2 Solution Method Using Decomposition Approach

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.

Minimize energy consumption while satisfying plant demand at maximum

production rate

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

These tasks are exhibited in the 10-Steps procedures below:

1. Site survey through templates, checklists and interviewing of process
owners/proponents to gather the right amount of data that enable the energy team
build the plants big picture and understand the goals and the constraints of the
facility
2. Define the criteria for focusing on potential areas of interest
3. Develop site energy/utility nominal design/normal operation models with the
appropriate level of details in a high level generic path diagrams for, power, fuel,

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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

3.1 Energy Flow Diagrams Overview

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.

Money-based graphs will help quickly to pinpoint the areas of focus.

Furthermore, the BTU-based graphs will double check the pre-defined priority
list, direct the study towards the process reasons behind certain energy
elephant and find more efficient ways to satisfy the process target(s).

Fuel
Energy Sources

Energy
Generation

Boilers & Cogeneration

Steam Energy
Electricity
Distribution

Energy
Buildings & Others Process
Utilization
Energy
Byproducts

Figure 1 - Overall Energy Flow Diagram

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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

3.2 Steam and Power Diagram

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

Heat integration of process#1 and # 4

98 t/h Estimated saving of 10%
HP Boiler
Enhance condensate recovery
By 10 %
HP
Shut down MP boiler
68 t/h 21 t/h 8 t/h 0.0 t/h 0.0 t/h Reduce letdown via turbine
flow increase or new turbine
Proc. #1

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

Figure 2 - Overall Steam and Power Diagram

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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

3.3 Fuel Diagram

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.

Hydrogen Off-Gas Fuel Gas

400 psig

380 psig
PSA

350 psig

180 psig

NG

150 psig 150 psig

52 psig

50 psig

boilers furnaces
15 psig

5 psig

Figure 3 - Overall Fuel Diagram

3.4 Energy Saving Housekeeping List

3.4.1. Operation and Maintenance

Piping insulation
Preventive maintenance of energy system components such as heat
exchangers, pumps, fans, compressors, turbines, furnaces, boilers
(e.g., clean the fin fan tubes of gas coolers)

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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

Enhance boilers and furnaces insulation

Improve cooling towers and cooling system maintenance
Compressed air leaks
Condensate recovery system and condensate traps maintenance
Furnaces tuning through better combustion control and monitoring
O2 analyzer
Optimize air compressors operation

3.4.2. Load Management

Optimize BFW pumps load allocation
Shut down compressors at low feed rate
Minimize slow rolling of steam turbines
Booster, shipper and condensate pumps load management
Compressors load management
Turbines load management

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

3.4.4. Monitoring Tools and Management System

Energy monitoring and indices / energy management system
Optimize the CHP system
Flare mitigation program
Heat exchangers foaling monitoring program

3.4.5. Steam and Water System

Establish steam trap auditing program to determine the number of
traps (working, leaking, blockingetc.) and periodically check it and

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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

repair or replace the defected ones.

Boilers tuning through better combustion control
Minimize boilers and cooling towers blow down
Steam trap management (consider self-regulating electrical tracing)
Maintain plant steam reserve
Minimize/Eliminate the use of steam reducing stations and vents

3.5 Energy Saving Generic Checklist

3.5.1. Furnaces and Boilers Optimization

Increase boiler steam pressure and temperature to the extent that
matches process needs unless electricity generation is the controlling
factor
Preheat combustion air
Optimize the furnaces/boilers excess oxygen
Optimize the furnaces/boilers stack temperature
Boilers and furnaces efficiency enhancement through advanced
process control, on-line performance monitoring and optimization
Install low NOX burners
Clean and maintain boilers/furnaces tubes from deposits & scale for
better heat transfer

3.5.2. Steam Turbines Optimization

Replace gas turbines with more efficient steam turbines
Use auxiliary turbines to minimize steam let downs
Optimize let down stations and steam turbine operation
Use highest efficiency turbines
Maintain your steam turbines to reduce steam consumption
Replace turbine drives with electric motors if more economical since
they are more efficient

3.5.3. Steam Usage Optimization

Optimize the operation of waste heat boilers
Give frequent attention to steam traps and leaks

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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

3.5.4. Boilers and Cooling Tower blow down Optimization

Treat and recycle blow down to force lower cycles of concentration
in cooling towers and boilers
Boiler blow-down could be considered for cooling tower make-up
Flash the low pressure steam from the boiler blowdown
Consider re-using the boiler blowdown for reserving the boiler
Cooling tower blow-down should not be treated but segregated to
sewer
Boiler blow-down should not be sent to wastewater treatment but
segregate to sewer.

3.5.5. Water Management

Maximize use of stripped sour water
Minimize generation of wastewater
Eliminate direct water injection for cooling purposes
Use process water effluent as a source on the next lower water
quality level
Minimize water used in desalter
Automate desalter operation, avoid water slipping through with crude
during desalting/maximize the separation of free water upstream of
the crude desalting (each lb of water will require roughly lb steam for
processing)
Minimize the water-wheel in the plant

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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

Use lowest quality water possible for desalter operation

Maximize utilization of treated oily-water from the waste-water
treatment plant

3.5.6. Heat Integration

Re-use the flue gases in process heating
Thermal Heat and power integration (CHP)
Mechanical energy integration
Apply Pinch Technology to reduce fuel gas consumption
Consider the use of Cogeneration
Increase waste heat steam generation
Insulate condensate return lines, valves, flanges, etc.

3.5.7. Variable Frequency Drivers and Recycle Optimization

Cool down the inlet temperature to compressors
Reduce cooling medium return temperature in refrigeration cycles
Avoid unnecessary recycles
Use ASD on BFW pumps
Adjustable speed motors/devices for pumps, compressors, etc.

3.5.8. Flaring, Off-gas, and Fuel gas System Optimization

Recover valuable gases from your fuel gases
Seek out and repair all hydrocarbon leaks
Reduce natural gas consumption by understanding fuel gas sinks and
constraints
Measure the composition of off-gas streams and recover C2 and C3+
Avoid unnecessary processing of off-gas
Avoid unnecessary processing of wastes and inert
Minimize the unnecessary production of off-gas
Keep H2 separate from fuel gas system
Reduce the H2 wheel in your plant
Avoid leaks in the pressure relieve valves to the fuel system

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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

4. Reference Detailed Energy Assessment Studies

Detailed Energy Assessment Study at Hawiyah Gas Plant Department, SAER-5995,
June 26, 2005.

Detailed Energy Assessment Study at Abqaiq Plants Operating Department, SAER-6361,

December-2011.

Detailed Energy Assessment Study at Ras Tanura Refinery Department, SAER-6461,

January-2013.

Detailed Energy Assessment Study at Yanbu Refinery Department, SAER-6517,

December-2013.

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

Typical Oil Refinery Overall Energy Flow Diagram

$ 0.5 MM
$ 0.9 MM
Other users
Process
Purchase
$ 52.4 MM $ 0.8 MM Machine
$ 24.4 MM Drive

$ 0.0 MM $ 45.9 MM $ 41.5 MM Re-boilers

Steam
heaters

$ 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

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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 II

Typical Gas Plant Overall Energy Flow Diagram

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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