Sabp A 060 PDF
Sabp A 060 PDF
Sabp A 060 PDF
Table of Contents
1 INTRODUCTION .............................................................................................................................................. 2
1.1 PURPOSE ................................................................................................................................................. 2
1.2 SCOPE ..................................................................................................................................................... 2
1.3 INTENDED USERS ....................................................................................................................................... 2
1.4 REFERENCES AND RELATED DOCUMENTS......................................................................................................... 3
2 GENERAL ........................................................................................................................................................ 3
2.1 DEFINITIONS............................................................................................................................................. 3
APPENDIX A ......................................................................................................................................................... 20
APPENDIX B ......................................................................................................................................................... 23
I. COMBUSTION EFFICIENCY/FUEL AIR RATIO ............................................................................................ 23
II. FLASH STEAM.............................................................................................................................................. 23
III. CONDENSATE REMOVAL FROM STEAM LINES........................................................................................... 23
IV. OPTIMIZE DEAERATOR VENT RATE .......................................................................................................... 24
V. HIGH PRESSURE CONDENSATE RECEIVING SYSTEMS ............................................................................... 24
1 Introduction
Most of the guidance contained in this best practice is not intended to be a comprehensive
technical guide on improving steam systems or called Combined Heat and Power
Systems - CHP, but rather a document that makes users aware of potential performance
improvements, provides some practical guidelines, and directs the user to helpful
resources. A systems approach analyzes the supply and the demand sides of the system
and how they interact, essentially shifting the focus from individual components to total
system performance. The cost-effective operation of CHP systems require attention not
only to the needs of individual pieces of equipment, but also to the system as a whole.
Often, operators are so focused on the immediate demands of the equipment; they
overlook the broader question of how system parameters affect the equipment.
The best practice SABP-A-23 provided an overview of the (CHP) models. Its main
objective is to explain how to develop CHP systems models that can be used to
optimize steam system at operating facilities. However, to capture operational
modifications from the CHP systems we need to have an online advisory and
model/system. Unfortunately, the number and quality and accuracy of the existing
measurements are not sufficient to build such models. Thus, a high level advisory tool
is required to help operating facilities capture key operational changes in the steam
system which is the objective of this best practice.
1.1 Purpose
1.2 Scope
This Best Practice is intended for use by the CHP' operation engineers and
plants shift superintendent and plants energy coordinators who are responsible
for efficient operation of their facility.
Page 2 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
International Standard
2 General
2.1 Definitions
CHP Systems: Is defined as combined heat and power systems. Its basically
composed of the steam systems components of a major oil and gas facility.
The system may involve steam headers, boilers, cogeneration units, steam
turbines, major motors driving large equipment, letdown stations,
de-superheaters, deaerators, process heat exchangers, condensate returned
system and make-up water system. The name CHP system is applied here,
because the thermal efficiency of such a system is in the 70% range which is
close to Cogen or CHP system efficiency.
CHP Model: Is basically a model simulating the CHP systems and include
optimization layer to optimize and provide a better solution of a given operating
mode. SABP-A-023 describes the CHP model in more details.
Page 3 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Load Management (LM): An operating policy that distributes the load among
multiple machines or equipment installed as series-parallel networks in a way
that minimizes their energy (fuel + power) consumption, without compromising
safety or reliability.
Page 4 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Note -1: For a facility with fired heaters (furnaces) along with convection section
producing steam at different pressure headers, then, 90% shall be used
for calculating its fuel consumption in the equation. For fired heaters with
air-preheating use 70% and for fired heaters with no heat recovery use 55%.
For simple cycle gas turbines use 32%.
Note -2: For existing facility, the minimum efficiency requirement is not a mandate.
The selection criteria among several alternatives for such projects shall be
based on economic analysis (NPV). In case economic analysis resulted in
equivalent NPV for some alternatives, then system efficiency improvement
from base case is the selection criteria for the best.
Note -3: In case the new or existing facility is importing power, the fuel value for this
imported power in the efficiency formula shall be based on the following:
a. For projects require the installation of new cogen trains and STGs with
net power production over 200 MW, then SEC efficiency factor in the
formula shall be based on Combined Cycle of 50%.
b. Otherwise, SEC efficiency factor in the formula shall be based on the
overall average efficiency of SEC network at this operating area
according to Portfolio Analysis Department.
Page 5 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
In addition to the opportunities identified in Table 1 and the appendixes; CHP system
studies for various facilities within Saudi Aramco have demonstrated the existence of a
substantial potential for energy efficiency improvement in almost all facilities within
the following three initiatives;
1. Minimizing excess steam via the optimum operation of steam turbines and motors
2. Maximizing Cogeneration units operation if available
3. Boilers load management (maximize loading on high efficient boilers)
The deployment of this best practice on CHP systems optimization would help
operations to capture high savings with almost no investment cost. This best practice of
a steam system operation focuses on these three main initiatives. These offer the most
low investment opportunities, while other opportunities may require higher investments.
In general, all projects require operating costs as well as engineering resources to
develop and implement the project. Every facility will be different. The most favorable
selection of energy efficiency opportunities should be made on a plant-specific basis.
The high excess low pressure steam of a facility is a key indicator of its
inefficient operation. Huge energy is being wasted in form of excess
steam, while, most of this energy can be captured through operational
changes. Thus, its very important to start with checking this area in our
operating facilities and ensure its been reduced to the minimum level
possible. We can till if the operation is inefficient if there is high excess
steam from LP side and the led-down stations between headers are passing
high steam flow. In this we can reduce boilers load and minimize excess
steam in all headers. However, if the steam reserve condition is limiting
doing so, then plant operation need to justify why having more reserve
than required. Below example will give some idea about the potential
benefits can be realized from reducing the excess steam at LP.
There are several technologies can be used to recover the excess low
pressure steam such as: condensing steam turbine generator,
Absorption chillers, water desalination or ORC. Thus, techno-
economical evaluation has to be conducted to identify the best
option. The use of a condensing turbine for power generation,
compared to a fin fan condenser adds additional power generation
flexibility to operating facilities steam system. However, compared
to back pressure steam turbines and depending on site specific steam
Page 6 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
In order to deploy the implementation of this best practice, we need to do the following:
1. Include all required information in the daily morning report prepared by operations
(list of all information required is shown below)
2. Establish a simple steam balance diagram from PI process flow diagram and
include key information
Page 7 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
3. Identify amount of excess steam, let down steam flow, and cogen operations, etc.
4. Follow flow chart to optimize system
5. Make actions for operations to optimize
This flow chart summarizes Section 6, and provides high level directions according to a
given mode of operation. It focuses on key areas of the steam system; the excess steam
from low-pressure steam header, steam flow in let-down stations, cogeneration units
load and boilers load management.
Page 8 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Following the flow chart seems is not so difficult, however, the challenge comes from
getting the information of the steam balance on real time basis. As some of
measurements are not connected to PI or could be there is no measurement which
makes it difficult to follow the flow chart. Thus, its very important to establish the
steam balance for the site with reasonable accuracy level.
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Figure 1 - CHP Operational Implementation Flow-Chart
Step # 1
No Check Yes
IF there is LP excess steam through
LP fin fan condenser,
(Excess LP > 50 kIb/h)
No Yes
Check IF
Cogens are No
Maximized Check IF the excess LP
Steam >
RS (HP-LP or MP-LP)
Yes
In case Boilers at
Apply Boilers Load No minimum load then
Go to: Step # 1 Apply switchability till
Management check steam reserves
you have minimum LP
(BLM) and if possible turn
excess steam + reduce
boiler load off one boiler
through(BLM)
Check IF RS (HP-MP, Check if RS (HP-LP) &(MP-LP) > 50 KIb/h,
No operational
No
MP-LP) >50 Then, check Then:
changes, Potential switchability & run Minimize RS -flow to zero if possible via
New STG Investment. more ST turbines & boiler load management + If not possible, then
Stop motors Minimize excess steam to LP reduce Cogen load &
End its steam production
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Yes
8 Case Study
The following cases provides general insights for CHP operation to enhance the overall
performance of the plants steam system. Flow-chart would help operations to achieve
a better performance.
In this case study, the example covers an operating facility with the following
requirements:
The facility has two cogen units and four (4) boilers with the following details:
The facility has two cogen units with the following details:
Table 4 - Cogen Related Information Based on Different Load and Ambient Temperature
[kpph]
Tamb[C] W [MW] GT [%] HR [BTU/kWh] FF [MMSCFD]
(600psig)
50 87.22 33% 10378.96 22.51 329.01
59 84.47 33% 10450.96 21.95 326.7
68 81.67 32% 10534.28 21.4 324.36
77 78.98 32% 10622.97 20.86 322.35
86 76.23 32% 10724.51 20.33 320.3
95 73.48 31% 10837.97 19.8 318.19
104 70.74 31% 10963.43 19.29 316.15
113 67.74 31% 11111.54 18.72 312.47
122 64.65 30% 11279.47 18.13 307.47
The facility has process heaters equipped with heat recovery generating steam at
different pressure headers summarized as follows:
The goal of this case study, is to show the difference in the facility total operating cost
and efficiency from one operating mode to another. The operating cost consists of fuel
cost, electrical power export / import tariffs, make-up and chemical treatment cost.
In the base-case, it was assumed that the plant is operating with 250 klb/h of excess LP
steam. 2-cogen units are maximized, 2-boilers are running taking into consideration the
optimum load management. Turbines and motors are optimized.
In cases from 1-5, we will see the difference between each operating mode and we will
see how effective to follow the flow chart above to achieve a better performance and to
be close to the optimum operation mode.
Page 12 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Figure 2 - (Case-1) High Excess Steam from LP Steam Header, Cogen is Max., with Boilers LM and with Drivers LM
Page 13 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Figure 3 - (Case-2) Min Excess Steam from LP Steam Header, Cogen is Partial, with BLM, and Drivers LM
Page 14 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Figure 4 - (Case-3) Min Excess Steam from LP Steam Header, Cogen is Max., with BLM, and with Drivers LM
Page 15 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Figure 5 - (Case-4) Min Excess Steam from LP Steam Header, Cogen is Max., without BLM, and with Drivers LM
Page 16 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Figure 6 - (Case-5) Min Excess Steam from LP Steam Header, Cogen is Max., with BLM, and without Drivers LM
Page 17 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Page 18 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Revision Summary
18 January 2016 New Saudi Aramco Best Practice. The purpose is to establish a simplified flow-chart and
procedure to be used by CHP operations to help them improve operating facilities steam
systems. It will help capturing key CHP systems operational changes at the sites and
improve plants energy efficiency. The scope of this best practice is to provide
recommendations for DCS operators and operation engineers to capture energy savings
opportunities. This is done via ensure having maximum operation of Cogeneration units,
minimizing excess low pressure steam via the optimum operation of steam turbines and
motors and utilizing Boilers load management. The intended Users of this Best Practice
are operation engineers and plants shift superintendent and plants energy coordinators
who are responsible for efficient operation of steam systems at the facility.
Page 19 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Appendix A
Some general tips and best practices for CHP operation to follow:
Use heat recovery of flue gas where possible to preheat incoming combustion air.
Eliminate or reduce all sources of undesired air infiltration into the furnace.
Perform proper maintenance on a regular schedule to reduce soot and other deposits
on heat transfer surfaces, thus ensuring efficient transfer of heat to the process.
Ensure burner is operating properly and most efficiently within the limits set by controls
and operators.
Install a blowdown heat recovery device. This will generally include two methods of
recovery, heat exchanger and flash steam generation.
Page 20 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Continually inspect steam distribution and condensate return lines for leaks and repair
as necessary.
All pipes or tubes should be welded, which minimizes leaks as the pipe expands and
contracts during heating and cooling cycles. Welding also eliminates leaks from
corrosive carbonic acid in the system, which is formed from carbon dioxide in the air
and water.
Flanges are utilized in applications larger than two inches where maintenance or
removal may be required.
All steam supply and condensate return pipes should be properly supported,
guided, and anchored, allowing for expansion of the pipes during temperature
changes. A structure that is too tight can deform pipes and cause leaks.
Always connect the branch line to the top of the main steam line. This will ensure dry,
saturated steam to the process.
Use proper drip-pocket steam traps, correct branch connections, and installation
procedures where applicable.
Install and maintain proper insulation on all steam and condensate return lines.
Ensure proper pipe sizing is used to maintain correct velocities in steam line based on
specifications of operation.
Implement the use of steam filters throughout the process steam system.
Page 21 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Standard operating procedures for using air vents at startup should be instituted.
Ball valves with a class four shutoff should be used in conjunction with air vents.
Consider corrosion coupons for the piping of condensate systems. This will help
determine chemical treatment effectiveness and gauge the condition of the piping.
All heat transfer units require vacuum breakers. (Check valves that have been
installed backwards do not suffice as vacuum breakers.)
Page 22 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
Appendix B
Page 23 of 24
Document Responsibility: Energy Systems Optimization Standards Committee SABP-A-060
Issue Date: 18 January 2016
Next Planned Update: TBD Steam Systems Operational Energy Efficiency
The condensate volume will depend on the steam line insulation, steam pressure, and
steam line length. The condensate will flow with the steam at the bottom of the steam
line in a swaying motion (not a straight line); thus the steam line drip pocket must be
large (drip pocket is the name of the branch line extending down).
Where to install condensate removal drip pockets on the steam lines
All low points
Any change of direction
All valves that could be in the off position (control or isolation)
Every 500 feet of straight steam piping
Drip pockets must be properly sized
Drip pockets must be properly installed
iv. Optimize Deaerator Vent Rate
What is the Correct Venting of Steam? The rule of thumb in the deaerator industry is that
the vent valve passes a maximum 1/10 of 1% of the deaerator capacity. The exact vent
rate can be calculated as follows:
Vent Rate in lbs/hr = 24.24 x Pa x D
Where:
Pa = Deaerator operating in PSIA (absolute)
D = Diameter (inches) of opening in the manual valve or orifice
The minimum loss of steam is a requirement in all plant operations and one area to ensure
no unnecessary loss is occurring is the deaerator operation.
Best Practices
1. Visual inspection of the vent from the deaerator operation
2. Check the venting mechanism for proper sizing
3. If unknown, consult with the deaerator manufacturer
4. Use a stainless steel needle valve instead of a gate valve for better performance
v. High Pressure Condensate Receiving Systems
Before changing everything to a medium or high pressure condensate system, the first
step is to insure the steam system and the steam processes will be able to operate with the
desired system. Flash Steam Recovery Systems (Non-modulating steam conditions)
Condensate and flash steam (two-phase flow) discharging from a non-modulating
steam system process can operate with a medium or high pressure condensate system.
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