Pcsd newsletter-special edition-2007

Downstream Upstream Control Instrumentation

A Patent on Hydrogen Computer Modeling Yanbu‘ Gas Plant Key Elements for Oil &
Purification Optimization of rate of change with Dynamic Optimizer Gas Wireless Networks
System is Granted applications in Pipeline Implementation
Protection and check
valves economic selection

“Knowing is not enough; we must apply.
Being willing is not enough; we must do.”
Leonardo Da Vinci
Issue No. 8 Special Edition 2007 Leaders in process engineering and automation

Message from
Vice President
It gives me a great pleasure to reach out to our

customers in this issue of the Process and

Control System Department (P&CSD)

newsletter. Our goal at P&CSD is to

communicate our dedication to the continuous

improvement of facilities' business performance.

The development of new leading edge technologies is one of our main
“We all
drivers in the engineering strategies to achieve operational excellence.
committed to
We focus on deploying proven process and control technologies that will

give our company a competitive edge. As the main stakeholders, our support our

customers’ participation and collaboration are essential to the success of facilities with
the development and implementation of these technologies. leading edge

technologies to
We are all aware of the global shortage in technically skilled job
achieve
candidates. Engineering Services is leading an initiative to develop that
operational
talent in-Kingdom using technical competency maps. These maps focus on

required technical competencies that can be acquired by attending excellence.“
training courses, achieving professional certifications, participating in

technical exchange forums and professional society events, as well as

learning practical engineering skills in the field. Technical competency

maps will guide the development of more than 5000 engineers in our

surface facilities. By remaining competitive, we will improve the lives of

our people, diversify and grow our economy, and ensure that Saudi

Aramco will remain a leader in the oil & gas industry.

Isam Al Bayat

Contents
Process & Control Systems
Department Newsletter

15 JRD/FCCU MTC Technology
Evaluation by FCC Aspen
Kinetic Model

7
Troubleshooting YR
Cyclemax Regenerator
Catalyst Blow out
16
P&CSD Technology
Partnership Meeting with
YR and RTR

20
Saudi Aramco’s Fuel
8 Distillation Workshop

Quality Roadmap

P&CSD Supports Local
21
11 A Patent on Hydrogen
Purification Optimization is Professional
Granted Societies: AIChE-SAS

Application of Flare
12 22 Rate of Change
Modeling

Gas Recovery
Systems in Saudi
Aramco facilities
TORR Technology for
25
Produced Water
Treatment

Suggested topics and related technical articles for this
newsletter are encouraged and welcome, and may be

28
submitted to Abdulaziz Tijani, EOB, E-3410, Dhahran 120 120

100 100

or e-mailed to tijaniah@aramco.com
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ReL ReImp

Process & Control Systems Newsletter is published Basket Impeller Column:
250 250

200 200

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100
100
50
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Bi-annually by the Process & Control Systems Department
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30 Data Validation and
Reconciliation
A Crucial Technology for
44
Industrial Time
Processing Plants Synchronization

32
Optimizing Projects with a
Main Automation Contractor 46
Trim Integrity for
Compressor Anti-
surge Valves

36
Advanced Multivariable &
Regulatory Control
Performance Monitoring 48
Industrial Wireless LAN
Security For Oil & Gas
Process Automation
Networks
38
Yanbu‘ Gas Plant
Dynamic Optimizer
Implementation
Process Automation
Alarm System Improvement 51 Focus Team Update

40 at AINDAR GOSP-2

42 52
Engineering the
Automatic Valve Future
Characterization – Why
didn’t we think of that?

43
Key Elements for Oil & Gas
Wireless Networks
54
Safety of the Issue
HOT SPOT

VISION - To b e c o m e l e a d e r s i n p r o c e s s e n g i n e e r i n g a n d a u t o m a t i o n !

Letter from the Team
“The link between Innovation,
Plant Experience, and Hard Work”
Newsletter team: Abdulaziz Tijani, Omar Halawani, Jim Sprague, Jim Anderson

Do you ever wonder how our Saudi Aramco
innovators come up with such good ideas? Are they
born inventors, bred with special imagination? We
think not. Our view is that innovation in Saudi Aramco
is much like it was in Thomas Edison’s day, “90%
Abdulaziz Tijani perspiration and 10% inspiration”.
Now you may ask, where does all that perspiration
come from? Well, in our view, a large part of it comes from an
innovator’s early years working at the plant, dealing with
process and control problems every day — day after day. You
work and expend so much energy that the process and its
Omar Halawani
problems are burned into your consciousness. And guess what,
that’s a good thing! Because in the end, all those years of
perspiration make you what you are — an experienced
specialist with a keen understanding of your plant and its
problems.
Now here is where the innovation part comes in. If that
Jim Sprague
experienced specialist keeps a sharp eye out — he will
ultimately come across some new technology, gadget, or
combination — that can solve one of those problems.
Sometimes the technology is already applied somewhere else,
and the innovation is applying it to your application.
Jim Anderson Sometimes it’s combining multiple technologies into one to

4 Process & Control Systems Department Issue No. 8 – Special Edition 2007

MISSION - We i n n o v a t e a n d o p t i m i z e o p e r a t i o n s f o r i m p r o v e d p e r f o r m a n c e t h r o u g h l e a d e r s h i p
and professional services in process engineering and process automation!

come up with a solution. The next important step is to sell and
implement that solution. Innovation thrives on risk and change.
It is important to understand that new ideas and solutions come
from an attitude, an environment, and a culture that embraces
change.
We know that the world is changing faster than it ever
has before and that everyone is part of that change. The old
“It is saying of “I paid my dues” has become as obsolete and
important to
outdated as the typewriter. Today, as an engineer, your dues are
understand that paid daily. This means that each of us as a customer, supplier, or
new ideas and employee is being evaluated on a daily basis with an ever
changing measurement. The key is to stay on top in our field
solutions come
through continuous learning and updating our experience and
from an
knowledge. Saudi Aramco’s learning organization initiatives
attitude, an can certainly help.
environment,
In the end, innovation comes from the following:
a culture that
• the experienced and knowledgeable engineer with
embraces • watching out for solutions while
change.. ” • anticipating change and managing risks.
So, for those of you who are gaining work experiences
– and that should include all of us – you are Saudi Aramco’s next
innovators. Just make sure you keep your eyes open for the
solutions.
Remember — rarely does innovation just happen:
instead, it is nearly always born in the struggle to solve a
problem. Sometimes that innovation solves a completely
different problem in a very unanticipated way.

Sincerely,
P&CSD Newsletter Team

Process & Control Systems Department Issue No. 8 – Special Edition 2007 5


Professional Engineers in P&CSD
Licensure and certification are the mark of a professional. It demonstrates a commitment to the high standards of
professionalism to which the engineering profession subscribes.

Licensure and certification are important because they demonstrate the accomplishment of a set of standards to which
all engineering professionals recognize. The following engineers in P&CSD carry professional engineering
licenses/certifications in various areas that demonstrate their accomplishments to internationally recognized standards.
Other engineers are presently pursuing licenses/certifications.

Name Unit License/Certification

Instrumentation, Control & Automation
Jim E. Anderson APCU Certified Automation Professional (CAP), ISA
Steve Wagner APCU P.E. (Canada)
Henry Chan APCU P.E. (Ontario, Canada)
Mohammed Salim CMU MIET CEng (Member of Institute Engineering &
Technology - Chartered Engineer)
Zia Soofi CMU P.E. (Texas, USA)
Ralph Hartman IU P.E. (Texas, USA)
Doug Esplin PASU P.E. (Utah, USA)
Farrukh Chawla PASU P.E. (Ontario, Canada)
Hashim Ghalib PASU Certified Automation Professional (CAP), ISA
TüV/CFSEGB Certified Functional Safety Professional
Austin Brell PASU P.E. (Chartered Engineering License with European
Counsel of IChemE),
TUV Certified Functional Safety Professional
Computer Networking
Abduladhim, Abdullatif CCNU Registered Communications Distribution
Designer, by BICSI
Abdullah Nufaii CCNU Certified Wireless Network Administrator (CWNA)
Mohammed Saeed CCNU Certified Wireless Security Professional (CWSP),
Cisco Certified Design Professional (CCDP),
Cisco Advanced Wireless LAN Specialist (CAWDS),
Cisco Certified Design Associate (CCDA),
Cisco Certified Network Associate (CCDA)
Soliman Walaie CCNU Certified Wireless Networks Professional (CWNP)
Process Engineering
Gene Yeh DPED P.E. (Louisiana, USA)
Sam Zoker DPED P.E. (Texas, USA)
Prasad Pantula DPED P.E. (Corporate member for Engineer’s Australia)
Gabriel Fernandez OPU P.E. (Alberta, Canada)
Jack Dempsey P&SU Chartered Engineer Registrant for the Engineering
Council (UK)
Pierre Crevier UPED P.E. Chemical Engineer (Alberta, Canada)
Saleh Mulhim UPED P.E. (Texas, USA)
Yuv Mehra UPED P.E. (Texas & California, USA)



P&CSD Technology Partnership Meeting with YR and RTR

P&CSD held one-day “Technology Partnership Meetings” in May and June at Yanbu‘
and Ras Tanura refineries, in line with Engineering Services business line’s strategic
initiatives to accelerate technology exploitation.

The meetings were organized to promote a selected for further evaluation through an Engineering
Service Agreement (ESA) between the two refineries. The
technology culture among refinery personal
brainstorming sessions in YR and RTR were facilitated by
and provide a platform for engineers to Engineering Services’ performance consultant and the
brainstorm new technologies that could be leadership center in Dhahran.
deployed in a partnership between the
refineries and P&CSD. Another goal was to Forty-five engineers participated in the Yanbu’ Refinery
increase the awareness of Saudi Aramco’s meeting from Saudi Aramco, Saudi Aramco Mobil
Refinery (Samref), Saudi Aramco Lubricating Oil Refinery
technology program.
Co. (Lubref), American company Honeywell and
At the meetings, the Research and Development Center’s Honeywell subsidiary UOP. The Ras Tanura meeting was
Technology Management Division presented an overview attended by 33 engineers.
of the center’s technology program to encourage future
Both meetings were coordinated by Mohammad
participation by employees attending the meetiing.
Balamesh and Saeed Al-Alloush from P&CSD’s Catalytic
P&CSD representative then discussed three new
Conversion Unit.
technologies that were successfully implemented at the
two refineries after P&CSD evaluation, and a Yanbu‘
Refinery representative talked about new technologies
that have been implemented at that refinery.

Fruitful brainstorming sessions conducted at the meetings
identified more than 70 technical items important to the
two refineries. The items were categorized, and 11 were

Right: Brain Storming Session at
Rastanura Refinery

Below: Yanbu‘ Refinery Gathering



Saudi Aramco’s Fuel Quality Roadmap
Author: Walid A. Al-Naeem

A cross-functional team composed of EPD, FPD, RTSD, OSPAS, and chaired by
P&CSD was charged with the development of a transportation fuel quality
roadmap to enhance the overall gasoline and diesel qualities to be environmen-
tally friendly.

This team along with a reputable consultancy firm IFQC the Green House Gases (GHG) – the main cause of climate
(International Fuel Quality Center) has done extensive change. Saudi Aramco believes that the best way to
data gathering and analysis to develop the roadmap. The combat climate change is to look forward and act
main parameters that are affected by the roadmap is a proactively. So far, Saudi Aramco has already taken
reduction in sulfur content in both the gasoline and diesel serious steps to improve the environmental situation in
products to 50 ppm & ultimately to 10 ppm, a reduction the Kingdom by establishing an Environmental Master
in the gasoline benzene to 1.0 vol. % or less, and a Plan that addresses all sources of contamination to the air,
reduction in benzene aromatic contents to 35 vol. %. earth, and water. This master plan was endorsed by the
These reductions is planned to take place at different Saudi Aramco board in 2001.
stages of the roadmap.

Those stages are:
So far, Saudi Aramco has
Step 1: Immediate operational changes that do not
require capital investments. already taken serious steps to
Step 2: Changes that require capital projects and can
improve the environmental
be implemented by 2013.
Step 3: More stringent specifications that require situation in the Kingdom by
additional capital projects to step 2 and can
establishing an Environmental
be implemented by 2016.
Master Plan that addresses all
Background
Today, the world’s policy makers and business leaders are sources of contamination to the
increasingly in agreement that climate change is
occurring and it has to be addressed. As a responsible air, earth, and water.
corporate citizen, Saudi Aramco is committed to reduce

Figure 1 Gasoline Quality Roadmap Figure 2 Diesel Quality Roadmap



The primary objective of the master plan is to bring all
Saudi Aramco facilities into compliance with the
government environmental regulations. It is also in line
with the company’s strategic initiatives to protect the
environment and ultimately improve public health.

In addition and due to high sulfur levels in transportation
diesel, which eventually contributes to high SO2 emissions,
the company has decided to include transportation diesel
fuel into the master plan with the idea of addressing
other fuels and air pollutants in the future. As a result,
the master plan has recommended to lower sulfur in
transportation diesel from 10,000 ppm to 500 ppm
mitigating SO2 emissions from diesel engines.

Figure 3 Sophisticated Emission Control Systems

As a result, the master plan has
Impact of Fuel Quality on Vehicle
recommended to lower sulfur
Performance
in transportation diesel from There is without doubt global recognition that climate
change abatement and the drive toward lesser GHG can
10,000 ppm to 500 ppm only be achieved if vehicle manufacturers, refiners and
legislation work together. Since fuels and engines are
mitigating SO2 emissions from technically linked with each other, the improvement in
gasoline and diesel fuels quality will permit the adoption
diesel engines.
of up-to-date low emission engines in the kingdom as
opposed to the currently available. It is important to
mention at this point in time that vehicle manufacturers
have been supplying high emission vehicles to the
Future Environmental Challenges kingdom in the past and they continue to do so at the
to KSA present time. This is because their up to date engine
Since future challenges are always their ahead of us, components are very sensitive to high sulfur fuels, which
Saudi Aramco has taken proactive measures by will cause it to be in-effective in a short while. For
establishing the fuel quality roadmap (Figures 1 & 2) that example, NOx and PM pollutants require special emission
will ensure compliance to the government environmental control systems to be embedded into the vehicles to trap
regulations at all times. and convert those pollutants into friendly gases. For
those systems to operate efficiently (Figure 3), sulfur in
The fuel quality roadmap, which was recently both gasoline and diesel fuels need to be further reduced
approved by the company board, has provided an from 500 ppm to 50 as an intermediate step and
ultimately to 10 ppm. At 10 ppm the emission control
update to the existing environmental master plan,
systems will give the utmost optimum performance that
bearing in mind the following future challenges:
will drastically mitigate the NO2/PM emissions to the least.
• The kingdom has high urbanization level, Therefore, it is clear that reduction of NO2 and PM
meaning that people tend to move to bigger cities emissions are solely dependent on low emission engine
which ultimately cause high population and traffic technology. To introduce those low emission engines to
densities, especially in Riyadh, Jiddah, Makkah, the kingdom’s fleet, it requires around 18 years to have
and Dammam. full replacement of our high emission vehicle fleet. As a
result, the actual realization of NO2 and PM emissions
• Since 1998 the number of registered vehicles has reduction will take more time as compared with the other
increased by 45%. pollutants.



For this year, it is planned to conduct two workshops for
scientists during December 9–10, 2007, and for executives
during December 11, 2007. The objective of this year’s
workshops is to underscore, at a strategic level, the inter-
On the other hand, the required relation between stringent fuel specifications, engine
performance, environment protection and the
capital investment program sustainability of oil market. Several other concepts will be
addressed, as well as the future of Dieselization and the
associated with implementing Kingdom’s environment, as a result of the recently
approved Fuel Quality Roadmap.
the long term strategy of the
roadmap has been recently
approved by the company Today, the world’s policy
board to be injected into the makers and business leaders
2009 – 2013 business plan cycle. are increasingly in agreement
that climate change is occurring
Updates and it has to be addressed.
The transportation fuel quality roadmap was presented
to the Management Committee on June 5, 2007. and
successfully acquired the MC‘s endorsement, to be
injected into the environmental master plan. In addition,
several roadmap parameters were already implemented
such as 800 ppm sulfur diesel (in major cities) and 5000 Acknowledgment
ppm sulfur diesel (country wide) as compared to 10,000 P&CSD would like to thank all the multidepartmental
ppm sulfur diesel, updating MTBE specification to 15 vol. members who participated in the development of the
% as opposed to 10 vol. %, etc. Fuel Quality Roadmap for their great efforts and
continuous support. Their time, dedication, and
The required capital investment program associated with
contribution towards the completion of the roadmap
implementing the long term strategy of the roadmap has
added great value.
recently been approved by the company board to be
included in the 2009 – 2013 business plan cycle.

Fuels Technology
In line with Engineering Services knowledge sharing
strategy and to promote the understanding of the ever
changing dynamics of vehicles technology and its relation
with fuel quality, P&CSD conducts regular workshops for
Walid A. Al-Naeem is the Supervisor of Distillation and
Saudi Aramco executives and scientists. Treating Unit of P&CSD. He is also the Chairman of Saudi
Aramco Products Specifications Committee which is com-
In 2006, P&CSD sponsored a full-day manager’s workshop posed of cross functional members from various departments
such as FPD, EPD, R&DC, OSPAS, Distribution, RTSD, Sales and
titled “Importance of Fuel Quality & Effect on Vehicle Marketing, and Domestic Refineries. This committee is
Performance” on December 2nd, 2006. This workshop charged to look after various issues related to Saudi Aramco
Products and Fuels Specifications. Walid holds a Master
was designed for relevant department managers who
Degree in Chemical Engineering from KFUPM since 2003.
directly deal with fuels production, distribution, and Walid is a member in several local and international techni-
specifications. The primary objective was to raise their cal societies and very active in IK / OOK events as chairman,
speaker, and as a delegate.
awareness to the global trend towards producing clean
fuels and to underscore the interaction between engine
and fuel technologies.



A Patent on Hydrogen Purification Optimization
System is Granted
Author: Ibrahim M. Al-Babtain

This patent relates to the recovery of hydrogen from gas mixtures and, more
particularly, to a method for obtaining increased hydrogen recovery from oil
refineries and petrochemical or natural gas operations by combining a steam
reformer hydrogen product stream with an off gas stream and utilizing a combined
stream as a feed to a single Pressures Swing Adsorption (PSA) unit.
This idea was generated during the initial start up of a has provided his support and encouragement to consider
new refinery that includes multiple PSA units utilized to implementing this patent in the project if applicable as
treat different feed streams of CCR off gas and refinery significant capital savings could potentially be realized.
off gas. One of these streams exceeded the capacity of the The sketches below show the system before and after the
related PSA unit and this portion of the excess gas is not modification.
effectively utilized and typically sent to the flare or fuel
gas system in the refinery. Another disadvantage is that
one of the PSA units is operating at high feed capacity
which can increase the probability of damaging the
adsorbent material within the PSA unit and carrying
impurities between the adsorbent layers. Also, flaring this
portion of excess gas requires compensation of same
flared quantity from another feed stream that feeds the
other PSA unit.

Prior to development of this invention, there has been no
single method of hydrogen recovery in refinery
operations in which some or all of the feed streams from Figure 1 System before the modification
separate PSA units were combined and utilized as feed for
a single PSA unit, and in which some or all of a steam
reformer product stream and a refinery offgas stream
being used as feed streams for separate PSA units were
combined and utilized as feed for a single PSA unit. By
applying this invention in the refinery, the total hydrogen
recovery was increased in the refinery by effectively
utilizing the excess gases that were flared, the load on the
steam reformer was reduced by lowering reformer feed
rate, the refinery fuel gas consumption was reduced in
the steam reformer furnace, and the hydrocarbon
content and heating value of the tail gas, from the PSA
unit fed by the steam reformer product stream, was Figure 2 System after the modification
enriched.

The full utility patent application for this invention was
filed at the United States Patent & Trademark office
(USPTO) on July 2003 and the patent was granted under Ibrahim M. Al-Babtain is a Refining Specialist in the
Downstream Process Engineering Division of Saudi Aramco.
US Patent # US 7,252,702 dated August 7, 2007. Ibrahim has 18 years of experience in refining business.
Joined P&CSD and participated with FPD and NBD as a
With regard to implementing this invention, Yanbu‘ technical member in the development of major refining
projects and evaluation of several technologies.
Export Refinery Project’s director; Mohammad S. Al-Subhi



Application of Flare Gas Recovery Systems in
Saudi Aramco facilities
Authors: Ra’ed Husseini, Prasad Pantula

The corporate Flaring Task Team led by P&CSD developed the Flaring Minimization
Roadmap that was endorsed by the Management committee in June 2006, The
roadmap recommended installing flare gas recovery (FGRS) units in company
locations where the normal daily flare gas exceeds 1-2 MMSCFD. This article
presents the concepts of FGRS and its application in Saudi Aramco.

“Protecting the Environment,” “Managing and The emissions of sulfur dioxide, ozone precursors
Protecting Resources,” and “Improving Health & Safety” and particulates have a significant environmental
are all part of our Business Line Strategies to meet the and health impact.
Corporate Imperatives. Installing a Flare gas recovery sys-
tem (FGRS) at the tail end of a gas plant or a refinery will • It provides an economic incentive in returning the
achieve all the above strategies, plus recover fuel gas recovered flared gas to the value chain, thus saving
worth $2/MMBtu. The Flaring Minimization Roadmap as on plant fuel gas.
endorsed by the Management Committee in June 2006, • FGRS improves the reliability of the main flare tip.
recommended installing flare gas recovery units in com- This is an important consideration for the larger
pany facilities where the normal daily flare gas rate
diameter flares that are prone to damage from oper-
exceeds 1-2 MMSCFD, after exhausting all possible flaring
ation at the low daily flaring rates. With FGRS, the
minimization efforts.
main flare is in stand-by mode, which improves its
reliability and life, and minimizes the recurring cost
Why Flare Gas Recovery?
of flare tip replacement
The main drivers for a FGRS project are;
• It’s a proven technology • The project has a potential for emission trading and
CO2 credits, thus generating additional revenue.
• It eliminates daily flaring, except for the pilots, thus
providing intangible benefits from reduced emis- • FRGS reinforces Saudi Aramco’s (& the Kingdom’s)
sions of CO2 (green house gas), SOX, NOX, & VOCs. positive image as a responsible corporate citizen.

Recovered Gas to Process
Flare Gas

Knockout Drum
FGRS
6 MMSCFD
N2 Purge

Existing Flares
HP/ACID or INLET
New
Staging
Device

Figure 1 FGRS concept



FGRS Components ever flow is detected. Basically, the staging devices enable
A flare gas recovery installation for an existing plant will safe operation of the entire system through sealing the
consist of four main components: elevated flares and provide backpressure in the flare
1. A compression based package (FGRS) to recover the header, allowing the flare gases to be routed to the FGRS.
flare gases for re-use in the existing processing facili-
ties Process Design of FGRS package
2. Staging devices to safely allow diverting the routine As shown above, the FGRS is a compression based pack-
daily flared gases to the FGRS package but not the age designed to recover the flare gases for reuse in the
emergency or abnormal relief loads. Figure 1 illus- existing processing facilities. The system configuration is
trates the integration of the FGRS into the flare sys- dependent on the final destination of the recovered gas
tem. and the type of compression equipment selected.
3. A nitrogen generation package to supplement exist-
ing nitrogen generation capacity. Nitrogen will be Destination of recovered gas:
used as purge gas, downstream of the staging device. Some of the potential destinations for the recovered gas
4. Control system within the package and interface with could be;
the plant DCS • Plant Fuel Gas header. This requires compression
As shown in Figure 1, the Flare gas recovery unit ties into facilities to compress the flare gases from near
the flare gas header between the knockout drum and the atmospheric pressure (3.5 psig max.) to approximately
staging device, and pulls flare gas from the header when- 100-120 psig.
• Plant inlet Gas header. This destination is typically the
suction of the LP compressors in the GOSPs (1ñ50 psig)
or the Inlet slug catchers in the gas plants (230 psig),
which also requires compression facilities to compress
the flare gases to the required pressure.

Type of Compression equipment
The choice of compression equipment will influence
greatly the configuration of FGRS system. A detailed
survey of existing technologies revealed that the

The Flaring Minimization
Vendor offered package for FGRS
Figure 2
with LRCs (courtesy: Envirocomb ltd) Roadmap as endorsed by the

Management Committee in

June 2006, recommended

installing flare gas recovery

units in company facilities

where the normal daily flare

gas rate exceeds 1-2 MMSCFD,

after exhausting all possible

Typical Screw compressor package
flaring minimization efforts.
Figure 3
offered by Man-Turbo



compressor types widely used for FGRS application are: exceeds the design capacity of the FGRS.
• Pressure control, low pressure alarms, and ESD systems
• Liquid ring compressor (LRC) with a variety of service
fluids, e.g., water, DGA, diesel, etc. should be provided at the inlet of the package to
ensure that positive pressure in the flare headers is
• Multistaged screw compressors (MSSC)
always maintained.
The major advantages of the above compressors types
• The staging control valve/seal drum should be
are as follows;
designed to open to existing flare stacks when each
• Can handle a wide range of gases with varying corresponding flare header flow exceeds the design
molecular weights with no effect on their capacity of the FGRS.
performance
• Can handle flow from zero to full capacity with a Nitrogen purge
robust recycle system.
To ensure positive pressure in the flare headers while the
• Can tolerate liquid in the feed better than any other FGRS is in use, the flare headers will be continuously
type of compressors. purged with nitrogen at a point downstream of the
Typical vendor offered packages are illustrated in Figures staging devices or the water seal drum. As a backup to the
2 & 3. The flare gas stream can be compressed in a LRC nitrogen purge, fuel gas from the existing fuel gas purge
based compression system to 100-110 psig with water as a header can be provided, with automatic controls.
service liquid in a closed loop. A heat exchanger to cool
the circulating water and a three phase separator to Impact on the existing flare system
remove oil and water are part of the package. The staging device seals the existing flare and imposes a
Alternately, a screw compressor package may be utilized. positive back pressure on the flare gas header. This allows
routing the flare gas to FGRS while maintaining a positive
The system configuration is dependent flare gas header pressure, which is important with regard
to the safety of the flare headers. Generally the maximum
on the final destination of the backpressure allowed will have no impact on the existing
recovered gas and the type of PZVs connected to the flare header; however the actual
impact should be checked with flare simulation models
compression equipment selected.
during the detailed engineering stage.

Design of staging device Conclusions
The flare gas stream is intercepted at a point downstream FGRS is a widely proven technology, though it has not
of the corresponding Flare Knockout drums by a staging been applied in Saudi Aramco. In future, all potential sites
device. The staging device is set to divert the routine will be considered for a detailed evaluation for its
flaring rate of flared gas to the FGRS or to the elevated application. Currently a DBSP is under development for
flare if the rate exceeds the capacity of FGRS. The staging installing a 6 MMSCFD FGRS units at ShGP & UGP . Other
devices required to seal the elevated flare can be a water potential sites being evaluated are Safaniya GOSP1 and
seal drum or a Buckling Pin/fast acting control valve Riyadh Refinery. Hawiyah NGL Recovery, Khurais
arrangement, similar to what is currently used at BGP, Development and potentially Khursaniyah are providing
HGP, HdGP, and proposed for the Hawiyah NGL project. tie-ins for future units.

Control System
The control system within the FGRS package and DCS Ra’ed Husseini is a Senior Engineering Consultant with
P&CSD. He has over 23 years of Aramco experience in gas
interface should be part of the FGRS process detailed processing, refining and in upstream.
design. The FGRS Process design vendors can provide the
control system design and interface to the DCS without
compromising process safety. The following are some
recommended features that should be part of a FGRS
package; Prasad Pantula is with F&RSU /DPED since 2002. He has 25
• The FGRS package should be isolated and safely shut- years of experience in upstream crude oil processing,
petroleum refineries and process plant design.
down or put in recycle mode automatically when the
staging device opens, in the event the flaring rate



JRD/FCCU MTC Technology Evaluation By FCC
Aspen Kinetic Model
Authors: Saeed Al-Alloush, Sidney Anderson, Talal Al- Ashwal

The purpose of this study is to determine the feasibility of installing the Mix
Temperature Control (MTC) technology from Stone & Webster/IFP New Technology
to improve Jeddah Refinery profitability by increasing conversions of gasoline and
LPG on the Fluid Catalytic Cracking Unit (FCCU).
The evaluation study will identify for JR major impacts of the use of MTC. These are:
2. Control of the optimum
the implementation of this technology by focusing in the
regenerator temperature.
following area: unit conversion, gasoline sulfur content, 3. Adjustment of the feed
Rx velocity, vapor line velocity and overhead cooling temperature up to its
bubble point to achieve
capacity after recycling all LCO stream. P&CSD/DPED/CCU
better atomization and
has signed with JR an Engineering Service Agreement faster vaporization.
(ESA) to evaluate this technology by utilizing FCC Aspen 4. The heat absorbed with the
Kinetic Models. recycle quench is recovered
as steam production,
preheating, or reboiling in
Fig. 1 Mix Temperature Control at
Proposed Technology the fractionation section of
FCCU Feed Riser Section
the FCCU.
The MTC technology allows for independent temperature
control of the catalyst cracking zone that results in Study Conclusion
decreasing yields of less desirable products (coke and gas).
The study evaluates the implementation and potential
MTC is performed by injecting a recycle quench stream of
application of MTC at JRD/FCCU by FCC Kinetic Model
either cracked FCC naphtha or light cycle oil, further up
simulation model. The annual revenue incremental from
the reactor riser downstream of the combined feed applying this technology is significant. P&CSD
injection point (See Figure 1) recommends consideration of the following future work
This recycle quench stream results in separating the if JR plans to implement the MTC technology:
reactor riser into two separate reaction zones.
Consider MTC technology for increasing the unit
• The first zone, (Zone 1), between the fresh feed
conversion and production of more gasoline yield.
injection point and the recycle quench stream
Utilize of the FCC Aspen Kinetic Model to evaluate several
injection point, is characterized by high temperature,
scenarios at different feedstock conditions.
high catalyst to oil ratio and very short contact time of
The author acknowledges the support from Graham Jones, Ahmad
oil and catalyst. Al-Othman from Pipeline & Simulation unit, Christopher Dean,
• The second zone, (Zone 2), between the recycle Abdulaziz Al-Ghamdi and Adel Bawizer for finishing the ESA with
quench stream injection point and the riser JRD on time.
termination into the reactor vessel, is where reactions
occur under more conventional and milder catalytic
cracking conditions.
The primary objectives of the MTC system are: Saeed S. Al-Alloush is a senior process engineer in the
1. To provide independent control of the catalyst and oil mix Downstream Process Engineering Division, Process & Control
temperature in Zone 1. Systems Dept. (P&CSD). He has 15 years of experience with
Saudi Aramco in refining area and mainly in Fluid Catalytic
This recycle quench is a heat sink that behaves similarly to a steam
Cracking area . He graduated with Master Degree of Science
cooler or a catalyst cooler in the regenerator side of the FCC
in Engineering from University of Tulsa (TU), USA. He is a
reaction section. By behaving as a cooler the regenerated catalyst member in American Institute of Chemical Engineering
temperature can somewhat be controlled during the catalyst (AICHE) since 1997.
regeneration. Usually the minimum regenerated catalyst
temperature is the one that results with adequate catalyst Sidney V. Anderson is an Engineer II in Saudi Aramco’s Jiddah
regeneration of coke. The cooler catalyst temperature causes Refinery Operation Engineering Unit. He has over 38 years of
higher catalyst circulation rates for meeting the heat requirements process engineering and refinery management experience
for the cracking reactions and maintaining reactor outlet and has previously served on the NPRA Q&A panel. He has
temperature. Additionally, there are also secondary objectives from also written or co-authored several other papers related to
FCCU operations.



Troubleshooting YR Cyclemax Regenerator
Catalyst Blow out
Authors: Rabea M. Al-Saggaf, Hamzah Z. Abuduraihem, Neelay Bhattacharya, Sajeesh Padmanabhan

P&CSD/DPED/CCU assisted Yanbu‘ Refinery Engineering in resolving the recent CCR
Platformer regeneration catalyst pinning and blow out problem that resulted from
the over-design of the regeneration gas blower by installing a restriction orifice in
the Regeneration gas blower suction line.
P&CSD Downstream Process Engineering has promptly spent catalyst is regenerated in four steps: 1) Coke
extended troubleshooting support to Yanbu‘ Refinery Burning; 2) Oxychlorination – for dispersing the catalyst
Engineering and recommended a course of action to put metals and adjusting the catalyst chloride content; 3)
the unit in a normal mode of operation. The Continuous Catalyst Drying; 4) Reduction – for changing the catalyst
Catalyst Regeneration (CCR) section of Yanbu‘ Refinery metals to the reduced state. Finally, the regenerated
(YR) CCR Platformer Plant experienced successive catalyst catalyst is circulated back to the first Platforming reactor.
blowouts leading to the regeneration section shutdown. Over a period of time catalyst fines plugs the Regenerator
This caused the Platformer section to operate at reduced screen. The CCR has to be shutdown and the screen
feed rate and severity. Prolonged shutdown of the removed for cleaning every 12 months.
catalyst regeneration section would have led to the
shutdown of the Platformer Plant and the consequence of Incident Background
losing the gasoline production. Since the first startup in June 2006, the CCR Regeneration
Tower has been operating with a partially plugged screen
Introduction as a result of catalyst fines generated in the system from
The Yanbu‘ Refinery Platformer unit was revamped in the containment loss in the Platformer reactors. This has
June 2006 from a fixed bed unit to a Continuous Catalyst effectively reduced the Regeneration gas flow without
Regeneration Unit. Coked spent catalyst from the affecting the CCR operability. It was recommended by the
Platforming reactors is continuously sent to the CCR licensor to clean the screen at the earliest opportunity.
Regeneration Tower where the coke is burnt off and the The CCR was shutdown for a period of 5 days to carry out

Figure 1 DCS Pressure Trends



Table 1: Regeneration Tower Normal and Incident procedure at 50˚C/Hr. When the blower was switched to
Temperature Profiles low speed at 350˚C a blowout was again observed. A
Licenser similar phenomenon was observed when the blower was
Normal Shifted
TI Specified Profile Profile switched from low speed to high speed during the reheat.
Range There was no improvement in the unit performance.
TI -1 479-510˚C 380˚C 250˚C Therefore, the regeneration section was again shutdown
as a result of repetitive blow out occurring between the
TI -2 493-593˚C 563˚C 465˚C disengaging hopper and the regeneration tower. The CCR
TI -3 493-593˚C 557˚C 475˚C Platformer throughput was lowered from the design of
40 to 30 MBD and 95.0 operating severity to control coke
TI -4 493-560˚C 503˚C 511˚C lay down.
TI -5 491-504o˚C 492˚C 543˚C
Analysis & Findings
TI -6 491-504˚C 487˚C 479˚C
It is very unusual for a blowout to take place in a CCR
TI -7 491-504˚C 485˚C 472˚C because it is normally catalyst full. During normal
operation the catalyst flows down due to gravity. The
TI -8 479-499˚C 485˚C 465˚C
Disengaging Hopper operates at approximately 9
kg/cm2(g) and the Regeneration Tower operates at
the cleaning of the regeneration tower screen. The unit approximately 2.5 Kg/cm2(g). This huge pressure
was restarted in black burn mode. The startup was normal differential is taken by the catalyst in the long transfer
and the regeneration tower temperature profile had its pipes between the Disengaging Hopper and the
peak at the second TI in the Burn Zone. The operation of Regeneration Tower. If due to any reason a void is created
the regenerator for the next 36 hours was absolutely in the Regeneration Tower, the huge differential pressure
normal with regenerated catalyst carbon at 0.095 wt% will force the catalyst down, causing a pressure
and spent catalyst carbon at 4.3 wt%. fluctuation that generates a lot of fines and dust. The
fines will block the Regenerator screen, causing the
On Tuesday, January 23, a blow out occurred between the
temperature profile to slip down.
disengaging hopper and the regeneration tower which
caused the disengaging hopper level to drop from 52 % P&CSD analyzed the problem on the
to 47 %. The Disengaging pressure dropped and the following lines:
Regeneration Tower pressure increased momentarily.
1. One probable cause could be something blocking the
Figure 1 below shows the pressure fluctuation and level
catalyst transfer pipe. But this would be a one time
drop at the time the blow out occurred.
occurrence that would get automatically cleared after
Due to the blowout, a lot of fines and chips were the blowout. But since the blowout reoccurred it was
generated that plugged the Regenerator screen. A shift in obvious that it was not due to plugging of the
burn zone temperature profile has being experienced and transfer pipes.
the peak temperatures shifted to fifth TI which is at the 2. The only difference between the two startups was the
bottom of the burn zone (refer to Table 1). condition of the screen. Since initial startup the unit
was operating with a plugged screen. The recent
Maintaining a proper burn profile in this section is
startup was the first time with a clean screen.
extremely important for safe operation of the unit. If the
burn profile shifts down, un-regenerated catalyst will 3. The blowout was clearly related to the blower
enter the chlorination zone potentially causing catalyst to operation because the blowout had happened on two
agglomerate and damage the Regenerator internals. occasions when the blower speed was switched.

Intensive discussions were held between Refinery Analysis of the previous operating data showed that the
engineers and licensor experts on this subject and it was blower flow was 102 % of design even with a partially
concluded that it is very difficult to pin-point the root plugged screen. Once the screen was cleaned the flow
cause of the blowout. An attempt was made as suggested increased causing the catalyst to pin in the Regeneration
by licensor to stop the regeneration blower and carry out Tower. Since the Lock Hopper is removing catalyst, a void
cold circulation of the catalyst in order to clear the screen. was created at some location in the Regeneration Tower.
Accordingly the regeneration tower was cooled as per When the differential pressure between the Disengaging



Hopper and the Regeneration Tower was high enough, it to install a restriction orifice in the regeneration gas
forced the catalyst to fill the void creating a blowout. This outlet line, to reduce the regeneration gas blower flow by
would also explain why the blowout occurred when the approximately 15%, and prevent catalyst pinning on the
blower speed was changed. The first time when the regeneration tower screen. Unit licensor designed a
blower was switched from high speed to low speed the restriction orifice with a bore size of 340mm, which was
catalyst unpinned, causing an immediate blowout. The fabricated by YR and installed in the Regeneration gas
second time the blower was switched from low speed to outlet line to reduce the flow by approximately 15%.
high speed caused the catalyst to pin. The blowout did
not occur immediately. During subsequent heat up the CCR Restart
catalyst slumped, creating a void below the pinned area, The regeneration section was restarted on Feb 6, 2007,
causing a blowout. after the installation of the restriction orifice. The startup
was smooth without any pressure fluctuations or signs of
A conference call was initiated by YR Engineering and
blowout. The circulation rate was slowly increased to 95
P&CSD with the Licenser on January 31, 2007. P&CSD
% of design and the oxygen concentration was slowly
convinced the licensor that the blower could be a highly
reduced from 1.0 mole% to 0.9 mole%. Laboratory results
probable cause for the blowout and it was decided that:
showed less than 0.07 wt% carbon, indicating complete
1. The licensor would size a restriction orifice to reduce regeneration. The temperature profile in the
the Regeneration Gas flow by 15-20 % to avoid regeneration section was satisfactory, indicating no
pinning. YR would keep it ready for installation in the reduction in the unit capacity.
Regeneration tower gas outlet line.
In conclusion, installation of the restriction orifice on the
2. Conduct inspection of the disengaging hopper and regeneration gas blower suction eliminated the pinning
regeneration tower screen. problem from the over-design of the blower. Normal CCR
Platformer operation resumed.
3. If inspection did not reveal any obvious reason to
explain the blowouts, then install the restriction
orifice in the Regeneration gas outlet line and observe
the unit performance on restart.

Field Inspection Rabea M. Al-Saggaf is a process engineer working with Saudi
Aramco Yanbu‘ Refinery Department. He has 10 years
The regeneration tower and the Disengaging Hopper experience in refineries. Rabea holds a B.S degree in chemical
engineering from King Abdulaziz University, Jeddah 1996.
were open for inspection. While unloading the catalyst, He joined Saudi Aramco in 1996.
the last few drums from the Disengaging Hopper
contained fresh catalyst. YR had added 12 drums of fresh
catalyst to the Disengaging hopper during the recent
reload. Since the catalyst had been circulated for 500 Neelay Bhattacharya is a process engineer working with
Saudi Aramco Process and Control Systems Department. He
cycles there should not have been any fresh catalyst has 17 years experience in Refineries and Petrochemical
remaining in the Disengaging Hopper. This clearly plants. Neelay holds a B.E degree in Petroleum and
Petrochemicals from Pune University, India 1990. He joined
indicated that the catalyst was not moving as a result of Saudi Aramco in 2006.
localized catalyst pinning on the regeneration tower
screen. No clumps or debris were found between the
disengaging hopper and the regeneration tower. The
Hamzah Z. Abuduraihem is a process engineer working with
Regeneration screen was heavily plugged. There was no Saudi Aramco Process and Control Systems Department. He
has 15 years experience in refinery operation and project.
sign of integrity loss or severe damage to the screen.
Hamzah holds a M.S degree in Chemical Engineering and
P&CSD concluded that the root cause for this problem was Petroleum Refining from Colorado School of Mines, USA
2001. He joined Saudi Aramco in 1992.
the oversizing of the regeneration gas blower.

Recommendations
Sajeesh Padmanabhan is a chemical engineer and works with
P&CSD recommended installing a restriction orifice in the the Operation Engineering & Automation Unit at Yanbu‘
Regeneration gas blower suction line to reduce the Refinery. He has 11 years of experience in Hydrotreating,
Plaforming and Petrochemicals. He joined Saudi Aramco in
Regeneration gas flow and increase the pinning margin. Jan 2005.
YR and Licenser supported P&CSD’s findings and decided



Distillation Workshop
DHAHRAN — As company refineries look for new
technologies and ways to revamp operations and best
practices, more than 100 engineers, specialists and
consultants gathered on March 28 to discuss the latest
crude and vacuum distillation technologies.
Personnel came from Saudi Aramco domestic refineries
and central engineering services to join worldwide
industry experts on March 28 for the first Distillation
Workshop.
The event was conducted and organized by the Process
and Control Systems Department (P&CSD) at the Research
and Development Technical Exchange Center under the
theme, “Distillation: Revamping, Troubleshooting,
Technology and Energy Conservation.” The aim was to
create a learning organization, a stated goal of
Engineering and Operations Services. Saleh A. Al-Zaid, manager of P&CSD left talks with Said Al-Zahrani &
Mohammed Slamah during break time.
P&CSD Manager Saleh A. Al-Zaid highlighted the
importance of the distillation process in every plant and
The Sulzer representative delivered the second
refinery. He also concentrated on the importance of
technology presentation, “Maximize Distillate Recovery
P&CSD in supporting Saudi Aramco’s domestic refineries,
by Means of Advanced Mass Components.” That was
especially given the rise in fuel demand.
followed by a panel discussion on energy conservation at
“The importance of this workshop is derived from the crude distillation units, moderated by Tariq A. Al-Zahrani
importance of crude and vacuum distillation processes,” and Khalid S. Al-Otaibi from P&CSD’s Distillation and
Al-Zaid said. “Crude and vacuum units are the heart and Treating Unit.
the main gate of every refinery in the world. Their
“It was a great opportunity to exchange experiences
importance is not negotiable.”
with engineers, specialists and consultants from
Representatives from two leading companies in crude different organizations within Saudi Aramco and
distillation process revamps and technologies, Koch-Glitch worldwide industries,” said Mohammed S. Al-Ghamdi,
and Sulzer Chemtic, presented “Primary Refinery Yanbu‘Refinery Operations Engineering and Automation
Treatment: Process and Technology.” That was followed Unit supervisor, of the value of the workshop.
by panel discussions on Crude Distillation
Walid A. Al-Naeem, supervisor of D&TU, concluded the
(Atmospheric/Vacuum) and Crude Handling and
workshop by thanking the attendees for their
Desalting, featuring panelists from Saudi Aramco, and
participation.
Sulzer and Koch-Glitsch.

Distillation workshop attendees, organizers and panelists pose for a picture in R&DC Technical Exchange Center.



P&CSD Supports Local Professional
Societies: AIChE-SAS
The American Institute of Chemical Engineers (AIChE) – Saudi Arabian Section
(SAS) is a non-profit professional association. It has memberships from all major
companies of Saudi Arabia including SABIC, Saudi Aramco, KFUPM, SWCC, Royal
Commission, and many other private companies. One of the major activities is
the Monthly Technical Dinner Meeting of the members. The Meeting is
highlighted with presentation from a well-known expert/specialist on chemical
engineering-related subjects and major activities in the downstream industries.
Further information about the meeting or the society can be viewed by visiting
our web-site @: http://www.kfupm.edu.sa/sas-aiche.

Process & Control Systems Dept. (P&CSD) has sponsored April 8, 2007, Meeting
of AIChE-SAS in the Meridian Hotel, Khobar. The Guest Speaker was Mr. Khaled The Guest Speaker Mr.
Khaled Al-Faleh, Sr. VP.
Al-Faleh, Sr. VP, Industrial Relations of Saudi Arabian Oil Company (Saudi
Industrial Relations of Saudi
Aramco). Mr. Al-Faleh discusses Saudi Aramco’s global and national business Arabian Oil Company (Saudi
Aramco) addressed his
challenges and the need to elevate IK educational outcomes to meet the presentation “Educational
Outcomes & Industry Needs:
country’s rapid economic growth and international competition. In this regard, Saudi Aramco’s Perspective”
during AIChE-SAS April
he has addressed the state of the Kingdom’s educational system and its monthly meeting sponsored
competitiveness at an international level. In addition, three key Board Officers by P&CSD.

from P&CSD are investing a lot of after-hours to make this chapter successful and
serve the chemical engineering society for the year 2007.
ague
e society pl
hand on th
Chairman,
AIChe-SAS ntribution.
-Majnouni, k him for hi
s co
ohsen D. Al er, to than
Mr. Abdulm CSD Manag
h Al-Zaid, P&
to Mr. Sale



Rate of Change Modeling
Authors: M. A. Al-Rasheed, Nazar A. Al-Nasr

A New Method is proposed to simulate rate of change of process variables. The
method can be appllied in the oil and gas industry such as in pipelines overpressure
protection and valve selection.
N. A. Al-Nasr and M.A. Al-Rasheed co-authored a joint Pipeline Simulation Interest Group (PSIG) that will take
paper titled “A Method of Simulating Rate of Change place in October this year in Canada.
with Applications in Pipelines Protection and Check
Valves Selection.” The paper has been accepted for The paper introduces new method of simulating a process
presentation and publication in the 2007 Conference of variable (PV) rate of change with respect to time (time

N.UWSS1.SUCT N.UWSS1.DISCH

E.UWSS1.SUCT UPUMP1 NODE5 UBLOCK1 B.UWHW.IN NODE7 LOOP NODE8 T.UWSS1B.HCWIP

NODE3 B.SRV
UPUMP2 UBLOCK2 T.UWSS1A.HCWIP

B.UWHW.OUT

NODE1
NODE6 HWELLS NHCWIP001

V.SRV

E.SRV NODE4 H.SRV NODE2
Figure 1 Schematic of water injection pipeline system

derivative d(PV)/dt), that is usually not readily available or
directly calculated by some dynamic pipeline simulators.
The method makes use of elementary concepts of
Proportional-Integral-Derivative (PID) controllers along
with commercial software packages of pipeline dynamic
simulators, like Stoner Pipeline Simulator (SPS). The paper
describes the method and its application in the oil and gas
industry. One application is related to overpressure
protection of cross-country pipelines (Figure-1). The
method can also be applied to the proper selection of a
check valve as an integral part of a pipeline system
(Graph-1).

In pipelines process dynamic simulation packages, flow,
pressure and temperature are the most commonly used
Pressure & Flow Profile of the Simulated calculated PVs. Flow, on the other hand, is the most
Graph 1
Pipeline System common PV rate of change of mass or volume with


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