Best Practice

SABP-Z-034 20 January 2016

Industrial Facilities Initial Energy Assessment Study (IEAS) Guidelines
Document Responsibility: Energy Systems Optimization Standards Committee

Contents
1 Introduction…………………………………….. 2
2 Definitions………………………………………. 2
3 Purpose of Document and Intended Users…. 3
4 Planning Initial 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………….… 8

Previous Issue: 8 January 2014 Next Planned Update: TBD

Revised paragraphs are indicated in the right margin Page 1 of 14
Primary contact: Farooq, Zeeshan (farooqzx) on +966-13-8809465
Secondary contact: Kamel, Akram (kamelah) on +966-13-8809452

Copyright©Saudi Aramco 2016. All rights reserved.

Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

1 Introduction
Initial 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 “Initial energy assessment Study”. Initial energy assessment
study might be initial, definitive and details and each of these types of energy
assessments has its own approaches, methods and tools. Initial 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 initial energy assessment studies is to enable the process/ plant/
facility/ site to reach a near-optimal performance that minimizes 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
Initial Energy Assessment Study (IEAS): 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.
Definitive Energy Assessment Study (DEAS): The process of transferring identified
energy optimization idea(s)/initiatives to engineered solution(s).

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

Consultant: The expert or Company who conducts the Initial Energy Assessment study.

CHP: Combined Heat and Power

ECA: Energy Conservation Action or Initial 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 Initial 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 Initial 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 Initial energy assessment study for their plants. Energy conservation
engineers and plants energy coordinators who are going to review Initial 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. This document does not
apply to Capital Projects Energy Assessment studies (ESAS) and Definitive Initial
Energy Assessment Studies (DEAS). (ESAS) is covered in Engineering Procedure
SAEP-42, Capital Projects Efficient Energy Systems By-Design and (DEAS) is covered
in SABP-A-062, Definitive Initial Energy Assessment Study Guidelines.

4 Planning Initial Energy Assessment Studies

Proper planning is essential for conducting and getting maximum benefits from initial
energy assessment studies for any facility. Planning of initial 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. Figure 1 illustrates the main phases during an initial energy assessment study.
Initial 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 initial energy

assessment study for their facility. In-house initial energy assessment study
requires an Engineering Service Agreement which needs to be established using
Customer Relationship Management (CRM) System. In addition, P&CSD/EEU

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

shall be contacted and notified of the planned study during the Operating Plan
period to secure the required resources in advance accordingly.

Initiation

Scope of Work Development

Engineering Services Agreement

Brainstorming

In Process Modification
Data Collection & Validation
Equipment Performance Analysis
Load Management Analysis
Technical Analysis CHP Analysis & Supply Targets
Initiatives Identification Pinch Analysis & Demand Targets

Initial Techno Economic Evaluation Develop Priority List

Project summary and Roadmap Agree on High Potential Initiatives/Projects

Propose Scope of work for DEA

Report and Presentation Project Submission to FDP

Close Out

Figure 1 - Initial Energy Assessment Study Main Phases/Elements

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

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

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 as per SABP-A-058.

5 Study Frequency

Frequency of Initial energy assessment studies mainly depends on the complexity of the
facility. Complexity of all facilities have been categorized into three categories:
a. Complex Facilities: Such as Refineries, Gas Plants, NGL Recovery Plants, NGL
Fractionation Plants where frequency of Initial energy assessment study is
recommended to be 4-5 years.
b. Semi-Complex Facilities: Such as Abqaiq Plants, Shaiybah Producing, Khurais
Producing, SAF Onshore where frequency of Initial energy assessment study is
recommended to be 5-6 years.
c. Simple Facilities: Such as Pipelines, Distribution, Terminal, GOSPs, where
frequency of Initial energy assessment study is recommended to be 6-7 years.

The frequency of initial energy assessment study could be relaxed if the facilities did
not undergo any projects expansions or changes such as operation modifications.
Project master plan for the facilities could be utilized in setting the required frequency
and the timing of Initial energy assessment studies.

6 Study Scope of Work

The scope of Initial 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 initial 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.

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

b) Serve as a mean of 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
In-House studies).

For any subsequent studies after the initial energy assessment study for the facility,
consultant must check and verify all identified recommendations from previous Initial
energy assessment study prior conducting a new one. If previous Initial 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 Initial energy assessment Study or Definitive Energy Assessment Study
(DEAS).
b) Revalidate the economic feasibility of the non-implemented recommendations of
the previous Initial energy assessment Study.
c) Inclusion of Saudi Aramco approved/piloted New Technologies related to energy
optimization/conservation.
d) Update/optimize CHP Model for new conditions.

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

7 Study Recommendations Implementation

The intended energy optimization cannot be achieved if Initial 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 Initial Energy Assessment Study is completed.

8 References

There are several Saudi Aramco Best Practices that can be referenced by the Energy
Team to conduct Initial 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 Initial energy assessment
studies:

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

Table 1 - List of Saudi Aramco Best Practices

and Engineering Procedures for Energy Conservation

No. Abbreviation Title

1 SABP-A-002 Load Management for Energy Efficiency: Pumps and Compressors

2 SABP-A-008 Load Management for Energy Efficiency: Heat Transfer Equipment

3 SABP-A-009 Pinch Technology for Energy Efficiency Optimization

4 SABP-A-023 In-House Combined Heat and Power Optimization Model

5 SABP-A-030 Energy Assessment for Efficiency Optimization in GOSP

Quick Energy Assessment Methodology for Energy Efficiency
6 SABP-A-005
Optimization
7 SAEP-A-062 Definitive Energy Assessment Study Guidelines

Revision Summary
8 January 2014 New Saudi Aramco Best Practice.
20 January 2016 Minor revision. Initial Energy Assessment has been differentiated from Definitive Energy
Assessment which requires different scope of work. In addition, Initial Energy Assessment
Study main phases/elements has been added as well as List of Saudi Aramco Best Practices
and Engineering Procedures for Energy Conservation.

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

Appendix A - Generic Scope of Work

Initial 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 Initial energy assessment study.
● Conduct a workshop about “Initial 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 Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial 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 Initial 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 Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

Initial 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 plant’s “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 Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

Initial Energy Assessment Study Detailed Tasks

Mobilization
o Logistic arrangements (i.e., Saudi 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.
o Identify/assemble core team from the facility, and “CONSULTANTS”
o Preliminary planning and kick-off meeting at the facility
o 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&ID’s) 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.
o Obtain and compile updated baseline energy data (from DCS or PI system), for
production rates, fuel use, steam and power consumption.
o 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.
o Evaluate data quality and process variability in order to establish the design
basis (use data validation and reconciliation techniques, if required).
o Prepare fuel, steam, power users list, and establish a balance between
consumption and production.
o 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.
o Preparing baseline Simplified Heat Flow Diagrams (proprietary tools) for each
process unit (Big Picture).
o Obtain pumps, compressors, turbines, and furnaces operating data.

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

o 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.
o Prepare a baseline energy balance. Produce a summary of energy usage, by
equipment in relation to the design basis production rate(s).
o Energy and utility costs will be calculated using the guidelines prescribed by
Saudi Aramco.
o 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.
o 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).
o Analysis of Temperature Profiles for the process to identify potential heat
recovery/process modifications.
o Preparation of Simplified Heat Flow Diagrams to demonstrate heat flow in each
process unit as well as to demonstrate recommended modification in simple
layout.
o Identifying potential heat recovery improvements and representing them on the
Simplified Heat Flow Diagrams.
o Analysis of Pressure Profiles for the process to identify potential power
recovery.
o Building Combined Heat and Power (CHP) system model (off-line).
o Assessment of the CHP system to identify and evaluate potential improvements.
o Performance Analysis of major equipment.
o Load Management analysis of major pumping and compression systems.
o Adjustable Speed Drives (ASD) analysis for major pumps and pumping
systems.
o Brainstorming sessions with proponent to capture operational energy saving
opportunities.

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial 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.
o All initiatives should comply with Saudi Aramco’s safety health and
environment standard.
o 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.
o 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)
o A chart of annual cost savings versus capital investment will be developed.
o A phased implementation schedule shall be recommended.
o In addition, a summary sheet shall be prepared for each individual recommended
project, detailing the concept, motivation, benefits, costs, and potential risks.

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Document Responsibility: Energy Systems Optimization Standard Committee SABP-Z-034
Issue Date: 20 January 2016
Next Planned Update: TBD Industrial Facilities Initial Energy Assessment Study Guidelines

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.
● 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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