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Best Practice

SABP-Z-034
8 January 2014
Industrial Facilities Energy Assessment Study Guidelines
Document Responsibility: Energy Optimization and Co-Generation Standards
Committee

Saudi Aramco DeskTop Standards


Table of Contents
1. Introduction.. 2
2. Definitions. 2
3. Purpose of Document and Intended Users. 3
4. Planning Energy Assessment Studies. 3
5. Study Frequency. 5
6. Study Scope of Work.. 5
7. Study Recommendations Implementation.. 6
8. References... 6
Appendix A - Generic Scope of Work. 7

Previous Issue:

New

Next Planned Update: TBD


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Primary contact: Hajri, Mohammed Fahad on +966-13-8809451


Secondary contact: Farooq, Zeeshan on +966-13-8809465
CopyrightSaudi Aramco 2014. All rights reserved.

Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Introduction
Energy Assessment is the methodology of collecting and analyzing available energy
utilities related process data without losing the context of the whole process
requirements in order to establish the big picture of the energy requirements of a
particular facility. Then, it identifies opportunities to minimize utility demand and
optimizing resources to fulfill this demand without affecting facility objectives.
Then, evaluating each opportunity from operating versus capital cost point of view and
prioritizing them for implementation. Conducting such an assessment for any industrial
facility is referred here as Energy Assessment Study. Energy Assessment Study is
applicable to the following type of industrial facilities:

Refineries
Gas Plants
NGL Recovery Plants
NGL Fractionation Plants
GOSPs
Terminal Facilities
Distribution Facilities
Pipelines
Others such as; Abqaiq Plants, Sea Water Injection Plant, Khurais Producing
Facilities, etc.

The objective of energy assessment studies is to enable the process/ plant/ facility/ site
reach its near-optimal performance that minimizes its energy consumption and GHG
emissions while satisfying all site-wide objectives. This objective can be achieve by
operational and/ or design modifications/ enhancements with minimum capital
investment. The consultants conducting this study will list all technically and
economically viable operation and design options/ actions/ modifications necessary to
achieve the specified/ desired energy efficiency target(s).
2

Definitions
Energy Assessment Study: the methodology of collecting and analyzing available
energy utilities related process data without losing the context of the whole process
requirements in order to establish the big picture of the energy requirements of a
particular facility.
Consultant: The expert or Company who conducts the energy assessment study.
CHP: Combined Heat and Power
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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

ECA: Energy Conservation Action or Energy Assessment Study Recommendation


P&CSD/EEU: P&CSD/ESD/Energy Engineering Unit
P&CSD/ECU: P&CSD/ESD/Energy Compliance Unit
3

Purpose of Document and Intended Users


The purpose of this document is to provide guidelines to planning, frequency, scope of
work and recommendations implementation of Energy Assessment Studies for an
industrial facility. To avoid conflict of interest in 3rd party studies; the study shall not
be conducted by the process licensor but by qualified and independent process
integration/ optimization consultant(s). The completed energy assessment study draft
report, including all supporting data and calculations must be submitted to
P&CSD/EEU for review before the submission of the final report.
The intended users of this document are all industrial facilities engineers/ Energy
Coordinators who need to coordinate an energy assessment study for their plants.
Energy conservation engineers and plants energy coordinators who are going to review
energy assessment study report can also get benefits from this document as it will be acting
as guidelines to review and confirm that intended purpose from the study is met.

Please note that this document does not apply to Capital Projects energy Assessment
Studies.
4

Planning Energy Assessment Studies


Proper planning is essential for conducting and getting maximum benefits from Energy
Assessment Studies for any facility. Planning of Energy Assessment Studies is the
responsibility of the proponent, which includes but not limited to allocation of proper
resources, funds, inclusion in operating/ 3 years single business plan of the facility.
Energy Assessment Study can be conducted either internally by P&CSD or by external
consultants and can be summarized in two categories as mentioned below:
4.1

In-House
P&CSD/EEU shall be approached by proponent to conduct Energy Assessment
Study for their facility. In-house Energy Assessment study requires an
Engineering Service Agreement which needs to be established using Customer
Relationship Management (CRM) System. In addition, P&CSD/EEU shall be
contacted and notified of the planned study during the Operating Plan period to
secure the required resources in advance accordingly.

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

4.2

3rd Party
Proponent initiates study and P&CSD/EEU will support in scope finalization
and recommendation of qualified consultants to conduct study. P&CSD/EEU
will oversee and monitor progress of the study and review/discuss results with
the proponents, an Engineering Service Agreement (ESA) or Engineering
Service Request (ESR) needs to be established using Customer Relationship
Management (CRM) System but with much less man-hours than In-House
Studies. For 3rd party study any one from the below two options can be utilized,
budget shall be planned by facility proponent and reflected in its Operating/ 3
Years Single Business Plan:
4.2.1

Utilizing P&CSD Energy Efficiency Optimization Assessment Studies


Long Form Contract. You may contact P&CSD/EEU for further details.

4.2.2

Utilizing open bidding where P&CSD/EEU recommends the listed


consultants in (Table 1).

Table 1 - List of Recommended Consultants for Energy Assessment Studies


Company
AspenTech Ltd.
Birkdale House, The Links
Kelvin Close, Birchwood
Warrington WA3 7RB
England, UK
Process Integration Limited
PO Box 4245 Manchester M60 3SR
UK

KBC Process Technology Ltd


Targeting House, Gadbrook Park
Northwich, Cheshire CW9 7UZ
England, UK
JGC Corporation
2-3-1, Minato Mirai, Nishi-ku,
Yokohama 220-6001
Japan
Belsim SA
29A rue George Berotte
4470 St Georges-sur-Meuse
Belgium
Matrix Process Integration
2441 High Timbers, Suite 130
The Woodlands, TX 77380
USA

Contact Person
Angus Simpson, angus.simpson@aspentech.com
Direct +973 1750 2732
Fax +973 1750 2727
Mobile +966 50 580 0279
Professor Robin Smith
The Managing Director
Phone:+44(0)161 408 2488
(E-Mail Address): Robin.smith@proint.org
Web: www.proint.org
Alan R. Eastwood, aeastwood@kbcat.com
Direct +44 (1606) 815111
Fax +44 (1606) 815151
Kazuyoshi Obata, obata.kazuyoshi@jgc.co.jp
Direct 81-45-682-8450
Fax 81-45-682-8830
Dr. Boris Kaliventzeff,
boris.kalitventzeff@belsim.com
Tel +32 (4) 259-8888
Fax +32 (4) 259-8889
Dr.Dennis Spriggs
President
Phone: 1(713)828-9522
(E-Mail Address): harolddennis@earthlink.net
Dr. Mahmoud El-Halwagi
Technical Director
Phone: 1(979)845-3484
(E-Mail Address): el-halwagi@tamu.edu
Web: http://matrixprocessintegration.com/

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Study Frequency
Frequency of energy Assessment studies mainly depends on the complexity of the
facility. Complexity of all facility had been categorized into three categories:

a.

Complex Facilities: Such as Refineries, Gas Plants, NGL Recovery Plants, NGL
Fractionation Plants where frequency of energy assessment study is recommended
to be 3-4 years.

b.

Semi-Complex Facilities: Such as Abqaiq Plants, Shaiybah Producing, Khurais


Producing, SAF Onshore where frequency of energy assessment study is
recommended to be 4-5 years.

c.

Simple Facilities: Such as Pipelines, Distribution, Terminal, GOSPs, where


frequency of energy assessment study is recommended to be 5-6 years.

Study Scope of Work


The scope of energy assessment study shall include but not limited to provide
engineering solutions to enhance the energy efficiency of the process/ plant/ facility/
site energy systems including but not limited to power, heating and cooling systems
which are mandatory to satisfy process needs in the best possible cost-effective way.
This document details the proposed scope of work for the Energy Assessment Study
that will be conducted for a desired facility. The main objective of this study is to:
a)

Demonstrate the overall magnitude of energy consumption savings possible in the


desired facility to reach near-optimal process targets and the most efficient utility
system (practically possible) to satisfy those process needs.

b)

Serve as a vehicle for technology transfer, by providing training to the desired


facility engineers to keep the right level of expertise to maintain and serve the
company Energy Conservation projects implemented. (Not applicable to InHouse studies).

If previous energy assessment study was conducted without implementing any of its
recommendations then study scope shall also consider the following:
a)

Validate the performance of any of the implemented recommendations made in


previous Energy Assessment Study.

b)

Revalidate the economic feasibility of the non-implemented recommendations of


the previous Energy Assessment Study.

c)

Inclusion of Saudi Aramco Approved/piloted New Technologies related to energy


optimization/conservation.

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

d)

Update/optimize CHP Model for new conditions.

Appendix A details an energy assessment study generic scope of work.


7

Study Recommendations Implementation


The intended energy optimization cannot be achieved if Energy Assessment is completed
alone. Implementation of the study recommendations or Energy Conservation Actions
(ECAs) is the only way to confirm the claimed energy savings in reality.
Implementation of study recommendations or Energy Conservation Actions (ECAs) is
the responsibility of the facility proponent. ECAs implementation plan shall be set and
shared with P&CSD/ECU right after the Energy Assessment Study is completed.

References
There are several Saudi Aramco Best Practices that can be referenced by the Energy
Team to conduct energy assessment studies for different types of facilities. Following are
all available SABPs related to energy conservation in the company that can be adopted by
the Energy Team to apply them during energy assessment studies:
Table 2 - List of Saudi Aramco Best Practices
and Engineering Procedures for Energy Conservation

8 January 2014

No.

Abbreviation

Title

SABP-A-002

SABP-A-008

SABP-A-009

Pinch Technology for Energy Efficiency Optimization

SABP-A-023

In-House Combined Heat and Power Optimization Model

SABP-A-030

Energy Assessment for Efficiency Optimization in GOSP

Load Management for Energy Efficiency: Pumps and


Compressors
Load Management for Energy Efficiency: Heat Transfer
Equipment

Revision Summary
New Saudi Aramco Best Practice.

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Appendix A - Generic Scope of Work


Energy Assessment Study Scope of work shall include:

Conduct whole plant/process integration and optimization for simultaneous process


and utility systems optimization (including HEN retrofit). All re-sequencing,
re-piping for existing exchanger and addition of new exchanger option shall be
thoroughly investigated to check the feasibility.

Evaluate the use of adjustable speed drives, load management techniques and waste
mechanical energy recovery options.

Evaluate savings due to major equipment energy efficiency enhancement using


excel and off-line CHP models.

Conceptually evaluate the feasibility of:

Cogeneration installation

Absorption Chiller Technology applications in process cooling use and/or other


plants equipment energy enhancement

Rank energy conservation projects based on the feasibility and Net Present Value
(NPV).

Enable the developing of definitive assessment of most favorable initiatives / top


ranked energy initiatives/projects

Provide training to help facility Engineers understand the principles and


methodology of the energy assessment study.

Conduct a workshop about Energy Assessment Study for facility Energy Focus
Team.

Software/worksheets developed during this study should be available for facility


engineers access and use during the study and for a one year after completion.

The consultant should provide a dedicated representative to collect the necessary


data for the study completion at the site if PI data access is not possible and/or field
verifications are required.

The consultant should conduct progress meetings and submit progress reports to the
facility engineers to keep them updated about all the stages of the study and the
background about the selecting or discarding of a potential idea to be a potential
initiative.

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Exploration of all Approved/piloted New Technologies related to energy


optimization/conservation.

The output of this study will be a detailed list of energy saving initiatives with
conceptual techno-economic evaluation. The study scope will cover as applicable
the following major elements:

Combined Heat and Power (CHP) system modeling (off-line) including


assessment of the CHP system to identify potential improvements.

Heat Exchanger Network (HEN) analysis and optimization.

Energy Efficiency Analysis of major process and utility equipment.

Power Recovery analysis and Load Management analysis of major pumping and
compression systems.

This energy assessment study scope of work shall include the review and
consider if applicable of any previous/unimplemented energy efficiency
optimization recommendations using new energy prices.

Technical Terms and Conditions

The tools/soft-wares used for the study shall be Saudi Aramco approved software
and licenses should be available with Saudi Aramco for any model which needs
deployment at site for use of proponents during the study and for one year after the
completion of the study.

The applicable documents (PFDs, P&IDs, etc.) required (whichever are available)
shall be provided by proponents but site survey shall be conducted by
CONSULTANT for validation (if required for any study). The operating process
conditions might be different from actual normal process condition used in design
documents whichever is more applicable or both conditions shall be used for the
study.

The mark-up documents (PFDs, P&IDs, etc.) shall be properly prepared to


demonstrate each initiative and the proposed changes.

Plant Overview

Plant/Process Overview: Process description associated with PI graphs or PFDs for


the plant/process included in the study.

Utility system Overview: Utility description associated with PI graphs and, PFDs
as well as CHP model graphs, if any.

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Energy Assessment Study Main Tasks

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.

Understand the Big Picture of the existing plant and the new future expansions,
if any, plant-wide operations to ensure synergy between the old plant and the new
expansion. Check that the big picture depicted for the process and the utility
plants is correct with enough degree of confidence before you proceed.

Thorough review of PI data, process design system drawings and all energy
systems related data to analyze them and develop site energy/utility nominal
design/normal operation base case(s).

Define the criteria for focusing on potential areas of interest (when to be rigorous
and get to the second level of details).

Understand process energy needs and utility systems preference.

Understand the interaction between the process and hot utility system.

Understand the interaction between the process and the cold utility system.

Establish objectives/targets for the overall facility now, and for the future, power;
steam; fuel; and water consumptions.

Identify all opportunities for energy savings for at least two operating modes (e.g.,
summer and winter).

Propose scope for verification using definitive assessment with some economic
analysis including the simulation of the newly defined process schemes, for
instance.

Propose plant-wide energy-utility strategy and optimal CHP operation.

Discuss findings with the proponent before the submission of the draft and then
final reports. This is needed in order to prioritize and screen the initiatives,
discussion should be back-up by description of the opportunity and energy utility
savings estimate.

Prepare report including analysis of the results, mapping of the opportunities and
prioritization basis for each initiative (back-up by mark-ups drawings and other
documents).

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Energy Assessment Study Detailed Tasks


Mobilization
o

Logistic arrangements (i.e., Aramco IDs, Stickers, accommodation, site office,


etc.). Frequent visits to the facility will be conducted by team members with
more days spent on site at the beginning of the study.

Identify/assemble core team from the facility, and CONSULTANTS

Preliminary planning and kick-off meeting at the facility

The proponent will be responsible for the team members accommodation


during site visits as well as logistic arrangements to ensure smooth startup and
execution of the study.

Data Collection and Validation


o

Obtain updated process flow diagrams (PFDs), Piping & Instrumentation


Diagrams (P&IDs) and PI data if possible of the facility for the units to be
studied as well as design documents for the upcoming projects. These should
show not only the major process equipment, but also flow rates, temperatures,
and pressures. Proponent shall be responsible for ensuring that the data
contained on the PFDs is representative of the actual plant operating conditions.

Obtain and compile updated baseline energy data (from DCS or PI system), for
production rates, fuel use, steam and power consumption.

Obtain all the relevant data sheets for boilers, heat exchangers, pumps,
compressors, motors, and other major equipment. Proponent shall be responsible
to provide these documents.

Evaluate data quality and process variability in order to establish the design
basis (use data validation and reconciliation techniques, if required).

Prepare fuel, steam, power users list, and establish a balance between
consumption and production.

Prepare Heat exchangers list, containing information about the equipment tag
numbers, design duty, hot/cold side flow rates, in/out temperatures, number of
shells, and total surface area.

Preparing baseline Simplified Heat Flow Diagrams (proprietary tools) for each
process unit (Big Picture).

Obtain pumps, compressors, turbines, and furnaces operating data.

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Obtain/establish load profiles for all compressors and pumps, in/out pressures,
static and dynamic head, fluid density, brake horsepower, motor size/speed, and
characteristic curves for all such applications.

Prepare a baseline energy balance. Produce a summary of energy usage, by


equipment in relation to the design basis production rate(s).

Energy and utility costs will be calculated using the guidelines prescribed by
Saudi Aramco.

Capital cost correlations; in order to evaluate economic feasibility of the


proposed projects, capital cost will be based on previous similar jobs, vendor
quotations for new equipment and/or published literature.

Establish Design Basis and schedule for the study.

Initiatives/Project Identification and Evaluation


o

Analysis of Heat Recovery potential targets of the plant/process/unit(s).

Analysis of Temperature Profiles for the process to identify potential heat


recovery/process modifications.

Preparation of Simplified Heat Flow Diagrams to demonstrate heat flow in each


process unit as well as to demonstrate recommended modification in simple
layout.

Identifying potential heat recovery improvements and representing them on the


Simplified Heat Flow Diagrams.

Analysis of Pressure Profiles for the process to identify potential power


recovery.

Building Combined Heat and Power (CHP) system model (off-line).

Assessment of the CHP system to identify and evaluate potential improvements.

Performance Analysis of major equipment.

Load Management analysis of major pumping and compression systems.

Adjustable Speed Drives (ASD) analysis for major pumps and pumping
systems.

Brainstorming sessions with proponent to capture operational energy saving


opportunities.

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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Technical and Economic Feasibility Analysis


o

Each energy saving initiative identified shall be evaluated for technical and
economic feasibility. This involves:

Brief description of the initiative in a project sheet shall include enough


technical data to illustrate the modification compared to prior modification
case including the solution concept; unit(s) equipment involved, mass and
heat balances as well as pressure and temperatures conditions in a sketch/
flow sheet format, besides any supporting related process simulation files.

Quantification of savings and costs (energy as well as non-energy), on


marginal cost basis.

Recommended major equipment, including budgetary investment cost


estimates.

Simple payback and NPV evaluation.

All initiatives should comply with Saudi Aramcos safety health and
environment standard.

All project ideas that meet the technical and economic feasibility criteria shall be
compiled into a master list of recommended items, showing the energy savings
potential, and capital cost estimates.

Initiatives shall be grouped into several categories:

Easy Pickings (operational changes, with no or low investment)

Small capital projects

Major capital (requiring corporate funding)

Strategic initiatives ( for future and new plant expansions)

A chart of annual cost savings versus capital investment will be developed.

A phased implementation schedule shall be recommended.

In addition, a summary sheet shall be prepared for each individual recommended


project, detailing the concept, motivation, benefits, costs, and potential risks.

Deliverables

The Assessment Team shall prepare a draft report, and present the key assessment
findings to plant management and engineers. Based on their feedback, the vendor
shall prepare the final report, including the detailed information of the projects
agreed upon. The preliminary information available about the initiatives which
have been rejected shall also be include but in the report appendices.
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Document Responsibility: Energy Optimization & Co-Generation Standard Committee


SABP-Z-034
Issue Date: 8 January 2014
Next Planned Update: TBD
Industrial Facilities Energy Assessment Study Guidelines

Preliminary economics sufficiently accurate to make the right decision for future
project(s) conceptual design stage using simple payback and NPV calculations of all
recommended projects shall be included.

The consultant/contractor shall assist/enable the proponent in the preparation of


initiatives definitive assessment/conceptual design and future business cases for top
ranked energy projects by providing the vital technical and economic data required.
Capital costs shall be estimated based on literatures; previous experience formulas
and vendor quotations for major equipment.

The contractor shall provide a 2-day workshop introducing the State-of-the-Art


technologies on energy optimization as well as training for selected engineers on the
use of off-line CHP models for analysis, if any.

Mark-up PFDs and Plot plans, if necessary, should be provided for major design
modifications initiatives.

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