Pcsd newsletter-special edition-2007
OmarMHalawani
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Sep 16, 2012
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About This Presentation
This publication made by a teamwork to illustrate the department achievements professionally and attractively.
Slide Content
“Knowing is not enough; we must apply.
Being willing is not enough; we must do.
”
Leonardo Da Vinci
“Knowing is not enough; we must apply.
Being willing is not enough; we must do.
”
Leonardo Da Vinci
Downstream Upstream Control Instrumentation
APatent on Hydrogen
Purification Optimization
System is Granted
Computer Modeling
of rate of change with
applications in Pipeline
Protection and check
valves economic selection
Yanbu‘ Gas Plant
Dynamic Optimizer
Implementation
Key Elements for Oil &
Gas Wireless Networks
Issue No. 8 Special Edition 2007Leaders in process engineering and automation
Being willing is not enough; we must do.
”
Leonardo Da Vinci
“Knowing is not enough; we must apply.
Being willing is not enough; we must do.
”
Leonardo Da Vinci
Downstream Upstream Control Instrumentation
APatent on Hydrogen
Purification Optimization
System is Granted
Computer Modeling
of rate of change with
applications in Pipeline
Protection and check
valves economic selection
Yanbu‘ Gas Plant
Dynamic Optimizer
Implementation
Key Elements for Oil &
Gas Wireless Networks
Issue No. 8 Special Edition 2007Leaders in process engineering and automation
©Copyright2007,SaudiAramco
Allrightsreserved
Allrightsreserved
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
drivers in the engineering strategies to achieve operational excellence.
We focus on deploying proven process and control technologies that will
give our company a competitive edge. As the main stakeholders, our
customers’ participation and collaboration are essential to the success of
the development and implementation of these technologies.
We are all aware of the global shortage in technically skilled job
candidates. Engineering Services is leading an initiative to develop that
talent in-Kingdom using technical competency maps. These maps focus on
required technical competencies that can be acquired by attending
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 morethan 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
“We all
committed to
support our
facilities with
leading edge
technologies to
achieve
operational
excellence.
“
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
drivers in the engineering strategies to achieve operational excellence.
We focus on deploying proven process and control technologies that will
give our company a competitive edge. As the main stakeholders, our
customers’ participation and collaboration are essential to the success of
the development and implementation of these technologies.
We are all aware of the global shortage in technically skilled job
candidates. Engineering Services is leading an initiative to develop that
talent in-Kingdom using technical competency maps. These maps focus on
required technical competencies that can be acquired by attending
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 morethan 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
“We all
committed to
support our
facilities with
leading edge
technologies to
achieve
operational
excellence.
“
Suggested topics and related technical articles for this
newsletter are encouraged and welcome, and may be
submitted to Abdulaziz Tijani, EOB, E-3410, Dhahran
or e-mailed to [email protected]
Process & Control Systems
Department Newsletter
Contents
Process & Control Systems Newsletter is published
Bi-annually by the Process & Control Systems Department
P&CSD Technology
Partnership Meeting with
YR and RTR
7
Saudi Aramco’s Fuel
Quality Roadmap
8
Troubleshooting YR
Cyclemax Regenerator
Catalyst Blow out
16
P&CSD Supports Local
Professional
Societies: AIChE-SAS
21
TORR Technology for
Produced Water
Treatment
25
A Patent on Hydrogen
Purification Optimization is
Granted
11
Application of Flare
Gas Recovery
Systems in Saudi
Aramco facilities
12
JRD/FCCU MTC Technology
Evaluation by FCC Aspen
Kinetic Model
Distillation Workshop
15
20
Rate of Change
Modeling22
0
1000
2000
30 00
0. 6
0. 8
1
1. 2
0
20
40
60
80
100
120
Re I m p
Re I m p
Re I m p
Re I m p
ReL
ReL
ReL
ReL 0
1000
2000
3000
0. 6
0. 8
1
1.2
0
20
40
60
80
100
120
ReG ReG
ReG ReG
0
1000
2000
30 0 0
0.6
0. 8
1
1.2
0
50
100
150
200
250
0
1000
2000
3000
0.6
0.
8
1
1.2
0
50
100
150
200
250
Basket Impeller Column:
New Approach
28
newsletter are encouraged and welcome, and may be
submitted to Abdulaziz Tijani, EOB, E-3410, Dhahran
or e-mailed to [email protected]
Process & Control Systems
Department Newsletter
Contents
Process & Control Systems Newsletter is published
Bi-annually by the Process & Control Systems Department
P&CSD Technology
Partnership Meeting with
YR and RTR
7
Saudi Aramco’s Fuel
Quality Roadmap
8
Troubleshooting YR
Cyclemax Regenerator
Catalyst Blow out
16
P&CSD Supports Local
Professional
Societies: AIChE-SAS
21
TORR Technology for
Produced Water
Treatment
25
A Patent on Hydrogen
Purification Optimization is
Granted
11
Application of Flare
Gas Recovery
Systems in Saudi
Aramco facilities
12
JRD/FCCU MTC Technology
Evaluation by FCC Aspen
Kinetic Model
Distillation Workshop
15
20
Rate of Change
Modeling22
0
1000
2000
30 00
0. 6
0. 8
1
1. 2
0
20
40
60
80
100
120
Re I m p
Re I m p
Re I m p
Re I m p
ReL
ReL
ReL
ReL 0
1000
2000
3000
0. 6
0. 8
1
1.2
0
20
40
60
80
100
120
ReG ReG
ReG ReG
0
1000
2000
30 0 0
0.6
0. 8
1
1.2
0
50
100
150
200
250
0
1000
2000
3000
0.6
0.
8
1
1.2
0
50
100
150
200
250
Basket Impeller Column:
New Approach
28
Key Elements for Oil & Gas
Wireless Networks
Optimizing Projects with a
Main Automation Contractor
Yanbu‘ Gas Plant
Dynamic Optimizer
Implementation
Automatic Valve
Characterization – Why
didn’t we think of that?
Data Validation and
Reconciliation
A Crucial Technology for
Processing Plants
Alarm System Improvement
at AINDAR GOSP-2
Process Automation
Focus Team Update
51
43
30
32
38
40
42
Advanced Multivariable &
Regulatory Control
Performance Monitoring
36
Industrial Wireless LAN
Security For Oil & Gas
Process Automation
Networks
48
Engineering the
Future
52
Industrial Time
Synchronization
44 HOT SPOT
Safety of the Issue
54
Trim Integrity for
Compressor Anti-
surge Valves
46
Wireless Networks
Optimizing Projects with a
Main Automation Contractor
Yanbu‘ Gas Plant
Dynamic Optimizer
Implementation
Automatic Valve
Characterization – Why
didn’t we think of that?
Data Validation and
Reconciliation
A Crucial Technology for
Processing Plants
Alarm System Improvement
at AINDAR GOSP-2
Process Automation
Focus Team Update
51
43
30
32
38
40
42
Advanced Multivariable &
Regulatory Control
Performance Monitoring
36
Industrial Wireless LAN
Security For Oil & Gas
Process Automation
Networks
48
Engineering the
Future
52
Industrial Time
Synchronization
44 HOT SPOT
Safety of the Issue
54
Trim Integrity for
Compressor Anti-
surge Valves
46
4
VISION - To become leaders in process engineering and automation!
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%
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
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
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.
Sometimes it’s combining multiple technologies into one to
Letter from the Team
“The link between Innovation,
Plant Experience, and Hard Work”
Abdulaziz Tijani
Omar Halawani
Jim Sprague
Jim Anderson
Newsletter team: Abdulaziz Tijani, Omar Halawani, Jim Sprague, Jim Anderson
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
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%
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
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
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.
Sometimes it’s combining multiple technologies into one to
Letter from the Team
“The link between Innovation,
Plant Experience, and Hard Work”
Abdulaziz Tijani
Omar Halawani
Jim Sprague
Jim Anderson
Newsletter team: Abdulaziz Tijani, Omar Halawani, Jim Sprague, Jim Anderson
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
5
MISSION - We innovate and optimize operations for improved performance through leadership
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
saying of “I paid my dues” has become as obsolete and
outdated as the typewriter. Today, as an engineer, your dues are
paid daily. This means that each of us as a customer, supplier, or
employee is being evaluated on a daily basis with an ever
changing measurement. The key is to stay on top in our field
through continuous learning and updating our experience and
knowledge. Saudi Aramco’s learning organization initiatives
can certainly help.
In the end, innovation comes from the following:
•the experienced and knowledgeable engineer with
•watching out for solutions while
•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
“It is
important to
understand that
new ideas and
solutions come
from an
attitude, an
environment,
a culture that
embraces
change..
”
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
MISSION - We innovate and optimize operations for improved performance through leadership
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
saying of “I paid my dues” has become as obsolete and
outdated as the typewriter. Today, as an engineer, your dues are
paid daily. This means that each of us as a customer, supplier, or
employee is being evaluated on a daily basis with an ever
changing measurement. The key is to stay on top in our field
through continuous learning and updating our experience and
knowledge. Saudi Aramco’s learning organization initiatives
can certainly help.
In the end, innovation comes from the following:
•the experienced and knowledgeable engineer with
•watching out for solutions while
•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
“It is
important to
understand that
new ideas and
solutions come
from an
attitude, an
environment,
a culture that
embraces
change..
”
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
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.
Professional Engineers in P&CSD
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)
6 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
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.
Professional Engineers in P&CSD
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)
6 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
7
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
The meetings were organized to promote a
technology culture among refinery personal
and provide a platform for engineers to
brainstorm new technologies that could be
deployed in a partnership between the
refineries and P&CSD. Another goal was to
increase the awareness of Saudi Aramco’s
technology program.
At the meetings, the Research and Development Center’s
Technology Management Division presented an overview
of the center’s technology program to encourage future
participation by employees attending the meetiing.
P&CSD representative then discussed three new
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
selected for further evaluation through an Engineering
Service Agreement (ESA) between the two refineries. The
brainstorming sessions in YR and RTR were facilitated by
Engineering Services’ performance consultant and the
leadership center in Dhahran.
Forty-five engineers participated in the Yanbu’ Refinery
meeting from Saudi Aramco, Saudi Aramco Mobil
Refinery (Samref), Saudi Aramco Lubricating Oil Refinery
Co. (Lubref), American company Honeywell and
Honeywell subsidiary UOP. The Ras Tanura meeting was
attended by 33 engineers.
Both meetings were coordinated by Mohammad
Balamesh and Saeed Al-Alloush from P&CSD’s Catalytic
Conversion Unit.
P&CSD Technology Partnership Meeting with YR and RTR
Right:Brain Storming Session at
Rastanura Refinery
Below: Yanbu‘ Refinery Gathering
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.
7Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
The meetings were organized to promote a
technology culture among refinery personal
and provide a platform for engineers to
brainstorm new technologies that could be
deployed in a partnership between the
refineries and P&CSD. Another goal was to
increase the awareness of Saudi Aramco’s
technology program.
At the meetings, the Research and Development Center’s
Technology Management Division presented an overview
of the center’s technology program to encourage future
participation by employees attending the meetiing.
P&CSD representative then discussed three new
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
selected for further evaluation through an Engineering
Service Agreement (ESA) between the two refineries. The
brainstorming sessions in YR and RTR were facilitated by
Engineering Services’ performance consultant and the
leadership center in Dhahran.
Forty-five engineers participated in the Yanbu’ Refinery
meeting from Saudi Aramco, Saudi Aramco Mobil
Refinery (Samref), Saudi Aramco Lubricating Oil Refinery
Co. (Lubref), American company Honeywell and
Honeywell subsidiary UOP. The Ras Tanura meeting was
attended by 33 engineers.
Both meetings were coordinated by Mohammad
Balamesh and Saeed Al-Alloush from P&CSD’s Catalytic
Conversion Unit.
P&CSD Technology Partnership Meeting with YR and RTR
Right:Brain Storming Session at
Rastanura Refinery
Below: Yanbu‘ Refinery Gathering
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.
7Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
Saudi Aramco’s Fuel Quality Roadmap
Author: Walid A. Al-Naeem
This team along with a reputable consultancy firm IFQC
(International Fuel Quality Center) has done extensive
data gathering and analysis to develop the roadmap. The
main parameters that are affected by the roadmap is a
reduction in sulfur content in both the gasoline and diesel
products to 50 ppm & ultimately to 10 ppm, a reduction
in the gasoline benzene to 1.0 vol. % or less, and a
reduction in benzene aromatic contents to 35 vol. %.
These reductions is planned to take place at different
stages of the roadmap.
Those stages are:
Step 1: Immediate operational changes that do not
require capital investments.
Step 2: Changes that require capital projects and can
be implemented by 2013.
Step 3: More stringent specifications that require
additional capital projects to step 2 and can
be implemented by 2016.
Background
Today, the world’s policy makers and business leaders are
increasingly in agreement that climate change is
occurring and it has to be addressed. As a responsible
corporate citizen, Saudi Aramco is committed to reduce
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.
the Green House Gases (GHG) – the main cause of climate
change. Saudi Aramco believes that the best way to
combat climate change is to look forward and act
proactively. So far, Saudi Aramco has already taken
serious steps to improve the environmental situation in
the Kingdom by establishing an Environmental Master
Plan that addresses all sources of contamination to the air,
earth, and water. This master plan was endorsed by the
Saudi Aramco board in 2001.
Figure 1 Gasoline Quality Roadmap Figure 2 Diesel Quality Roadmap
8 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
So far, Saudi Aramco has
already taken serious steps to
improve the environmental
situation in the Kingdom by
establishing an Environmental
Master Plan that addresses all
sources of contamination to the
air, earth, and water.
Saudi Aramco’s Fuel Quality Roadmap
Author: Walid A. Al-Naeem
This team along with a reputable consultancy firm IFQC
(International Fuel Quality Center) has done extensive
data gathering and analysis to develop the roadmap. The
main parameters that are affected by the roadmap is a
reduction in sulfur content in both the gasoline and diesel
products to 50 ppm & ultimately to 10 ppm, a reduction
in the gasoline benzene to 1.0 vol. % or less, and a
reduction in benzene aromatic contents to 35 vol. %.
These reductions is planned to take place at different
stages of the roadmap.
Those stages are:
Step 1: Immediate operational changes that do not
require capital investments.
Step 2: Changes that require capital projects and can
be implemented by 2013.
Step 3: More stringent specifications that require
additional capital projects to step 2 and can
be implemented by 2016.
Background
Today, the world’s policy makers and business leaders are
increasingly in agreement that climate change is
occurring and it has to be addressed. As a responsible
corporate citizen, Saudi Aramco is committed to reduce
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.
the Green House Gases (GHG) – the main cause of climate
change. Saudi Aramco believes that the best way to
combat climate change is to look forward and act
proactively. So far, Saudi Aramco has already taken
serious steps to improve the environmental situation in
the Kingdom by establishing an Environmental Master
Plan that addresses all sources of contamination to the air,
earth, and water. This master plan was endorsed by the
Saudi Aramco board in 2001.
Figure 1 Gasoline Quality Roadmap Figure 2 Diesel Quality Roadmap
8 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
So far, Saudi Aramco has
already taken serious steps to
improve the environmental
situation in the Kingdom by
establishing an Environmental
Master Plan that addresses all
sources of contamination to the
air, earth, and water.
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 SO
2emissions,
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 SO
2emissions from diesel engines.
Future Environmental Challenges
to KSA
Since future challenges are always their ahead of us,
Saudi Aramco has taken proactive measures by
establishing the fuel quality roadmap (Figures 1 & 2) that
will ensure compliance to the government environmental
regulations at all times.
The fuel quality roadmap, which was recently
approved by the company board, has provided an
update to the existing environmental master plan,
bearing in mind the following future challenges:
•The kingdom has high urbanization level,
meaning that people tend to move to bigger cities
which ultimately cause high population and traffic
densities, especially in Riyadh, Jiddah, Makkah,
and Dammam.
•Since 1998 the number of registered vehicles has
increased by 45%.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Impact of Fuel Quality on Vehicle
Performance
There is without doubt global recognition that climate
change abatement and the drive toward lesser GHG can
only be achieved if vehicle manufacturers, refiners and
legislation work together. Since fuels and engines are
technically linked with each other, the improvement in
gasoline and diesel fuels quality will permit the adoption
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
kingdom in the past and they continue to do so at the
present time. This is because their up to date engine
components are very sensitive to high sulfur fuels, which
will cause it to be in-effective in a short while. For
example, NOx and PM pollutants require special emission
control systems to be embedded into the vehicles to trap
and convert those pollutants into friendly gases. For
those systems to operate efficiently (Figure 3
both gasoline and diesel fuels need to be further reduced
from 500 ppm to 50 as an intermediate step and
ultimately to 10 ppm. At 10 ppm the emission control
systems will give the utmost optimum performance that
will drastically mitigate the NO
2/PM emissions to the least.
Therefore, it is clear that reduction of NO
2and PM
emissions are solely dependent on low emission engine
technology. To introduce those low emission engines to
the kingdom’s fleet, it requires around 18 years to have
full replacement of our high emission vehicle fleet. As a
result, the actual realization of NO
2and PM emissions
reduction will take more time as compared with the other
pollutants.
Figure 3 Sophisticated Emission Control Systems
9Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
As a result, the master plan has
recommended to lower sulfur
in transportation diesel from
10,000 ppm to 500 ppm
mitigating SO
2emissions from
diesel engines.
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 SO
2emissions,
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 SO
2emissions from diesel engines.
Future Environmental Challenges
to KSA
Since future challenges are always their ahead of us,
Saudi Aramco has taken proactive measures by
establishing the fuel quality roadmap (Figures 1 & 2) that
will ensure compliance to the government environmental
regulations at all times.
The fuel quality roadmap, which was recently
approved by the company board, has provided an
update to the existing environmental master plan,
bearing in mind the following future challenges:
•The kingdom has high urbanization level,
meaning that people tend to move to bigger cities
which ultimately cause high population and traffic
densities, especially in Riyadh, Jiddah, Makkah,
and Dammam.
•Since 1998 the number of registered vehicles has
increased by 45%.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Impact of Fuel Quality on Vehicle
Performance
There is without doubt global recognition that climate
change abatement and the drive toward lesser GHG can
only be achieved if vehicle manufacturers, refiners and
legislation work together. Since fuels and engines are
technically linked with each other, the improvement in
gasoline and diesel fuels quality will permit the adoption
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
kingdom in the past and they continue to do so at the
present time. This is because their up to date engine
components are very sensitive to high sulfur fuels, which
will cause it to be in-effective in a short while. For
example, NOx and PM pollutants require special emission
control systems to be embedded into the vehicles to trap
and convert those pollutants into friendly gases. For
those systems to operate efficiently (Figure 3
both gasoline and diesel fuels need to be further reduced
from 500 ppm to 50 as an intermediate step and
ultimately to 10 ppm. At 10 ppm the emission control
systems will give the utmost optimum performance that
will drastically mitigate the NO
2/PM emissions to the least.
Therefore, it is clear that reduction of NO
2and PM
emissions are solely dependent on low emission engine
technology. To introduce those low emission engines to
the kingdom’s fleet, it requires around 18 years to have
full replacement of our high emission vehicle fleet. As a
result, the actual realization of NO
2and PM emissions
reduction will take more time as compared with the other
pollutants.
Figure 3 Sophisticated Emission Control Systems
9Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
As a result, the master plan has
recommended to lower sulfur
in transportation diesel from
10,000 ppm to 500 ppm
mitigating SO
2emissions from
diesel engines.
VISION - To become leaders in process engineering and automation!
Updates
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
ppm sulfur diesel (country wide) as compared to 10,000
ppm sulfur diesel, updating MTBE specification to 15 vol.
% as opposed to 10 vol. %, etc.
The required capital investment program associated with
implementing the long term strategy of the roadmap has
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
Saudi Aramco executives and scientists.
In 2006, P&CSD sponsored a full-day manager’s workshop
titled “Importance of Fuel Quality & Effect on Vehicle
Performance” on December 2nd, 2006. This workshop
was designed for relevant department managers who
directly deal with fuels production, distribution, and
specifications. The primary objective was to raise their
awareness to the global trend towards producing clean
fuels and to underscore the interaction between engine
and fuel technologies.
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-
relation between stringent fuel specifications, engine
performance, environment protection and the
sustainability of oil market. Several other concepts will be
addressed, as well as the future of Dieselization and the
Kingdom’s environment, as a result of the recently
approved Fuel Quality Roadmap.
Acknowledgment
P&CSD would like to thank all the multidepartmental
members who participated in the development of the
Fuel Quality Roadmap for their great ef forts and
continuous support. Their time, dedication, and
contribution towards the completion of the roadmap
added great value.
Walid A. Al-Naeemis the Supervisor of Distillation and
Treating Unit of P&CSD. He is also the Chairman of Saudi
Aramco Products Specifications Committee which is com-
posed of cross functional members from various departments
such as FPD, EPD, R&DC, OSPAS, Distribution, RTSD, Sales and
Marketing, and Domestic Refineries. This committee is
charged to look after various issues related to Saudi Aramco
Products and Fuels Specifications. Walid holds a Master
Degree in Chemical Engineering from KFUPM since 2003.
Walid is a member in several local and international techni-
cal societies and very active in IK / OOK events as chairman,
speaker, and as a delegate.
10 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
On the other hand, the required
capital investment program
associated with implementing
the long term strategy of the
roadmap has been recently
approved by the company
board to be injected into the
2009 – 2013 business plan cycle.
Today, the world’s policy
makers and business leaders
are increasingly in agreement
that climate change is occurring
and it has to be addressed.
Updates
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
ppm sulfur diesel (country wide) as compared to 10,000
ppm sulfur diesel, updating MTBE specification to 15 vol.
% as opposed to 10 vol. %, etc.
The required capital investment program associated with
implementing the long term strategy of the roadmap has
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
Saudi Aramco executives and scientists.
In 2006, P&CSD sponsored a full-day manager’s workshop
titled “Importance of Fuel Quality & Effect on Vehicle
Performance” on December 2nd, 2006. This workshop
was designed for relevant department managers who
directly deal with fuels production, distribution, and
specifications. The primary objective was to raise their
awareness to the global trend towards producing clean
fuels and to underscore the interaction between engine
and fuel technologies.
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-
relation between stringent fuel specifications, engine
performance, environment protection and the
sustainability of oil market. Several other concepts will be
addressed, as well as the future of Dieselization and the
Kingdom’s environment, as a result of the recently
approved Fuel Quality Roadmap.
Acknowledgment
P&CSD would like to thank all the multidepartmental
members who participated in the development of the
Fuel Quality Roadmap for their great ef forts and
continuous support. Their time, dedication, and
contribution towards the completion of the roadmap
added great value.
Walid A. Al-Naeemis the Supervisor of Distillation and
Treating Unit of P&CSD. He is also the Chairman of Saudi
Aramco Products Specifications Committee which is com-
posed of cross functional members from various departments
such as FPD, EPD, R&DC, OSPAS, Distribution, RTSD, Sales and
Marketing, and Domestic Refineries. This committee is
charged to look after various issues related to Saudi Aramco
Products and Fuels Specifications. Walid holds a Master
Degree in Chemical Engineering from KFUPM since 2003.
Walid is a member in several local and international techni-
cal societies and very active in IK / OOK events as chairman,
speaker, and as a delegate.
10 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
On the other hand, the required
capital investment program
associated with implementing
the long term strategy of the
roadmap has been recently
approved by the company
board to be injected into the
2009 – 2013 business plan cycle.
Today, the world’s policy
makers and business leaders
are increasingly in agreement
that climate change is occurring
and it has to be addressed.
A Patent on Hydrogen Purification Optimization
System is Granted
Ibrahim M. Al-Babtainis a Refining Specialist in the
Downstream Process Engineering Division of Saudi Aramco.
Ibrahim has 18 years of experience in refining business.
Joined P&CSD and participated with FPD and NBD as a
technical member in the development of major refining
projects and evaluation of several technologies.
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
This idea was generated during the initial start up of a
new refinery that includes multiple PSA units utilized to
treat different feed streams of CCR off gas and refinery
off gas. One of these streams exceeded the capacity of the
related PSA unit and this portion of the excess gas is not
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
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
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
US Patent # US 7,252,702 dated August 7, 2007.
With regard to implementing this invention, Yanbu‘
Export Refinery Project’s director; Mohammad S. Al-Subhi
has provided his support and encouragement to consider
implementing this patent in the project if applicable as
significant capital savings could potentially be realized.
The sketches below show the system before and after the
modification.
Figure 1 System before the modification
Figure 2 System after the modification
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
11Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
System is Granted
Ibrahim M. Al-Babtainis a Refining Specialist in the
Downstream Process Engineering Division of Saudi Aramco.
Ibrahim has 18 years of experience in refining business.
Joined P&CSD and participated with FPD and NBD as a
technical member in the development of major refining
projects and evaluation of several technologies.
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
This idea was generated during the initial start up of a
new refinery that includes multiple PSA units utilized to
treat different feed streams of CCR off gas and refinery
off gas. One of these streams exceeded the capacity of the
related PSA unit and this portion of the excess gas is not
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
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
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
US Patent # US 7,252,702 dated August 7, 2007.
With regard to implementing this invention, Yanbu‘
Export Refinery Project’s director; Mohammad S. Al-Subhi
has provided his support and encouragement to consider
implementing this patent in the project if applicable as
significant capital savings could potentially be realized.
The sketches below show the system before and after the
modification.
Figure 1 System before the modification
Figure 2 System after the modification
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
11Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200712
VISION - To become leaders in process engineering and automation!
Application of Flare Gas Recovery Systems in
Saudi Aramco facilities
“Protecting the Environment,” “Managing and
Protecting Resources,” and “Improving Health & Safety”
are all part of our Business Line Strategies to meet the
Corporate Imperatives. Installing a Flare gas recovery sys-
tem (FGRS) at the tail end of a gas plant or a refinery will
achieve all the above strategies, plus recover fuel gas
worth $2/MMBtu. The Flaring Minimization Roadmap as
endorsed by the Management Committee in June 2006,
recommended installing flare gas recovery units in com-
pany facilities where the normal daily flare gas rate
exceeds 1-2 MMSCFD, after exhausting all possible flaring
minimization efforts.
Why Flare Gas Recovery?
The main drivers for a FGRS project are;
•It’s a proven technology
•It eliminates daily flaring, except for the pilots, thus
providing intangible benefits from reduced emis-
sions of CO
2(green house gas), SO
X, NO
X, & VOCs.
The emissions of sulfur dioxide, ozone precursors
and particulates have a significant environmental
and health impact.
•It provides an economic incentive in returning the
recovered flared gas to the value chain, thus saving
on plant fuel gas.
•FGRS improves the reliability of the main flare tip.
This is an important consideration for the larger
diameter flares that are prone to damage from oper-
ation at the low daily flaring rates. With FGRS, the
main flare is in stand-by mode, which improves its
reliability and life, and minimizes the recurring cost
of flare tip replacement
•The project has a potential for emission trading and
CO
2credits, thus generating additional revenue.
•FRGS reinforces Saudi Aramco’s (& the Kingdom’s)
positive image as a responsible corporate citizen.
Figure 1 FGRS concept
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
locations where the normal daily flare gas exceeds 1-2 MMSCFD. This article
presents the concepts of FGRS and its application in Saudi Aramco.Recovered Gas to P rocess
Existing Flare s
HP/ACID or INLET
Flare Gas
Knockout Drum
New
Staging
Device
FGRS
6 MMSCFD
N2 Purge
VISION - To become leaders in process engineering and automation!
Application of Flare Gas Recovery Systems in
Saudi Aramco facilities
“Protecting the Environment,” “Managing and
Protecting Resources,” and “Improving Health & Safety”
are all part of our Business Line Strategies to meet the
Corporate Imperatives. Installing a Flare gas recovery sys-
tem (FGRS) at the tail end of a gas plant or a refinery will
achieve all the above strategies, plus recover fuel gas
worth $2/MMBtu. The Flaring Minimization Roadmap as
endorsed by the Management Committee in June 2006,
recommended installing flare gas recovery units in com-
pany facilities where the normal daily flare gas rate
exceeds 1-2 MMSCFD, after exhausting all possible flaring
minimization efforts.
Why Flare Gas Recovery?
The main drivers for a FGRS project are;
•It’s a proven technology
•It eliminates daily flaring, except for the pilots, thus
providing intangible benefits from reduced emis-
sions of CO
2(green house gas), SO
X, NO
X, & VOCs.
The emissions of sulfur dioxide, ozone precursors
and particulates have a significant environmental
and health impact.
•It provides an economic incentive in returning the
recovered flared gas to the value chain, thus saving
on plant fuel gas.
•FGRS improves the reliability of the main flare tip.
This is an important consideration for the larger
diameter flares that are prone to damage from oper-
ation at the low daily flaring rates. With FGRS, the
main flare is in stand-by mode, which improves its
reliability and life, and minimizes the recurring cost
of flare tip replacement
•The project has a potential for emission trading and
CO
2credits, thus generating additional revenue.
•FRGS reinforces Saudi Aramco’s (& the Kingdom’s)
positive image as a responsible corporate citizen.
Figure 1 FGRS concept
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
locations where the normal daily flare gas exceeds 1-2 MMSCFD. This article
presents the concepts of FGRS and its application in Saudi Aramco.Recovered Gas to P rocess
Existing Flare s
HP/ACID or INLET
Flare Gas
Knockout Drum
New
Staging
Device
FGRS
6 MMSCFD
N2 Purge
13
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
FGRS Components
A flare gas recovery installation for an existing plant will
consist of four main components:
1. A compression based package (FGRS
flare gases for re-use in the existing processing facili-
ties
2. Staging devices to safely allow diverting the routine
daily flared gases to the FGRS package but not the
emergency or abnormal relief loads. Figure 1 illus-
trates the integration of the FGRS into the flare sys-
tem.
3. A nitrogen generation package to supplement exist-
ing nitrogen generation capacity. Nitrogen will be
used as purge gas, downstream of the staging device.
4. Control system within the package and interface with
the plant DCS
As shown in Figure 1, the Flare gas recovery unit ties into
the flare gas header between the knockout drum and the
staging device, and pulls flare gas from the header when-
ever flow is detected. Basically, the staging devices enable
safe operation of the entire system through sealing the
elevated flares and provide backpressure in the flare
header, allowing the flare gases to be routed to the FGRS.
Process Design of FGRS package
As shown above, the FGRS is a compression based pack-
age designed to recover the flare gases for reuse in the
existing processing facilities. The system configuration is
dependent on the final destination of the recovered gas
and the type of compression equipment selected.
Destination of recovered gas:
Some of the potential destinations for the recovered gas
could be;
•Plant Fuel Gas header. This requires compression
facilities to compress the flare gases from near
atmospheric pressure (3.5 psig max.) to approximately
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
Figure 3
Typical Screw compressor package
offered by Man-Turbo
Figure 2
Vendor offered package for FGRS
with LRCs (courtesy: Envirocomb ltd)
The Flaring Minimization
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
flaring minimization efforts.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
FGRS Components
A flare gas recovery installation for an existing plant will
consist of four main components:
1. A compression based package (FGRS
flare gases for re-use in the existing processing facili-
ties
2. Staging devices to safely allow diverting the routine
daily flared gases to the FGRS package but not the
emergency or abnormal relief loads. Figure 1 illus-
trates the integration of the FGRS into the flare sys-
tem.
3. A nitrogen generation package to supplement exist-
ing nitrogen generation capacity. Nitrogen will be
used as purge gas, downstream of the staging device.
4. Control system within the package and interface with
the plant DCS
As shown in Figure 1, the Flare gas recovery unit ties into
the flare gas header between the knockout drum and the
staging device, and pulls flare gas from the header when-
ever flow is detected. Basically, the staging devices enable
safe operation of the entire system through sealing the
elevated flares and provide backpressure in the flare
header, allowing the flare gases to be routed to the FGRS.
Process Design of FGRS package
As shown above, the FGRS is a compression based pack-
age designed to recover the flare gases for reuse in the
existing processing facilities. The system configuration is
dependent on the final destination of the recovered gas
and the type of compression equipment selected.
Destination of recovered gas:
Some of the potential destinations for the recovered gas
could be;
•Plant Fuel Gas header. This requires compression
facilities to compress the flare gases from near
atmospheric pressure (3.5 psig max.) to approximately
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
Figure 3
Typical Screw compressor package
offered by Man-Turbo
Figure 2
Vendor offered package for FGRS
with LRCs (courtesy: Envirocomb ltd)
The Flaring Minimization
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
flaring minimization efforts.
VISION - To become leaders in process engineering and automation!
exceeds the design capacity of the FGRS.
• Pressure control, low pressure alarms, and ESD systems
should be provided at the inlet of the package to
ensure that positive pressure in the flare headers is
always maintained.
• The staging control valve/seal drum should be
designed to open to existing flare stacks when each
corresponding flare header flow exceeds the design
capacity of the FGRS.
Nitrogen purge
To ensure positive pressure in the flare headers while the
FGRS is in use, the flare headers will be continuously
purged with nitrogen at a point downstream of the
staging devices or the water seal drum. As a backup to the
nitrogen purge, fuel gas from the existing fuel gas purge
header can be provided, with automatic controls.
Impact on the existing flare system
The staging device seals the existing flare and imposes a
positive back pressure on the flare gas header. This allows
routing the flare gas to FGRS while maintaining a positive
flare gas header pressure, which is important with regard
to the safety of the flare headers. Generally the maximum
backpressure allowed will have no impact on the existing
PZVs connected to the flare header; however the actual
impact should be checked with flare simulation models
during the detailed engineering stage.
Conclusions
FGRS is a widely proven technology, though it has not
been applied in Saudi Aramco. In future, all potential sites
will be considered for a detailed evaluation for its
application. Currently a DBSP is under development for
installing a 6 MMSCFD FGRS units at ShGP & UGP . Other
potential sites being evaluated are Safaniya GOSP1 and
Riyadh Refinery. Hawiyah NGL Recovery, Khurais
Development and potentially Khursaniyah are providing
tie-ins for future units.
compressor types widely used for FGRS application are:
•Liquid ring compressor (LRC) with a variety of service
fluids, e.g., water, DGA, diesel, etc.
•Multistaged screw compressors (MSSC)
The major advantages of the above compressors types
are as follows;
•Can handle a wide range of gases with varying
molecular weights with no effect on their
performance
•Can handle flow from zero to full capacity with a
robust recycle system.
•Can tolerate liquid in the feed better than any other
type of compressors.
Typical vendor offered packages are illustrated in Figures
2 & 3. The flare gas stream can be compressed in a LRC
based compression system to 100-110 psig with water as a
service liquid in a closed loop. A heat exchanger to cool
the circulating water and a three phase separator to
remove oil and water are part of the package.
Alternately, a screw compressor package may be utilized.
Design of staging device
The flare gas stream is intercepted at a point downstream
of the corresponding Flare Knockout drums by a staging
device. The staging device is set to divert the routine
flaring rate of flared gas to the FGRS or to the elevated
flare if the rate exceeds the capacity of FGRS. The staging
devices required to seal the elevated flare can be a water
seal drum or a Buckling Pin/fast acting control valve
arrangement, similar to what is currently used at BGP,
HGP, HdGP, and proposed for the Hawiyah NGL project.
Control System
The control system within the FGRS package and DCS
interface should be part of the FGRS process detailed
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;
• The FGRS package should be isolated and safely shut-
down or put in recycle mode automatically when the
staging device opens, in the event the flaring rate
Prasad Pantula is with F&RSU /DPED since 2002. He has 25
years of experience in upstream crude oil processing,
petroleum refineries and process plant design.
Ra’ed Husseiniis a Senior Engineering Consultant with
P&CSD. He has over 23 years of Aramco experience in gas
processing, refining and in upstream.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200714
The system configuration is dependent
on the final destination of the
recovered gas and the type of
compression equipment selected.
exceeds the design capacity of the FGRS.
• Pressure control, low pressure alarms, and ESD systems
should be provided at the inlet of the package to
ensure that positive pressure in the flare headers is
always maintained.
• The staging control valve/seal drum should be
designed to open to existing flare stacks when each
corresponding flare header flow exceeds the design
capacity of the FGRS.
Nitrogen purge
To ensure positive pressure in the flare headers while the
FGRS is in use, the flare headers will be continuously
purged with nitrogen at a point downstream of the
staging devices or the water seal drum. As a backup to the
nitrogen purge, fuel gas from the existing fuel gas purge
header can be provided, with automatic controls.
Impact on the existing flare system
The staging device seals the existing flare and imposes a
positive back pressure on the flare gas header. This allows
routing the flare gas to FGRS while maintaining a positive
flare gas header pressure, which is important with regard
to the safety of the flare headers. Generally the maximum
backpressure allowed will have no impact on the existing
PZVs connected to the flare header; however the actual
impact should be checked with flare simulation models
during the detailed engineering stage.
Conclusions
FGRS is a widely proven technology, though it has not
been applied in Saudi Aramco. In future, all potential sites
will be considered for a detailed evaluation for its
application. Currently a DBSP is under development for
installing a 6 MMSCFD FGRS units at ShGP & UGP . Other
potential sites being evaluated are Safaniya GOSP1 and
Riyadh Refinery. Hawiyah NGL Recovery, Khurais
Development and potentially Khursaniyah are providing
tie-ins for future units.
compressor types widely used for FGRS application are:
•Liquid ring compressor (LRC) with a variety of service
fluids, e.g., water, DGA, diesel, etc.
•Multistaged screw compressors (MSSC)
The major advantages of the above compressors types
are as follows;
•Can handle a wide range of gases with varying
molecular weights with no effect on their
performance
•Can handle flow from zero to full capacity with a
robust recycle system.
•Can tolerate liquid in the feed better than any other
type of compressors.
Typical vendor offered packages are illustrated in Figures
2 & 3. The flare gas stream can be compressed in a LRC
based compression system to 100-110 psig with water as a
service liquid in a closed loop. A heat exchanger to cool
the circulating water and a three phase separator to
remove oil and water are part of the package.
Alternately, a screw compressor package may be utilized.
Design of staging device
The flare gas stream is intercepted at a point downstream
of the corresponding Flare Knockout drums by a staging
device. The staging device is set to divert the routine
flaring rate of flared gas to the FGRS or to the elevated
flare if the rate exceeds the capacity of FGRS. The staging
devices required to seal the elevated flare can be a water
seal drum or a Buckling Pin/fast acting control valve
arrangement, similar to what is currently used at BGP,
HGP, HdGP, and proposed for the Hawiyah NGL project.
Control System
The control system within the FGRS package and DCS
interface should be part of the FGRS process detailed
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;
• The FGRS package should be isolated and safely shut-
down or put in recycle mode automatically when the
staging device opens, in the event the flaring rate
Prasad Pantula is with F&RSU /DPED since 2002. He has 25
years of experience in upstream crude oil processing,
petroleum refineries and process plant design.
Ra’ed Husseiniis a Senior Engineering Consultant with
P&CSD. He has over 23 years of Aramco experience in gas
processing, refining and in upstream.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200714
The system configuration is dependent
on the final destination of the
recovered gas and the type of
compression equipment selected.
the use of MTC. These are:
2. Control of the optimum
regenerator temperature.
3. Adjustment of the feed
temperature up to its
bubble point to achieve
better atomization and
faster vaporization.
4. The heat absorbed with the
recycle quench is recovered
as steam production,
preheating, or reboiling in
the fractionation section of
the FCCU.
Study Conclusion
The study evaluates the implementation and potential
application of MTC at JRD/FCCU by FCC Kinetic Model
simulation model. The annual revenue incremental from
applying this technology is significant. P&CSD
recommends consideration of the following future work
if JR plans to implement the MTC technology:
Consider MTC technology for increasing the unit
conversion and production of more gasoline yield.
Utilize of the FCC Aspen Kinetic Model to evaluate several
scenarios at different feedstock conditions.
The author acknowledges the support from Graham Jones, Ahmad
Al-Othman from Pipeline & Simulation unit, Christopher Dean,
Abdulaziz Al-Ghamdi and Adel Bawizer for finishing the ESA with
JRD on time.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
JRD/FCCU MTC Technology Evaluation By FCC
Aspen Kinetic Model
The evaluation study will identify for JR major impacts of
the implementation of this technology by focusing in the
following area: unit conversion, gasoline sulfur content,
Rx velocity, vapor line velocity and overhead cooling
capacity after recycling all LCO stream. P&CSD/DPED/CCU
has signed with JR an Engineering Service Agreement
(ESA) to evaluate this technology by utilizing FCC Aspen
Kinetic Models.
Proposed Technology
The MTC technology allows for independent temperature
control of the catalyst cracking zone that results in
decreasing yields of less desirable products (coke and gas).
MTC is performed by injecting a recycle quench stream of
either cracked FCC naphtha or light cycle oil, further up
the reactor riser downstream of the combined feed
injection point (See Figure 1)
This recycle quench stream results in separating the
reactor riser into two separate reaction zones.
•The first zone, (Zone 1), between the fresh feed
injection point and the recycle quench stream
injection point, is characterized by high temperature,
high catalyst to oil ratio and very short contact time of
oil and catalyst.
•The second zone, (Zone 2), between the recycle
quench stream injection point and the riser
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:
1.To provide independent control of the catalyst and oil mix
temperature in Zone 1.
This recycle quench is a heat sink that behaves similarly to a steam
cooler or a catalyst cooler in the regenerator side of the FCC
reaction section. By behaving as a cooler the regenerated catalyst
temperature can somewhat be controlled during the catalyst
regeneration. Usually the minimum regenerated catalyst
temperature is the one that results with adequate catalyst
regeneration of coke. The cooler catalyst temperature causes
higher catalyst circulation rates for meeting the heat requirements
for the cracking reactions and maintaining reactor outlet
temperature. Additionally, there are also secondary objectives from
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
to improve Jeddah Refinery profitability by increasing conversions of gasoline and
LPG on the Fluid Catalytic Cracking Unit (FCCU).
Saeed S. Al-Alloushis a senior process engineer in the
Downstream Process Engineering Division, Process & Control
Systems Dept. (P&CSD). He has 15 years of experience with
Saudi Aramco in refining area and mainly in Fluid Catalytic
Cracking area . He graduated with Master Degree of Science
in Engineering from University of Tulsa (TU
member in American Institute of Chemical Engineering
(AICHE) since 1997.
Sidney V. Andersonis an Engineer II in Saudi Aramco’s Jiddah
Refinery Operation Engineering Unit. He has over 38 years of
process engineering and refinery management experience
and has previously served on the NPRA Q&A panel. He has
also written or co-authored several other papers related to
FCCU operations.
15Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Fig. 1 Mix Temperature Control at
FCCU Feed Riser Section
2. Control of the optimum
regenerator temperature.
3. Adjustment of the feed
temperature up to its
bubble point to achieve
better atomization and
faster vaporization.
4. The heat absorbed with the
recycle quench is recovered
as steam production,
preheating, or reboiling in
the fractionation section of
the FCCU.
Study Conclusion
The study evaluates the implementation and potential
application of MTC at JRD/FCCU by FCC Kinetic Model
simulation model. The annual revenue incremental from
applying this technology is significant. P&CSD
recommends consideration of the following future work
if JR plans to implement the MTC technology:
Consider MTC technology for increasing the unit
conversion and production of more gasoline yield.
Utilize of the FCC Aspen Kinetic Model to evaluate several
scenarios at different feedstock conditions.
The author acknowledges the support from Graham Jones, Ahmad
Al-Othman from Pipeline & Simulation unit, Christopher Dean,
Abdulaziz Al-Ghamdi and Adel Bawizer for finishing the ESA with
JRD on time.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
JRD/FCCU MTC Technology Evaluation By FCC
Aspen Kinetic Model
The evaluation study will identify for JR major impacts of
the implementation of this technology by focusing in the
following area: unit conversion, gasoline sulfur content,
Rx velocity, vapor line velocity and overhead cooling
capacity after recycling all LCO stream. P&CSD/DPED/CCU
has signed with JR an Engineering Service Agreement
(ESA) to evaluate this technology by utilizing FCC Aspen
Kinetic Models.
Proposed Technology
The MTC technology allows for independent temperature
control of the catalyst cracking zone that results in
decreasing yields of less desirable products (coke and gas).
MTC is performed by injecting a recycle quench stream of
either cracked FCC naphtha or light cycle oil, further up
the reactor riser downstream of the combined feed
injection point (See Figure 1)
This recycle quench stream results in separating the
reactor riser into two separate reaction zones.
•The first zone, (Zone 1), between the fresh feed
injection point and the recycle quench stream
injection point, is characterized by high temperature,
high catalyst to oil ratio and very short contact time of
oil and catalyst.
•The second zone, (Zone 2), between the recycle
quench stream injection point and the riser
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:
1.To provide independent control of the catalyst and oil mix
temperature in Zone 1.
This recycle quench is a heat sink that behaves similarly to a steam
cooler or a catalyst cooler in the regenerator side of the FCC
reaction section. By behaving as a cooler the regenerated catalyst
temperature can somewhat be controlled during the catalyst
regeneration. Usually the minimum regenerated catalyst
temperature is the one that results with adequate catalyst
regeneration of coke. The cooler catalyst temperature causes
higher catalyst circulation rates for meeting the heat requirements
for the cracking reactions and maintaining reactor outlet
temperature. Additionally, there are also secondary objectives from
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
to improve Jeddah Refinery profitability by increasing conversions of gasoline and
LPG on the Fluid Catalytic Cracking Unit (FCCU).
Saeed S. Al-Alloushis a senior process engineer in the
Downstream Process Engineering Division, Process & Control
Systems Dept. (P&CSD). He has 15 years of experience with
Saudi Aramco in refining area and mainly in Fluid Catalytic
Cracking area . He graduated with Master Degree of Science
in Engineering from University of Tulsa (TU
member in American Institute of Chemical Engineering
(AICHE) since 1997.
Sidney V. Andersonis an Engineer II in Saudi Aramco’s Jiddah
Refinery Operation Engineering Unit. He has over 38 years of
process engineering and refinery management experience
and has previously served on the NPRA Q&A panel. He has
also written or co-authored several other papers related to
FCCU operations.
15Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Fig. 1 Mix Temperature Control at
FCCU Feed Riser Section
VISION - To become leaders in process engineering and automation!
P&CSD Downstream Process Engineering has promptly
extended troubleshooting support to Yanbu‘ Refinery
Engineering and recommended a course of action to put
the unit in a normal mode of operation. The Continuous
Catalyst Regeneration (CCR
(YR) CCR Platformer Plant experienced successive catalyst
blowouts leading to the regeneration section shutdown.
This caused the Platformer section to operate at reduced
feed rate and severity. Prolonged shutdown of the
catalyst regeneration section would have led to the
shutdown of the Platformer Plant and the consequence of
losing the gasoline production.
Introduction
The Yanbu‘ Refinery Platformer unit was revamped in
June 2006 from a fixed bed unit to a Continuous Catalyst
Regeneration Unit. Coked spent catalyst from the
Platforming reactors is continuously sent to the CCR
Regeneration Tower where the coke is burnt off and the
spent catalyst is regenerated in four steps: 1) Coke
Burning; 2) Oxychlorination – for dispersing the catalyst
metals and adjusting the catalyst chloride content; 3)
Catalyst Drying; 4) Reduction – for changing the catalyst
metals to the reduced state. Finally, the regenerated
catalyst is circulated back to the first Platforming reactor.
Over a period of time catalyst fines plugs the Regenerator
screen. The CCR has to be shutdown and the screen
removed for cleaning every 12 months.
Incident Background
Since the first startup in June 2006, the CCR Regeneration
Tower has been operating with a partially plugged screen
as a result of catalyst fines generated in the system from
the containment loss in the Platformer reactors. This has
effectively reduced the Regeneration gas flow without
affecting the CCR operability. It was recommended by the
licensor to clean the screen at the earliest opportunity.
The CCR was shutdown for a period of 5 days to carry out
Troubleshooting YR Cyclemax Regenerator
Catalyst Blow out
Figure 1 DCS Pressure Trends
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.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200716
P&CSD Downstream Process Engineering has promptly
extended troubleshooting support to Yanbu‘ Refinery
Engineering and recommended a course of action to put
the unit in a normal mode of operation. The Continuous
Catalyst Regeneration (CCR
(YR) CCR Platformer Plant experienced successive catalyst
blowouts leading to the regeneration section shutdown.
This caused the Platformer section to operate at reduced
feed rate and severity. Prolonged shutdown of the
catalyst regeneration section would have led to the
shutdown of the Platformer Plant and the consequence of
losing the gasoline production.
Introduction
The Yanbu‘ Refinery Platformer unit was revamped in
June 2006 from a fixed bed unit to a Continuous Catalyst
Regeneration Unit. Coked spent catalyst from the
Platforming reactors is continuously sent to the CCR
Regeneration Tower where the coke is burnt off and the
spent catalyst is regenerated in four steps: 1) Coke
Burning; 2) Oxychlorination – for dispersing the catalyst
metals and adjusting the catalyst chloride content; 3)
Catalyst Drying; 4) Reduction – for changing the catalyst
metals to the reduced state. Finally, the regenerated
catalyst is circulated back to the first Platforming reactor.
Over a period of time catalyst fines plugs the Regenerator
screen. The CCR has to be shutdown and the screen
removed for cleaning every 12 months.
Incident Background
Since the first startup in June 2006, the CCR Regeneration
Tower has been operating with a partially plugged screen
as a result of catalyst fines generated in the system from
the containment loss in the Platformer reactors. This has
effectively reduced the Regeneration gas flow without
affecting the CCR operability. It was recommended by the
licensor to clean the screen at the earliest opportunity.
The CCR was shutdown for a period of 5 days to carry out
Troubleshooting YR Cyclemax Regenerator
Catalyst Blow out
Figure 1 DCS Pressure Trends
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.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200716
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Licenser
Normal Shifted
TI Specified
Profile Profile
Range
TI -1 479-510˚C 380˚C 250˚C
TI -2 493-593˚C 563˚C 465˚C
TI -3 493-593˚C 557˚C 475˚C
TI -4 493-560˚C 503˚C 511˚C
TI -5 491-504o˚C 492˚C 543˚C
TI -6 491-504˚C 487˚C 479˚C
TI -7 491-504˚C 485˚C 472˚C
TI -8 479-499˚C 485˚C 465˚C
the cleaning of the regeneration tower screen. The unit
was restarted in black burn mode. The startup was normal
and the regeneration tower temperature profile had its
peak at the second TI in the Burn Zone. The operation of
the regenerator for the next 36 hours was absolutely
normal with regenerated catalyst carbon at 0.095 wt%
and spent catalyst carbon at 4.3 wt%.
On Tuesday, January 23, a blow out occurred between the
disengaging hopper and the regeneration tower which
caused the disengaging hopper level to drop from 52 %
to 47 %. The Disengaging pressure dropped and the
Regeneration Tower pressure increased momentarily.
Figure 1 below shows the pressure fluctuation and level
drop at the time the blow out occurred.
Due to the blowout, a lot of fines and chips were
generated that plugged the Regenerator screen. A shift in
burn zone temperature profile has being experienced and
the peak temperatures shifted to fifth TI which is at the
bottom of the burn zone (refer to Table 1).
Maintaining a proper burn profile in this section is
extremely important for safe operation of the unit. If the
burn profile shifts down, un-regenerated catalyst will
enter the chlorination zone potentially causing catalyst to
agglomerate and damage the Regenerator internals.
Intensive discussions were held between Refinery
engineers and licensor experts on this subject and it was
concluded that it is very difficult to pin-point the root
cause of the blowout. An attempt was made as suggested
by licensor to stop the regeneration blower and carry out
cold circulation of the catalyst in order to clear the screen.
Accordingly the regeneration tower was cooled as per
procedure at 50˚C/Hr. When the blower was switched to
low speed at 350˚C a blowout was again observed. A
similar phenomenon was observed when the blower was
switched from low speed to high speed during the reheat.
There was no improvement in the unit performance.
Therefore, the regeneration section was again shutdown
as a result of repetitive blow out occurring between the
disengaging hopper and the regeneration tower. The CCR
Platformer throughput was lowered from the design of
40 to 30 MBD and 95.0 operating severity to control coke
lay down.
Analysis & Findings
It is very unusual for a blowout to take place in a CCR
because it is normally catalyst full. During normal
operation the catalyst flows down due to gravity. The
Disengaging Hopper operates at approximately 9
kg/cm2(g
approximately 2.5 Kg/cm
2
(g). This huge pressure
differential is taken by the catalyst in the long transfer
pipes between the Disengaging Hopper and the
Regeneration Tower. If due to any reason a void is created
in the Regeneration Tower, the huge differential pressure
will force the catalyst down, causing a pressure
fluctuation that generates a lot of fines and dust. The
fines will block the Regenerator screen, causing the
temperature profile to slip down.
P&CSD analyzed the problem on the
following lines:
1.One probable cause could be something blocking the
catalyst transfer pipe. But this would be a one time
occurrence that would get automatically cleared after
the blowout. But since the blowout reoccurred it was
obvious that it was not due to plugging of the
transfer pipes.
2. The only difference between the two startups was the
condition of the screen. Since initial startup the unit
was operating with a plugged screen. The recent
startup was the first time with a clean screen.
3.The blowout was clearly related to the blower
operation because the blowout had happened on two
occasions when the blower speed was switched.
Analysis of the previous operating data showed that the
blower flow was 102 % of design even with a partially
plugged screen. Once the screen was cleaned the flow
increased causing the catalyst to pin in the Regeneration
Tower. Since the Lock Hopper is removing catalyst, a void
was created at some location in the Regeneration Tower.
When the differential pressure between the Disengaging
Table 1: Regeneration Tower Normal and Incident
Temperature Profiles
17Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
Licenser
Normal Shifted
TI Specified
Profile Profile
Range
TI -1 479-510˚C 380˚C 250˚C
TI -2 493-593˚C 563˚C 465˚C
TI -3 493-593˚C 557˚C 475˚C
TI -4 493-560˚C 503˚C 511˚C
TI -5 491-504o˚C 492˚C 543˚C
TI -6 491-504˚C 487˚C 479˚C
TI -7 491-504˚C 485˚C 472˚C
TI -8 479-499˚C 485˚C 465˚C
the cleaning of the regeneration tower screen. The unit
was restarted in black burn mode. The startup was normal
and the regeneration tower temperature profile had its
peak at the second TI in the Burn Zone. The operation of
the regenerator for the next 36 hours was absolutely
normal with regenerated catalyst carbon at 0.095 wt%
and spent catalyst carbon at 4.3 wt%.
On Tuesday, January 23, a blow out occurred between the
disengaging hopper and the regeneration tower which
caused the disengaging hopper level to drop from 52 %
to 47 %. The Disengaging pressure dropped and the
Regeneration Tower pressure increased momentarily.
Figure 1 below shows the pressure fluctuation and level
drop at the time the blow out occurred.
Due to the blowout, a lot of fines and chips were
generated that plugged the Regenerator screen. A shift in
burn zone temperature profile has being experienced and
the peak temperatures shifted to fifth TI which is at the
bottom of the burn zone (refer to Table 1).
Maintaining a proper burn profile in this section is
extremely important for safe operation of the unit. If the
burn profile shifts down, un-regenerated catalyst will
enter the chlorination zone potentially causing catalyst to
agglomerate and damage the Regenerator internals.
Intensive discussions were held between Refinery
engineers and licensor experts on this subject and it was
concluded that it is very difficult to pin-point the root
cause of the blowout. An attempt was made as suggested
by licensor to stop the regeneration blower and carry out
cold circulation of the catalyst in order to clear the screen.
Accordingly the regeneration tower was cooled as per
procedure at 50˚C/Hr. When the blower was switched to
low speed at 350˚C a blowout was again observed. A
similar phenomenon was observed when the blower was
switched from low speed to high speed during the reheat.
There was no improvement in the unit performance.
Therefore, the regeneration section was again shutdown
as a result of repetitive blow out occurring between the
disengaging hopper and the regeneration tower. The CCR
Platformer throughput was lowered from the design of
40 to 30 MBD and 95.0 operating severity to control coke
lay down.
Analysis & Findings
It is very unusual for a blowout to take place in a CCR
because it is normally catalyst full. During normal
operation the catalyst flows down due to gravity. The
Disengaging Hopper operates at approximately 9
kg/cm2(g
approximately 2.5 Kg/cm
2
(g). This huge pressure
differential is taken by the catalyst in the long transfer
pipes between the Disengaging Hopper and the
Regeneration Tower. If due to any reason a void is created
in the Regeneration Tower, the huge differential pressure
will force the catalyst down, causing a pressure
fluctuation that generates a lot of fines and dust. The
fines will block the Regenerator screen, causing the
temperature profile to slip down.
P&CSD analyzed the problem on the
following lines:
1.One probable cause could be something blocking the
catalyst transfer pipe. But this would be a one time
occurrence that would get automatically cleared after
the blowout. But since the blowout reoccurred it was
obvious that it was not due to plugging of the
transfer pipes.
2. The only difference between the two startups was the
condition of the screen. Since initial startup the unit
was operating with a plugged screen. The recent
startup was the first time with a clean screen.
3.The blowout was clearly related to the blower
operation because the blowout had happened on two
occasions when the blower speed was switched.
Analysis of the previous operating data showed that the
blower flow was 102 % of design even with a partially
plugged screen. Once the screen was cleaned the flow
increased causing the catalyst to pin in the Regeneration
Tower. Since the Lock Hopper is removing catalyst, a void
was created at some location in the Regeneration Tower.
When the differential pressure between the Disengaging
Table 1: Regeneration Tower Normal and Incident
Temperature Profiles
17Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
Hopper and the Regeneration Tower was high enough, it
forced the catalyst to fill the void creating a blowout. This
would also explain why the blowout occurred when the
blower speed was changed. The first time when the
blower was switched from high speed to low speed the
catalyst unpinned, causing an immediate blowout. The
second time the blower was switched from low speed to
high speed caused the catalyst to pin. The blowout did
not occur immediately. During subsequent heat up the
catalyst slumped, creating a void below the pinned area,
causing a blowout.
A conference call was initiated by YR Engineering and
P&CSD with the Licenser on January 31, 2007. P&CSD
convinced the licensor that the blower could be a highly
probable cause for the blowout and it was decided that:
1. The licensor would size a restriction orifice to reduce
the Regeneration Gas flow by 15-20 % to avoid
pinning. YR would keep it ready for installation in the
Regeneration tower gas outlet line.
2. Conduct inspection of the disengaging hopper and
regeneration tower screen.
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
The regeneration tower and the Disengaging Hopper
were open for inspection. While unloading the catalyst,
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
cycles there should not have been any fresh catalyst
remaining in the Disengaging Hopper . This clearly
indicated that the catalyst was not moving as a result of
localized catalyst pinning on the regeneration tower
screen. No clumps or debris were found between the
disengaging hopper and the regeneration tower. The
Regeneration screen was heavily plugged. There was no
sign of integrity loss or severe damage to the screen.
P&CSD concluded that the root cause for this problem was
the oversizing of the regeneration gas blower.
Recommendations
P&CSD recommended installing a restriction orifice in the
Regeneration gas blower suction line to reduce the
Regeneration gas flow and increase the pinning margin.
YR and Licenser supported P&CSD’s findings and decided
to install a restriction orifice in the regeneration gas
outlet line, to reduce the regeneration gas blower flow by
approximately 15%, and prevent catalyst pinning on the
regeneration tower screen. Unit licensor designed a
restriction orifice with a bore size of 340mm, which was
fabricated by YR and installed in the Regeneration gas
outlet line to reduce the flow by approximately 15%.
CCR Restart
The regeneration section was restarted on Feb 6, 2007,
after the installation of the restriction orifice. The startup
was smooth without any pressure fluctuations or signs of
blowout. The circulation rate was slowly increased to 95
% of design and the oxygen concentration was slowly
reduced from 1.0 mole% to 0.9 mole%. Laboratory results
showed less than 0.07 wt% carbon, indicating complete
regeneration. The temperature profile in the
regeneration section was satisfactory, indicating no
reduction in the unit capacity.
In conclusion, installation of the restriction orifice on the
regeneration gas blower suction eliminated the pinning
problem from the over-design of the blower. Normal CCR
Platformer operation resumed.
Rabea M. Al-Saggafis a process engineer working with Saudi
Aramco Yanbu‘ Refinery Department. He has 10 years
experience in refineries. Rabea holds a B.S degree in chemical
engineering from King Abdulaziz University, Jeddah 1996.
He joined Saudi Aramco in 1996.
Neelay Bhattacharyais a process engineer working with
Saudi Aramco Process and Control Systems Department. He
has 17 years experience in Refineries and Petrochemical
plants. Neelay holds a B.E degree in Petroleum and
Petrochemicals from Pune University, India 1990. He joined
Saudi Aramco in 2006.
Hamzah Z. Abuduraihemis a process engineer working with
Saudi Aramco Process and Control Systems Department. He
has 15 years experience in refinery operation and project.
Hamzah holds a M.S degree in Chemical Engineering and
Petroleum Refining from Colorado School of Mines, USA
2001. He joined Saudi Aramco in 1992.
Sajeesh Padmanabhanis a chemical engineer and works with
the Operation Engineering & Automation Unit at Yanbu‘
Refinery. He has 11 years of experience in Hydrotreating,
Plaforming and Petrochemicals. He joined Saudi Aramco in
Jan 2005.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200718
Hopper and the Regeneration Tower was high enough, it
forced the catalyst to fill the void creating a blowout. This
would also explain why the blowout occurred when the
blower speed was changed. The first time when the
blower was switched from high speed to low speed the
catalyst unpinned, causing an immediate blowout. The
second time the blower was switched from low speed to
high speed caused the catalyst to pin. The blowout did
not occur immediately. During subsequent heat up the
catalyst slumped, creating a void below the pinned area,
causing a blowout.
A conference call was initiated by YR Engineering and
P&CSD with the Licenser on January 31, 2007. P&CSD
convinced the licensor that the blower could be a highly
probable cause for the blowout and it was decided that:
1. The licensor would size a restriction orifice to reduce
the Regeneration Gas flow by 15-20 % to avoid
pinning. YR would keep it ready for installation in the
Regeneration tower gas outlet line.
2. Conduct inspection of the disengaging hopper and
regeneration tower screen.
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
The regeneration tower and the Disengaging Hopper
were open for inspection. While unloading the catalyst,
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
cycles there should not have been any fresh catalyst
remaining in the Disengaging Hopper . This clearly
indicated that the catalyst was not moving as a result of
localized catalyst pinning on the regeneration tower
screen. No clumps or debris were found between the
disengaging hopper and the regeneration tower. The
Regeneration screen was heavily plugged. There was no
sign of integrity loss or severe damage to the screen.
P&CSD concluded that the root cause for this problem was
the oversizing of the regeneration gas blower.
Recommendations
P&CSD recommended installing a restriction orifice in the
Regeneration gas blower suction line to reduce the
Regeneration gas flow and increase the pinning margin.
YR and Licenser supported P&CSD’s findings and decided
to install a restriction orifice in the regeneration gas
outlet line, to reduce the regeneration gas blower flow by
approximately 15%, and prevent catalyst pinning on the
regeneration tower screen. Unit licensor designed a
restriction orifice with a bore size of 340mm, which was
fabricated by YR and installed in the Regeneration gas
outlet line to reduce the flow by approximately 15%.
CCR Restart
The regeneration section was restarted on Feb 6, 2007,
after the installation of the restriction orifice. The startup
was smooth without any pressure fluctuations or signs of
blowout. The circulation rate was slowly increased to 95
% of design and the oxygen concentration was slowly
reduced from 1.0 mole% to 0.9 mole%. Laboratory results
showed less than 0.07 wt% carbon, indicating complete
regeneration. The temperature profile in the
regeneration section was satisfactory, indicating no
reduction in the unit capacity.
In conclusion, installation of the restriction orifice on the
regeneration gas blower suction eliminated the pinning
problem from the over-design of the blower. Normal CCR
Platformer operation resumed.
Rabea M. Al-Saggafis a process engineer working with Saudi
Aramco Yanbu‘ Refinery Department. He has 10 years
experience in refineries. Rabea holds a B.S degree in chemical
engineering from King Abdulaziz University, Jeddah 1996.
He joined Saudi Aramco in 1996.
Neelay Bhattacharyais a process engineer working with
Saudi Aramco Process and Control Systems Department. He
has 17 years experience in Refineries and Petrochemical
plants. Neelay holds a B.E degree in Petroleum and
Petrochemicals from Pune University, India 1990. He joined
Saudi Aramco in 2006.
Hamzah Z. Abuduraihemis a process engineer working with
Saudi Aramco Process and Control Systems Department. He
has 15 years experience in refinery operation and project.
Hamzah holds a M.S degree in Chemical Engineering and
Petroleum Refining from Colorado School of Mines, USA
2001. He joined Saudi Aramco in 1992.
Sajeesh Padmanabhanis a chemical engineer and works with
the Operation Engineering & Automation Unit at Yanbu‘
Refinery. He has 11 years of experience in Hydrotreating,
Plaforming and Petrochemicals. He joined Saudi Aramco in
Jan 2005.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200718
VISION - To become leaders in process engineering and automation!
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.
P&CSD Manager Saleh A. Al-Zaid highlighted the
importance of the distillation process in every plant and
refinery. He also concentrated on the importance of
P&CSD in supporting Saudi Aramco’s domestic refineries,
especially given the rise in fuel demand.
“The importance of this workshop is derived from the
importance of crude and vacuum distillation processes,”
Al-Zaid said. “Crude and vacuum units are the heart and
the main gate of every refinery in the world. Their
importance is not negotiable.”
Representatives from two leading companies in crude
distillation process revamps and technologies, Koch-Glitch
and Sulzer Chemtic, presented “Primary Refinery
Treatment: Process and Technology.” That was followed
by panel discussions on Crude Distillation
(Atmospheric/Vacuum) and Crude Handling and
Desalting, featuring panelists from Saudi Aramco, and
Sulzer and Koch-Glitsch.
The Sulzer representative delivered the second
technology presentation, “Maximize Distillate Recovery
by Means of Advanced Mass Components.” That was
followed by a panel discussion on energy conservation at
crude distillation units, moderated by Tariq A. Al-Zahrani
and Khalid S. Al-Otaibi from P&CSD’s Distillation and
Treating Unit.
“It was a great opportunity to exchange experiences
with engineers, specialists and consultants from
different organizations within Saudi Aramco and
worldwide industries,”
said Mohammed S. Al-Ghamdi,
Yanbu‘Refinery Operations Engineering and Automation
Unit supervisor, of the value of the workshop.
Walid A. Al-Naeem, supervisor of D&TU, concluded the
workshop by thanking the attendees for their
participation.
Distillation Workshop
Saleh A. Al-Zaid, manager of P&CSD left talks with Said Al-Zahrani &
Mohammed Slamah during break time.
Distillation workshop attendees, organizers and panelists pose for a picture in R&DC Technical Exchange Center.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200720
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.
P&CSD Manager Saleh A. Al-Zaid highlighted the
importance of the distillation process in every plant and
refinery. He also concentrated on the importance of
P&CSD in supporting Saudi Aramco’s domestic refineries,
especially given the rise in fuel demand.
“The importance of this workshop is derived from the
importance of crude and vacuum distillation processes,”
Al-Zaid said. “Crude and vacuum units are the heart and
the main gate of every refinery in the world. Their
importance is not negotiable.”
Representatives from two leading companies in crude
distillation process revamps and technologies, Koch-Glitch
and Sulzer Chemtic, presented “Primary Refinery
Treatment: Process and Technology.” That was followed
by panel discussions on Crude Distillation
(Atmospheric/Vacuum) and Crude Handling and
Desalting, featuring panelists from Saudi Aramco, and
Sulzer and Koch-Glitsch.
The Sulzer representative delivered the second
technology presentation, “Maximize Distillate Recovery
by Means of Advanced Mass Components.” That was
followed by a panel discussion on energy conservation at
crude distillation units, moderated by Tariq A. Al-Zahrani
and Khalid S. Al-Otaibi from P&CSD’s Distillation and
Treating Unit.
“It was a great opportunity to exchange experiences
with engineers, specialists and consultants from
different organizations within Saudi Aramco and
worldwide industries,”
said Mohammed S. Al-Ghamdi,
Yanbu‘Refinery Operations Engineering and Automation
Unit supervisor, of the value of the workshop.
Walid A. Al-Naeem, supervisor of D&TU, concluded the
workshop by thanking the attendees for their
participation.
Distillation Workshop
Saleh A. Al-Zaid, manager of P&CSD left talks with Said Al-Zahrani &
Mohammed Slamah during break time.
Distillation workshop attendees, organizers and panelists pose for a picture in R&DC Technical Exchange Center.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 200720
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
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
Al-Faleh, Sr. VP, Industrial Relations of Saudi Arabian Oil Company (Saudi
Aramco). Mr. Al-Faleh discusses Saudi Aramco’s global and national business
challenges and the need to elevate IK educational outcomes to meet the
country’s rapid economic growth and international competition. In this regard,
he has addressed the state of the Kingdom’s educational system and its
competitiveness at an international level.In addition, three key Board Officers
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.
The Guest Speaker Mr.
Khaled Al-Faleh,Sr. VP.
Industrial Relations of Saudi
Arabian Oil Company (Saudi
Aramco) addressed his
presentation “Educational
Outcomes & Industry Needs:
Saudi Aramco’s Perspective”
during AIChE-SAS April
monthly meeting sponsored
by P&CSD.
Mr. Abdulmohsen D. Al-Majnouni, AIChe-SAS Chairman, hand on the society plague
to Mr. Saleh Al-Zaid, P&CSD Manager, to thank him for his contribution.
21Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
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
Al-Faleh, Sr. VP, Industrial Relations of Saudi Arabian Oil Company (Saudi
Aramco). Mr. Al-Faleh discusses Saudi Aramco’s global and national business
challenges and the need to elevate IK educational outcomes to meet the
country’s rapid economic growth and international competition. In this regard,
he has addressed the state of the Kingdom’s educational system and its
competitiveness at an international level.In addition, three key Board Officers
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.
The Guest Speaker Mr.
Khaled Al-Faleh,Sr. VP.
Industrial Relations of Saudi
Arabian Oil Company (Saudi
Aramco) addressed his
presentation “Educational
Outcomes & Industry Needs:
Saudi Aramco’s Perspective”
during AIChE-SAS April
monthly meeting sponsored
by P&CSD.
Mr. Abdulmohsen D. Al-Majnouni, AIChe-SAS Chairman, hand on the society plague
to Mr. Saleh Al-Zaid, P&CSD Manager, to thank him for his contribution.
21Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Pipeline Simulation Interest Group (PSIG) that will take
place in October this year in Canada.
The paper introduces new method of simulating a process
variable (PV) rate of change with respect to time (time
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
calculated PVs. Flow, on the other hand, is the most
common PV rate of change of mass or volume with
22
VISION - To become leaders in process engineering and automation!
Rate of Change Modeling
N. A. Al-Nasr and M.A. Al-Rasheed co-authored a joint
paper titled “A Method of Simulating Rate of Change
with Applications in Pipelines Protection and Check
Valves Selection.
” The paper has been accepted for
presentation and publication in the 2007 Conference of
Graph 1
Pressure & Flow Profile of the Simulated
Pipeline System
Figure 1 Schematic of water injection pipeline system
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
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.V.SRV
NODE1
NODE2
B.SRVNODE3
H.SRVE.SRV NODE4
E.UWSS1.SUCT
N.UWSS1.SUCT
UPUMP1 NODE5
UPUMP2
UBLOCK1
N.UWSS1.DISCH
NODE6
NODE8
UBLOCK2
B.UWHW.IN T.UWSS1B.HCWIPNODE7
T.UWSS1A.HCWIP
LOOP
B.UWHW.OUT
HWELLS NHCWIP001
place in October this year in Canada.
The paper introduces new method of simulating a process
variable (PV) rate of change with respect to time (time
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
calculated PVs. Flow, on the other hand, is the most
common PV rate of change of mass or volume with
22
VISION - To become leaders in process engineering and automation!
Rate of Change Modeling
N. A. Al-Nasr and M.A. Al-Rasheed co-authored a joint
paper titled “A Method of Simulating Rate of Change
with Applications in Pipelines Protection and Check
Valves Selection.
” The paper has been accepted for
presentation and publication in the 2007 Conference of
Graph 1
Pressure & Flow Profile of the Simulated
Pipeline System
Figure 1 Schematic of water injection pipeline system
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
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.V.SRV
NODE1
NODE2
B.SRVNODE3
H.SRVE.SRV NODE4
E.UWSS1.SUCT
N.UWSS1.SUCT
UPUMP1 NODE5
UPUMP2
UBLOCK1
N.UWSS1.DISCH
NODE6
NODE8
UBLOCK2
B.UWHW.IN T.UWSS1B.HCWIPNODE7
T.UWSS1A.HCWIP
LOOP
B.UWHW.OUT
HWELLS NHCWIP001
respect to time. Fluid velocity (V) in a pipeline is another
example of a PV rate of change of the fluid traveled-
distance with respect to time, which is usually calculated
from flow rate based on physical properties of fluid (e.g.
density and viscosity) and pipe size and material. The
pressure rate of change (dP/dt) such as pressure rate of
rise (PRR), or velocity rate of change (dV/dt = a), that is,
acceleration or deceleration are not standard calculated
outputs in pipelines hydraulics and surge analysis
software programs.
A PV rate of change like dP/dt is very useful in surge
analysis to simulate rate-of-rise types of surge relief
valves. Also, knowing a PV rate of change like dV/dt from
a transient analysis simulation, helps identifying the
23
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Graph 2
PRR Controller Output (Red) & FSP Controller
Output (Black) After Surge
Graph 3
Response of SRV (Relieved Flow in Blue
& FSP Controllers After Surge
Graph 4
Dimensional Dynamic Performance Curve (DPC)
of Various Check Valves
Graph 5
Non-dimensional Dynamic Performance
Curve (DPC) of Various Check Valves
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
example of a PV rate of change of the fluid traveled-
distance with respect to time, which is usually calculated
from flow rate based on physical properties of fluid (e.g.
density and viscosity) and pipe size and material. The
pressure rate of change (dP/dt) such as pressure rate of
rise (PRR), or velocity rate of change (dV/dt = a), that is,
acceleration or deceleration are not standard calculated
outputs in pipelines hydraulics and surge analysis
software programs.
A PV rate of change like dP/dt is very useful in surge
analysis to simulate rate-of-rise types of surge relief
valves. Also, knowing a PV rate of change like dV/dt from
a transient analysis simulation, helps identifying the
23
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Graph 2
PRR Controller Output (Red) & FSP Controller
Output (Black) After Surge
Graph 3
Response of SRV (Relieved Flow in Blue
& FSP Controllers After Surge
Graph 4
Dimensional Dynamic Performance Curve (DPC)
of Various Check Valves
Graph 5
Non-dimensional Dynamic Performance
Curve (DPC) of Various Check Valves
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
Nazar A. Al-Nasr:Holds a PhD of Mathematics since 1981
from Clarkson University, NY, USA. An assistant professor of
mathematics at KFUP, for two years. Published several
papers on mathematical applications to multi-variable
control systems. Joined Saudi Aramco in 1983. Has 12 years
of experience in operator training simulators (OTS).
Developed in-house real-time custom models for OTS in the
Northern Area Producing. Currently an engineering specialist
in pipeline hydraulics and surge analysis simulation.
M. A. Al-Rasheed:A Pipeline Hydraulics & Surge Analysis
engineer in the Upstream Process Engineering Division. Has
more than 15 years experience in the oil industry. Holds a
degree in chemical engineering from King Fahd University
of Petroleum & Minerals in Dhahran. A member of the
Pipeline Simulation Interest Group (PSIG) and the American
Association of Chemical Engineering (AICHE).
suitable check valve for a specific system and application.
There are also situations where PV rate of change is
needed to be observed almost continuously and displayed
before an operator in the form of “rate of change”
alarms, where abnormal variation of PV data with respect
to time, such as sudden increase or decrease of pressure
can trigger rate of change alarms. While PV data may not
be high or low enough to trigger normal high or low
alarms, rapid fluctuation in PV value, in the from of rate
of change with respect to time, can indicate abnormal
operating conditions. Such rate of change alarms would
then alert the operator to respond ahead of time to the
observed abnormal situation and take a corrective action
before unacceptable operating conditions can occur.
These kinds of alarms can be simulated by applying the
proposed method.
Though, the derivative action in a PID controller can cause
amplification of any noise in the error signal, the
proposed method of derivative-only controller can be
applied in simulation with the absence of any source of
noise.
The proposed method is detailed with two illustrative
application examples in the PSIG paper.
Graph 6
Fluid Velocity Before & After Closure of the
Downstream Valve
Graph 7
Response of SRV (Relieved Flow in Blue
to PRR & FSP Controllers After Surge
24 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
A PV rate of change like dP/dt is
very useful in surge analysis to
simulate rate-of-rise types of
surge relief valves.
Though, the derivative action in
a PID controller can cause
amplification of any noise in
the error signal, the proposed
method of derivative-only
controller can be applied in
simulation with the absence of
any source of noise.
Nazar A. Al-Nasr:Holds a PhD of Mathematics since 1981
from Clarkson University, NY, USA. An assistant professor of
mathematics at KFUP, for two years. Published several
papers on mathematical applications to multi-variable
control systems. Joined Saudi Aramco in 1983. Has 12 years
of experience in operator training simulators (OTS).
Developed in-house real-time custom models for OTS in the
Northern Area Producing. Currently an engineering specialist
in pipeline hydraulics and surge analysis simulation.
M. A. Al-Rasheed:A Pipeline Hydraulics & Surge Analysis
engineer in the Upstream Process Engineering Division. Has
more than 15 years experience in the oil industry. Holds a
degree in chemical engineering from King Fahd University
of Petroleum & Minerals in Dhahran. A member of the
Pipeline Simulation Interest Group (PSIG) and the American
Association of Chemical Engineering (AICHE).
suitable check valve for a specific system and application.
There are also situations where PV rate of change is
needed to be observed almost continuously and displayed
before an operator in the form of “rate of change”
alarms, where abnormal variation of PV data with respect
to time, such as sudden increase or decrease of pressure
can trigger rate of change alarms. While PV data may not
be high or low enough to trigger normal high or low
alarms, rapid fluctuation in PV value, in the from of rate
of change with respect to time, can indicate abnormal
operating conditions. Such rate of change alarms would
then alert the operator to respond ahead of time to the
observed abnormal situation and take a corrective action
before unacceptable operating conditions can occur.
These kinds of alarms can be simulated by applying the
proposed method.
Though, the derivative action in a PID controller can cause
amplification of any noise in the error signal, the
proposed method of derivative-only controller can be
applied in simulation with the absence of any source of
noise.
The proposed method is detailed with two illustrative
application examples in the PSIG paper.
Graph 6
Fluid Velocity Before & After Closure of the
Downstream Valve
Graph 7
Response of SRV (Relieved Flow in Blue
to PRR & FSP Controllers After Surge
24 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
A PV rate of change like dP/dt is
very useful in surge analysis to
simulate rate-of-rise types of
surge relief valves.
Though, the derivative action in
a PID controller can cause
amplification of any noise in
the error signal, the proposed
method of derivative-only
controller can be applied in
simulation with the absence of
any source of noise.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
TORR Technology for Produced Water Treatment
As assets mature, and produced water volumes increase,
producing facilities face major problems in dealing with
the resultant process issues. On the other side of the
equation, increasingly stringent discharge specifications,
limit the disposal options open to these facilities; i.e.,
current oil-in-water content between 50-100 mg/l with
future reductions to less than 50 mg/l.
All these factors mean that produced water is no longer a
simple waste stream. Equally, the complexity of the
problem is such that no single item of equipment is
enough to mitigate the problem, and a truly integrated
approach is therefore needed to address all aspects of the
process.
This challenge is visible in NAOO as capital projects have
already been put in place, to expand and improve the
present water handling facilities, for the GOSPs to
operate at the maximum sustained rates/capacities (MSC).
Oil-In-Water Separation Theory:
The performance of any given separation technique will
Technology approach towards challenges faced by the significant increase of pro-
duced water from the oil fields “Optimize Operations for Improved Performance”
depend entirely on the condition of the oil-water
mixture. Present techniques for the separation of oil from
water are based on their difference of density.
Stoke’s Law states that rising velocity (Vr) is a function of
the square of the oil droplets’ diameter as shown in the
below equation: Vr
αd^2 (ρw – ρo) / μ
Where V ρ= rise velocity of oil droplet
ρw = density of water, ρo = density of oil
d = oil droplet diameter, μ= viscosity of water
From Stoke’s Law, it can be seen that droplet size has the
largest impact on the rising velocity rate of oil droplets in
water. Consequently, the bigger the droplet size, the less
time it takes for the droplet to rise to a collection surface
and thus easier to treat the water. The oil in the produced
water can be present as free-oil, and/or dispersed, and/or
dissolved states in different proportions.
Free-oil is defined as an oil droplet of 150 microns, which
will float immediately to the surface due to its large size
and high rising velocity. An emulsion is defined as oil
which is dispersed in the water in a stable fashion due to
its small diameter and its low rising velocity.
Author: Salah M. Al-BinHaji
Figure 1 Technology Oil-In-Water Separation Process
25Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
TORR Technology for Produced Water Treatment
As assets mature, and produced water volumes increase,
producing facilities face major problems in dealing with
the resultant process issues. On the other side of the
equation, increasingly stringent discharge specifications,
limit the disposal options open to these facilities; i.e.,
current oil-in-water content between 50-100 mg/l with
future reductions to less than 50 mg/l.
All these factors mean that produced water is no longer a
simple waste stream. Equally, the complexity of the
problem is such that no single item of equipment is
enough to mitigate the problem, and a truly integrated
approach is therefore needed to address all aspects of the
process.
This challenge is visible in NAOO as capital projects have
already been put in place, to expand and improve the
present water handling facilities, for the GOSPs to
operate at the maximum sustained rates/capacities (MSC).
Oil-In-Water Separation Theory:
The performance of any given separation technique will
Technology approach towards challenges faced by the significant increase of pro-
duced water from the oil fields “Optimize Operations for Improved Performance”
depend entirely on the condition of the oil-water
mixture. Present techniques for the separation of oil from
water are based on their difference of density.
Stoke’s Law states that rising velocity (Vr) is a function of
the square of the oil droplets’ diameter as shown in the
below equation: Vr
αd^2 (ρw – ρo) / μ
Where V ρ= rise velocity of oil droplet
ρw = density of water, ρo = density of oil
d = oil droplet diameter, μ= viscosity of water
From Stoke’s Law, it can be seen that droplet size has the
largest impact on the rising velocity rate of oil droplets in
water. Consequently, the bigger the droplet size, the less
time it takes for the droplet to rise to a collection surface
and thus easier to treat the water. The oil in the produced
water can be present as free-oil, and/or dispersed, and/or
dissolved states in different proportions.
Free-oil is defined as an oil droplet of 150 microns, which
will float immediately to the surface due to its large size
and high rising velocity. An emulsion is defined as oil
which is dispersed in the water in a stable fashion due to
its small diameter and its low rising velocity.
Author: Salah M. Al-BinHaji
Figure 1 Technology Oil-In-Water Separation Process
25Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
Salah M. Al-BinHajiis a process engineer with Oil
Production Unit /UPED. He has seven years of experience
with Saudi Aramco. He worked as a plant engineer, senior
engineer and safety/Environmental/Health engineer in
North Ghawar Producing Department. Currently he is on a
one year assignment with P&CSD.
The Challenge of Removing Small Oil-
In-Water Droplet:
Even under favorable conditions, oil droplets smaller than
about 30 mm in water are known to be quite difficult to
separate (From Literature). Oily water with small droplets
less than 30 mm are even more difficult to separate.
Therefore, it is important to fully understand the
characteristics of the produced water . The size
distribution curve for the dispersed oil in water must be
measured to effectively address the issues and meet and
exceed the set discharge targets.
TORR Technology (Newly introduced
technology for produced water treatment):
As part of P&CSD efforts in exploring technologies to
optimize operations for improved performance, new
produced water treatment technology (TORR™) is being
investigated for application.
The TORR™ (Total Oil Remediation and Recovery) System
was developed by EARTH (Canada
This technology is based on the filtration, coalescence,
and gravity separation process. These three principles are
combined together into a single process resulting in a
self-cleaning oily water filtration system. To achieve that,
the RPA® (Reusable Petroleum Absorbent
hydrophobic absorbent developed and patented by
EARTH (Canada
/coalescing medium. The RPA has the following
characteristics:
•Absorption of very fine emulsions down to 2 microns as
a result of being highly oleophillic.
•Capacity to continue absorbing the fine emulsions even
when it’s fully saturated with oil, while desorbing the
coalesced oil as free-floating oil.
The two previously mentioned characteristics of RPA
allows for an efficient process (removal of oil emulsions
down to 2 microns) and also a self-cleaning system
(continuous oil separation and recovery) with low
operations and maintenance.
The technology offers several potential benefits as
follows:
•Separates and recovers non-soluble dispersed
hydrocarbons in water with approximately 2 microns in
diameter and larger.
•Reduce the hydrocarbon content of non-soluble
hydrocarbons to below 10 PPM. The technology claims to
have the highest oil removal efficiency for oil-in-water
droplets size even below 30 mm (between 15-30 mm
•Accomplishes oil separation and recovery without the
need for chemicals or heat, thus operational costs are
minimal.
•Energy requirements for pumping the oily water are
minimal since the TORR™’ system’s pressure drop across
the process is low.
P&CSD has coordinated a technical meeting for the new
technology in which representatives from SAOO, NAOO,
EPD, FPD, and Aramco Service Company (ASC) attended
the meeting.
P&CSD is in the discussion stage with the vendor and
NAOO for conducting a trial test of this technology.
Figure 2 Technology Process Flow Diagram
26 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
The size distribution
curve for the
dispersed oil in water
must be measured to
effectively address the
issues and meet and
exceed the set
discharge targets.
Salah M. Al-BinHajiis a process engineer with Oil
Production Unit /UPED. He has seven years of experience
with Saudi Aramco. He worked as a plant engineer, senior
engineer and safety/Environmental/Health engineer in
North Ghawar Producing Department. Currently he is on a
one year assignment with P&CSD.
The Challenge of Removing Small Oil-
In-Water Droplet:
Even under favorable conditions, oil droplets smaller than
about 30 mm in water are known to be quite difficult to
separate (From Literature). Oily water with small droplets
less than 30 mm are even more difficult to separate.
Therefore, it is important to fully understand the
characteristics of the produced water . The size
distribution curve for the dispersed oil in water must be
measured to effectively address the issues and meet and
exceed the set discharge targets.
TORR Technology (Newly introduced
technology for produced water treatment):
As part of P&CSD efforts in exploring technologies to
optimize operations for improved performance, new
produced water treatment technology (TORR™) is being
investigated for application.
The TORR™ (Total Oil Remediation and Recovery) System
was developed by EARTH (Canada
This technology is based on the filtration, coalescence,
and gravity separation process. These three principles are
combined together into a single process resulting in a
self-cleaning oily water filtration system. To achieve that,
the RPA® (Reusable Petroleum Absorbent
hydrophobic absorbent developed and patented by
EARTH (Canada
/coalescing medium. The RPA has the following
characteristics:
•Absorption of very fine emulsions down to 2 microns as
a result of being highly oleophillic.
•Capacity to continue absorbing the fine emulsions even
when it’s fully saturated with oil, while desorbing the
coalesced oil as free-floating oil.
The two previously mentioned characteristics of RPA
allows for an efficient process (removal of oil emulsions
down to 2 microns) and also a self-cleaning system
(continuous oil separation and recovery) with low
operations and maintenance.
The technology offers several potential benefits as
follows:
•Separates and recovers non-soluble dispersed
hydrocarbons in water with approximately 2 microns in
diameter and larger.
•Reduce the hydrocarbon content of non-soluble
hydrocarbons to below 10 PPM. The technology claims to
have the highest oil removal efficiency for oil-in-water
droplets size even below 30 mm (between 15-30 mm
•Accomplishes oil separation and recovery without the
need for chemicals or heat, thus operational costs are
minimal.
•Energy requirements for pumping the oily water are
minimal since the TORR™’ system’s pressure drop across
the process is low.
P&CSD has coordinated a technical meeting for the new
technology in which representatives from SAOO, NAOO,
EPD, FPD, and Aramco Service Company (ASC) attended
the meeting.
P&CSD is in the discussion stage with the vendor and
NAOO for conducting a trial test of this technology.
Figure 2 Technology Process Flow Diagram
26 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
The size distribution
curve for the
dispersed oil in water
must be measured to
effectively address the
issues and meet and
exceed the set
discharge targets.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
27Process & Control Systems DepartmentIssue No. 8 – Summer 2007
and professional services in process engineering and process automation!
27Process & Control Systems DepartmentIssue No. 8 – Summer 2007
0
1000
2000
30 00
0. 6
0. 8
1
1. 2
0
20
40
60
80
100
120
Re I m p
Re I m p
Re I m p
Re I m p
ReL
ReL
ReL
ReL 0
1000
2000
3000
0. 6
0. 8
1
1.2
0
20
40
60
80
100
120
ReG ReG
ReG ReG
0
1000
2000
30 0 0
0. 6
0. 8
1
1.2
0
50
100
150
200
250
0
1000
2000
3000
0.6
0.
8
1
1.2
0
50
100
150
200
250 VISION - To become leaders in process engineering and automation!
The basket impeller column is an alternative catalytic
distillation reactor design for systems that require an
effective catalytic liquid renewal and high rate of
localized mixing to overcome severely limiting mass
transfer resistances. The basket impeller consists of 4-
blade wire mesh, distributed one per stage, that contains
solid catalysts typically found in a stirred basket slurry
reactor. The liquid contact with the catalyst is enhanced
with rotational speed of the basket impeller on a renewal
basis, allowing for slip velocities much higher than those
achieved with a static catalytic distillation column. The
impeller is located directly above a sieve plate in a column
without downcomers. The current configuration of the
basket impeller column, with dual flow action bubble
recirculation provided by the impeller, enhances the gas
liquid contact that results in higher mass transfer rates.
The objective of this study is to provide correlations of the
basket impeller column to better understand the system
and use them in future applications. Deriving process
modeling that characterizes such a configuration will
make the utilization of this system more widely applicable
for future experiments; this includes loading and flooding
envelopes. In addition, the hydrodynamics and gas to
liquid mass transfer, over a range operating parameters,
was determined. As the operating range lay in the
middle, it was found that the actual number of stages is
equal to the calculated N model ”calculated number of
stages”. The phenomenon of mechanically assisted forced
weeping was thoroughly investigated by using pressure
Hydrodynamics and Gas-Liquid Mass Transfer Characteristics of a Multistage
Dual-flow Spinning Basket Impeller Catalytic Distillation Column
drop and liquid hold up of stage correlations. The
volumetric mass transfer coefficient and interfacial area
were determined using the absorption chemical system of
carbon dioxide in sodium hydroxide and
carbonate/bicarbonate buffer solutions. The resulting
correlations were typical of those found in dual flow
columns, with improvement obtained through agitation.
Discussion
Loading and flooding Envelope:
It is clear from the above figure for the loading and
flooding envelope that the non-linearity occurred from
steep areas of change on the envelope surface. These
were represented using a power law type expression on
each surface. The loading envelope for this column with 7
and 13 % Open Area plates over the ranges of superficial
Reynold numbers:
0 ≤Re
G ≤250.0.6 ≤Re
L ≤1.6,0 ≤1.6 ≤0 ≤Ω≤300
are obtained by:
Re
G Loading = 8.875 * 10
-0.2
Re
L
-0.22
10
(5.108x10-
0.5
ReL+4.17)
θ
1.26
The ReG values obtained from this equation represents
the establishment of a froth structure in the presence of
the operating basket impeller, which is typically
illustrated by sustained large bubble formation.
The flooding envelope is similarly obtained over the same
range of operation for the basket impeller column for the
7 and 13 % Open Area plates by:
Re
G.Flooding= 6.406x10
-0.2
Re
L
-0.17
10
(6.08x10)-0.6 Re
1
+4
Those corresponding to this equation predict the onset
Basket Impeller Column: New Approach
Author: Salem Al-Qahtani
Figure 1 Experiment setup
Figure 2 Capacity Loading and flooding EnvelopeB asket Impel ler
Column
T
P
PP
Cumulative F low Meter
Gas Chromatograph TCD
Gas Feed Pre - S aturator
Gas Supply N
2 and CO2
RTD Pressurized Fraction Col lector
Liquid Phase Supply and Reciever
Variable Speed
Peristaltic pump
28 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
flooding where by the froth height has reached the
stages highest point of 0.15 m. When comparing loading
to flooding, the loading is generally sensitive to all
variables, while flooding is particulary affected by Re
Lthe
impeller Reynolds number and q the fractional plate open
area. The potentially significant interaction of these two
variables has been shown to strongly influence tray
capacity. These equation define the applicable range of
all correlation subsequently reported.
Residence Time Distribution (RTD)
The below figure shows a typicall RTD curves for the
system, it reflects the type of behavior observed during
the study:
As the basket impeller rotational speed Ωincreases, the E-
curves increase as well. This observed increase in variance
with Ωfrom 0 to 150 is caused by the higher axial
dispersion within the column, and increased residence of
the tracer within the packed basket. As the rotational
speed Ωincreased, the froth structure collapsed due to
the force of weeping that produced a return to plug flow.
Mass Transfer Gas-to-Liquid
As the surface area of mass transfer increases, the mass
transfer will increase as well. This fact is iullstrated in the
below figure for the two plates 7 and 13 % Open Area
(OA). The 13 % plate has a higher operating range than 7
% plate:
The 13 % OA plate has a higher throughput, which
provides for a higher gas to liquid mass transfer. Previous
work with this configuration showed that the efficiency
of distillation column at mid range of operation for the
small area plate is usually higher than large one. This
result is also true for the standard bubble column without
internals. The correlation for the effective mass transfer
coefficient for liquid k
La
L is as follows:
k
La
L= b
1Re
2
+b
2Re
1+b
0
b
1= 145x10
-09
– 1.36x10
-10
Re
G–4.74x10
-10
Re
L+1.28x10
-07
θ
b
2= 135x10
-06
+ 210x10
-07
Re
G+234x10
-05
Re
L–1.98x10
-01
θ
b
0= 244x10
-02
+ 9.36x10
-01
Re
G+1.01x10
-02
Re
L–1.21θ
Conclusion
It is concluded in this study that the basket impeller
column operating range becomes broader as the % OA of
the plate increases, the larger the OA, the higher the
operating maximum and minimum. The broader range of
operation will give flexibility on the column and allow the
gas and liquid flow rate to vary. Therefore, the
controllability of the basket column impeller with
higher % OA plate is easier than the low % OA one. The
efficiency with smaller plates is higher than the larger
one. Moreover, it is revealed from the RTD experiments
that at mid range of operation, the number of stages N
for the basket impeller column become close to the actual
number of stages. Operating at or close to loading and
flooding envelopes result in partial bypass and
recirculation, resulings in a highly back-mixing column. In
the gas to liquid mass transfer experiments, it revealed
that the mass transfer is typically of tray plate with
stationary basket, with additional, enhancement of the
impeller to a certain maximum, before froth collapsed
and force of weeping decreases the liquid. The mass
transfer of the 13 % OA is higher than the 7 % plate. A
high area provides more gas to liquid contact. The
behavior of dependent parameters is typically non-linear
with respect to rotational speed.
Salem Al-Qahtani is a Process Engineer with
P&CSD/UPED/GPU. Salem’s main specialty is NGL recovery
and fractionation. He holds a Master of Engineering Science
from the University of New South Wales, Sydney Australia.
Figure 3 Residence Time Distribution (RTD) Analysis
Figure 4 Mass Transfer Results0.1
E-(t)
0
0
20 40 60 80
0.09
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
t (min)
0 rpm
150 rpm
250 rpm
29Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
0.06
Ω
KLa (s-1)
0.05
0.04
0.03
0.02
0.01
0
0100200300
(rpm)
13% ReG 170.7
7% ReG 51.2
7% ReG 43.9
13% ReG 139.0
and professional services in process engineering and process automation!
flooding where by the froth height has reached the
stages highest point of 0.15 m. When comparing loading
to flooding, the loading is generally sensitive to all
variables, while flooding is particulary affected by Re
Lthe
impeller Reynolds number and q the fractional plate open
area. The potentially significant interaction of these two
variables has been shown to strongly influence tray
capacity. These equation define the applicable range of
all correlation subsequently reported.
Residence Time Distribution (RTD)
The below figure shows a typicall RTD curves for the
system, it reflects the type of behavior observed during
the study:
As the basket impeller rotational speed Ωincreases, the E-
curves increase as well. This observed increase in variance
with Ωfrom 0 to 150 is caused by the higher axial
dispersion within the column, and increased residence of
the tracer within the packed basket. As the rotational
speed Ωincreased, the froth structure collapsed due to
the force of weeping that produced a return to plug flow.
Mass Transfer Gas-to-Liquid
As the surface area of mass transfer increases, the mass
transfer will increase as well. This fact is iullstrated in the
below figure for the two plates 7 and 13 % Open Area
(OA). The 13 % plate has a higher operating range than 7
% plate:
The 13 % OA plate has a higher throughput, which
provides for a higher gas to liquid mass transfer. Previous
work with this configuration showed that the efficiency
of distillation column at mid range of operation for the
small area plate is usually higher than large one. This
result is also true for the standard bubble column without
internals. The correlation for the effective mass transfer
coefficient for liquid k
La
L is as follows:
k
La
L= b
1Re
2
+b
2Re
1+b
0
b
1= 145x10
-09
– 1.36x10
-10
Re
G–4.74x10
-10
Re
L+1.28x10
-07
θ
b
2= 135x10
-06
+ 210x10
-07
Re
G+234x10
-05
Re
L–1.98x10
-01
θ
b
0= 244x10
-02
+ 9.36x10
-01
Re
G+1.01x10
-02
Re
L–1.21θ
Conclusion
It is concluded in this study that the basket impeller
column operating range becomes broader as the % OA of
the plate increases, the larger the OA, the higher the
operating maximum and minimum. The broader range of
operation will give flexibility on the column and allow the
gas and liquid flow rate to vary. Therefore, the
controllability of the basket column impeller with
higher % OA plate is easier than the low % OA one. The
efficiency with smaller plates is higher than the larger
one. Moreover, it is revealed from the RTD experiments
that at mid range of operation, the number of stages N
for the basket impeller column become close to the actual
number of stages. Operating at or close to loading and
flooding envelopes result in partial bypass and
recirculation, resulings in a highly back-mixing column. In
the gas to liquid mass transfer experiments, it revealed
that the mass transfer is typically of tray plate with
stationary basket, with additional, enhancement of the
impeller to a certain maximum, before froth collapsed
and force of weeping decreases the liquid. The mass
transfer of the 13 % OA is higher than the 7 % plate. A
high area provides more gas to liquid contact. The
behavior of dependent parameters is typically non-linear
with respect to rotational speed.
Salem Al-Qahtani is a Process Engineer with
P&CSD/UPED/GPU. Salem’s main specialty is NGL recovery
and fractionation. He holds a Master of Engineering Science
from the University of New South Wales, Sydney Australia.
Figure 3 Residence Time Distribution (RTD) Analysis
Figure 4 Mass Transfer Results0.1
E-(t)
0
0
20 40 60 80
0.09
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
t (min)
0 rpm
150 rpm
250 rpm
29Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
0.06
Ω
KLa (s-1)
0.05
0.04
0.03
0.02
0.01
0
0100200300
(rpm)
13% ReG 170.7
7% ReG 51.2
7% ReG 43.9
13% ReG 139.0
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Data Validation and Reconciliation
A Crucial Technology for Processing Plants
This necessitates the need to validate plants’
measurement data utilizing all available and
possible process data, exploiting the basic
laws of physics. After data validation,
reconciliation is a method for extracting all
information present in plant data to gain the
greatest economic value.
EPIs, as well as KPIs for critical equipment,
provide the plants the means to monitor and
improve process performance, thereby
reducing energy consumption.
Understandably, instrument and equipment
maintenance in a large organization such as
Saudi Aramco can be a daunting and
overwhelming task resulting in several
measurements being inaccurate and
sometimes invalid.
In 2004, Saudi Aramco evaluated the five leading data
validation and reconciliation (DVR
provide the needed measurement data validation. VALI
from Belsim s.a./NAIZAK Global Solutions was the
primary choice application for data validation &
reconciliation (DVR).
Saudi Aramco has since implemented a project pilot at
Riyadh Refinery’s crude distillation unit as well as a plant-
wide material balance model. In addition, a pilot at the
Shedgum Gas Plant liquid recovery unit provided plant
EPIs and equipment KPIs for proactive and predictive
maintenance. The implementation of VALI-DVR revealed
potential opportunities for revenue enhancements as
well as insight for proactive predictive maintenance and
incident avoidance. A good example is the heat transfer
coefficient KPI, calculated for cleaned as well as new types
of tubes (see figure 1). One can clearly see the
The validity and accuracy of measurement data are crucial factors to successfully
exploit plants’ Key Performance Indicators (KPIs) and Energy Performance Indices
(EPIs
inaccuracies.
deterioration as well as the improvement in the heat
transfer coefficients before and after tube cleaning and
replacement. This information is provided online at any
desired time interval allowing for condition-based
maintenance as well as incident avoidance. Also, it
provides insight to equipment performance, revealing,
for example, that the new tubes’ types have higher heat
transfer coefficients than the old ones.
Saudi Aramco is proceeding to establish a corporate
license agreement for faster implementation of the
application across all its producing, gas processing and oil
refining facilities.
Dr. Amein Alsueziis the Data Validation & Reconciliation
team leader within PCD of P&CSD. With more than 20 years
of industrial experience, he has extensive knowledge in
successfully leading and managing projects. Prior to joining
Saudi Aramco, he worked in the USA as independent
consultant for various companies.
Author: Amein Alsuezi
Figure 1
Heat Transfer Coefficients’ KPI for cleaned as
well as new type of tubesStabilizer Reboilers
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
450.00
7/1/067/3/067/5/067/7/067/9/06
7/11/067/13/067/15/067/17/067/19/067/21/067/23/067/25/067/27/067/29/067/31/06
8/2/068/4/068/6/068/8/06
8/10/068/12/068/14/068/16/068/18/068/20/068/22/068/24/068/26/068/28/068/30/06
9/1/06
Heat Transfer Coefficient
E-26A
E-26B
Heat Transfer
Deterio ration
Desig n
Heat Transfer
Coefficient (HTC)
HTC high er
than previo us
desig n value
Tubes
Repl aced
Deterio rat
Tubes
Cleane d
Deterio r
30 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
Data Validation and Reconciliation
A Crucial Technology for Processing Plants
This necessitates the need to validate plants’
measurement data utilizing all available and
possible process data, exploiting the basic
laws of physics. After data validation,
reconciliation is a method for extracting all
information present in plant data to gain the
greatest economic value.
EPIs, as well as KPIs for critical equipment,
provide the plants the means to monitor and
improve process performance, thereby
reducing energy consumption.
Understandably, instrument and equipment
maintenance in a large organization such as
Saudi Aramco can be a daunting and
overwhelming task resulting in several
measurements being inaccurate and
sometimes invalid.
In 2004, Saudi Aramco evaluated the five leading data
validation and reconciliation (DVR
provide the needed measurement data validation. VALI
from Belsim s.a./NAIZAK Global Solutions was the
primary choice application for data validation &
reconciliation (DVR).
Saudi Aramco has since implemented a project pilot at
Riyadh Refinery’s crude distillation unit as well as a plant-
wide material balance model. In addition, a pilot at the
Shedgum Gas Plant liquid recovery unit provided plant
EPIs and equipment KPIs for proactive and predictive
maintenance. The implementation of VALI-DVR revealed
potential opportunities for revenue enhancements as
well as insight for proactive predictive maintenance and
incident avoidance. A good example is the heat transfer
coefficient KPI, calculated for cleaned as well as new types
of tubes (see figure 1). One can clearly see the
The validity and accuracy of measurement data are crucial factors to successfully
exploit plants’ Key Performance Indicators (KPIs) and Energy Performance Indices
(EPIs
inaccuracies.
deterioration as well as the improvement in the heat
transfer coefficients before and after tube cleaning and
replacement. This information is provided online at any
desired time interval allowing for condition-based
maintenance as well as incident avoidance. Also, it
provides insight to equipment performance, revealing,
for example, that the new tubes’ types have higher heat
transfer coefficients than the old ones.
Saudi Aramco is proceeding to establish a corporate
license agreement for faster implementation of the
application across all its producing, gas processing and oil
refining facilities.
Dr. Amein Alsueziis the Data Validation & Reconciliation
team leader within PCD of P&CSD. With more than 20 years
of industrial experience, he has extensive knowledge in
successfully leading and managing projects. Prior to joining
Saudi Aramco, he worked in the USA as independent
consultant for various companies.
Author: Amein Alsuezi
Figure 1
Heat Transfer Coefficients’ KPI for cleaned as
well as new type of tubesStabilizer Reboilers
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
400.00
450.00
7/1/067/3/067/5/067/7/067/9/06
7/11/067/13/067/15/067/17/067/19/067/21/067/23/067/25/067/27/067/29/067/31/06
8/2/068/4/068/6/068/8/06
8/10/068/12/068/14/068/16/068/18/068/20/068/22/068/24/068/26/068/28/068/30/06
9/1/06
Heat Transfer Coefficient
E-26A
E-26B
Heat Transfer
Deterio ration
Desig n
Heat Transfer
Coefficient (HTC)
HTC high er
than previo us
desig n value
Tubes
Repl aced
Deterio rat
Tubes
Cleane d
Deterio r
30 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
Optimizing Projects with a Main Automation Contractor
Process Automation Systems (PAS) are used in most Saudi
Aramco industrial capital projects and hence have
significant impact on the cost, quality and on stream
operation of Company plants and facilities. The Main
Automation Contractor (MAC) concept was created by
industry users in conjunction with process automation
suppliers to optimize PAS projects execution.
MAC is defined as a highly qualified, large projects
experienced, and well resourced control systems
contractor assigned to engineer, supply/procure and
manage Process Automation Solutions and associated
instrumentation for all project process areas and facilities.
As part of its strategic initiatives to support corporate
performance transformation, P&CSD has launched a
comprehensive study of the MAC concept to assess its
applicability and value to Saudi Aramco PAS projects. A
team comprising of representatives from P&CSD, PMT,
FPD, and PS&CD was formed to conduct the study, assess
risks and validate projected benefits.
Background
It is well known in the industry that PAS expenditures
represent about 3% - 5% of an overall project budget.
Improper planning, design and implementation can drive
the cost of PAS by an additional 10%-25% of its value.
Furthermore, PAS is the foundation for a plant operation
which can result in 100% downtime if not properly
designed and configured. Therefore, it is essential to
focus on PAS during the initial Project Proposal (PP
to ensure that overall PAS design, scope and integration
requirements are properly defined.
Traditional PAS projects proposal phase has been
executed by design contractors in the absence of Process
Control Supplier (PCS). Similarly, during the detail design
and construction phases, Lump-Sum Turn-Key (LSTK
contractors have typically performed the role of the
automation contractor while the scope of the PCS
remained limited to implementing the design packages.
This approach has resulted in numerous project execution
problems including:
•Unplanned scope changes
•Unplanned resources
Transform Corporate Performance is one of our Corporate Strategic Imperatives,
and Process Automation project execution is one of the processes that require
dynamic optimization to ensure quality and cost effectiveness.
•Design inconsistencies
•Poor interfaces between PMT, EPC, and subcontractors
•Inconsistent selection of equipment and materials
•High projects contingency
As a practice in the industry to overcome the problems
associated with the tradition project execution approach,
The MAC concept was created to address the following
business drivers:
•Economics
•Accurate definition of PAS scope prior to project
detailing
•Reduction in change orders
•Improvement is project schedule
•Better integration with third party equipment
Figure 1 shows that early involvement of MAC in the
project design can positively influence project cost while
late involvement in a project could result in additional
cost expenditures, due to change orders and
contingencies.
Findings and Benefits
The Team has concluded that the MAC concept is an
industry trend and widely used by major Oil & Gas users
as a strategic project execution tool. MAC has been
proven to reduce PA project costs by 10 – 15%, improve
overall Process Automation schedule, improve total
integration quality, and reduce risks.Definitive estimate & propos al at the early
stage is critical for customer succe s s
Ability to Influence Cost
High
Co ncept Phase Planning Phase Implementation Phase Close - Out-Phase
Low
Cost Inf luence
Cost Expenditure
20% 40% 60% 80%
Figure 1 MAC impact on Project Cost
Author: Saleh Al-Qaffas
32 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Optimizing Projects with a Main Automation Contractor
Process Automation Systems (PAS) are used in most Saudi
Aramco industrial capital projects and hence have
significant impact on the cost, quality and on stream
operation of Company plants and facilities. The Main
Automation Contractor (MAC) concept was created by
industry users in conjunction with process automation
suppliers to optimize PAS projects execution.
MAC is defined as a highly qualified, large projects
experienced, and well resourced control systems
contractor assigned to engineer, supply/procure and
manage Process Automation Solutions and associated
instrumentation for all project process areas and facilities.
As part of its strategic initiatives to support corporate
performance transformation, P&CSD has launched a
comprehensive study of the MAC concept to assess its
applicability and value to Saudi Aramco PAS projects. A
team comprising of representatives from P&CSD, PMT,
FPD, and PS&CD was formed to conduct the study, assess
risks and validate projected benefits.
Background
It is well known in the industry that PAS expenditures
represent about 3% - 5% of an overall project budget.
Improper planning, design and implementation can drive
the cost of PAS by an additional 10%-25% of its value.
Furthermore, PAS is the foundation for a plant operation
which can result in 100% downtime if not properly
designed and configured. Therefore, it is essential to
focus on PAS during the initial Project Proposal (PP
to ensure that overall PAS design, scope and integration
requirements are properly defined.
Traditional PAS projects proposal phase has been
executed by design contractors in the absence of Process
Control Supplier (PCS). Similarly, during the detail design
and construction phases, Lump-Sum Turn-Key (LSTK
contractors have typically performed the role of the
automation contractor while the scope of the PCS
remained limited to implementing the design packages.
This approach has resulted in numerous project execution
problems including:
•Unplanned scope changes
•Unplanned resources
Transform Corporate Performance is one of our Corporate Strategic Imperatives,
and Process Automation project execution is one of the processes that require
dynamic optimization to ensure quality and cost effectiveness.
•Design inconsistencies
•Poor interfaces between PMT, EPC, and subcontractors
•Inconsistent selection of equipment and materials
•High projects contingency
As a practice in the industry to overcome the problems
associated with the tradition project execution approach,
The MAC concept was created to address the following
business drivers:
•Economics
•Accurate definition of PAS scope prior to project
detailing
•Reduction in change orders
•Improvement is project schedule
•Better integration with third party equipment
Figure 1 shows that early involvement of MAC in the
project design can positively influence project cost while
late involvement in a project could result in additional
cost expenditures, due to change orders and
contingencies.
Findings and Benefits
The Team has concluded that the MAC concept is an
industry trend and widely used by major Oil & Gas users
as a strategic project execution tool. MAC has been
proven to reduce PA project costs by 10 – 15%, improve
overall Process Automation schedule, improve total
integration quality, and reduce risks.Definitive estimate & propos al at the early
stage is critical for customer succe s s
Ability to Influence Cost
High
Co ncept Phase Planning Phase Implementation Phase Close - Out-Phase
Low
Cost Inf luence
Cost Expenditure
20% 40% 60% 80%
Figure 1 MAC impact on Project Cost
Author: Saleh Al-Qaffas
32 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Highlighted benefits from vendor proposals/
presentations, interviews and work sessions with industry
users, LSTK contractors, and SAPMT are the following:
•MAC involvement in each automation area will
contribute to consistency and higher quality of
procedures and specification documentation
•MAC will contribute to higher quality integrated
systems from the field instrument to the board room
Early MAC involvement during FEED (Project Proposal)
reduces project cost via reduced change orders, lower
contingency, and shortens development time. Estimated
project cost avoidance is in the range of 10-15%.
MAC will improve overall automation schedule due to
early involvement in project proposal development.
Typically, more than 5 months are saved in a project
schedule due to MAC early selection and basic design
availability. This concept would take automation system
out of the critical path during detail design and
construction phases.
All system releases are managed by MAC to ensure latest
version upon project completion
Impacted Saudi Aramco Standards
In support of the MAC concept, a new engineering
procedure, SAEP-1650 has been developed. This
Procedure details MAC applicability, execution
methodology, selection criteria, scope boundaries and
proposed activity timeline. MAC responsibility and scope
boundaries include:
1. Equipment (DCS, SCADA, TMS, Auxiliary systems,
Instrumentation)
2.Engineering Services
3. Construction Services
4. Operation Services
Figure 3 shows the milestones structure should be
followed to capture the benefits realized from MAC
executed projects.
Recommendation
The team recommended that the MAC concept be applied
to all types of Saudi Aramco process automation projects,
including Maintain Potential and Master Appropriations
projects.
Contribution of this initiative goes to all team members:
Saleh A. Alqaffas (P&CSD
Farrukh N. Chawla (P&CSD), Abdulla A. Al-Mulla (PMT),
Kenneth T. Koval (PS&CD
(FPD) MAC BP
Prep.
Bid
Pac ka ge
Finalized
•M A C Bi d
Pac ka g e
•P EF S ’s re v A
•Units
•etc.
P P in cl u d es:
•Sys te m si zi ng a nd a rc hi te c tu re
•Im p le m en ta ti o n pl an & e xe cu t i on
Dur at io n ( W ee ks )
•Fun ct io na l D e si g n s pe cs
•Pro je ct st an d a rd s
•Site p lanning data
•N ew Q u ot at io n ( < Ce il i n g )
(Ceiling= Old Quote + /- Un its *
U ni t r at es + conting encies)
Work
Together
L ST K aw a rd
MAC
Bidding
MA C
Sel.
Quotation
•Pro je ct
LS co st
•Uni t r at es
•etc .
Sel ec ti o n
•Award for
W o rk on
P P Ph as e
Design Prep./
B as ic des ig n
Project Proposal phase
Imp leme ntation Phase
DBSP
Completed
PP
Com pl et e d
LSTK
BP
Design of
PAS
Strategy
Figure 2 MAC Project Timeline
Saleh Al-Qaffasis an Engineering Consultant with Process &
Control Systems Department. He holds a BS degree in
Electrical Engineerin from the Universsity of Pittsbirgh, USA
and an MBA degree from the university of Hull, UK. Saleh is
the Chairman of the Process Control Standards Committee
with Saudi Aramco and the Presidient of the Saudi Arabia
Section of the Instrumentation, Systems & Automation
Society (ISA).
33Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
Highlighted benefits from vendor proposals/
presentations, interviews and work sessions with industry
users, LSTK contractors, and SAPMT are the following:
•MAC involvement in each automation area will
contribute to consistency and higher quality of
procedures and specification documentation
•MAC will contribute to higher quality integrated
systems from the field instrument to the board room
Early MAC involvement during FEED (Project Proposal)
reduces project cost via reduced change orders, lower
contingency, and shortens development time. Estimated
project cost avoidance is in the range of 10-15%.
MAC will improve overall automation schedule due to
early involvement in project proposal development.
Typically, more than 5 months are saved in a project
schedule due to MAC early selection and basic design
availability. This concept would take automation system
out of the critical path during detail design and
construction phases.
All system releases are managed by MAC to ensure latest
version upon project completion
Impacted Saudi Aramco Standards
In support of the MAC concept, a new engineering
procedure, SAEP-1650 has been developed. This
Procedure details MAC applicability, execution
methodology, selection criteria, scope boundaries and
proposed activity timeline. MAC responsibility and scope
boundaries include:
1. Equipment (DCS, SCADA, TMS, Auxiliary systems,
Instrumentation)
2.Engineering Services
3. Construction Services
4. Operation Services
Figure 3 shows the milestones structure should be
followed to capture the benefits realized from MAC
executed projects.
Recommendation
The team recommended that the MAC concept be applied
to all types of Saudi Aramco process automation projects,
including Maintain Potential and Master Appropriations
projects.
Contribution of this initiative goes to all team members:
Saleh A. Alqaffas (P&CSD
Farrukh N. Chawla (P&CSD), Abdulla A. Al-Mulla (PMT),
Kenneth T. Koval (PS&CD
(FPD) MAC BP
Prep.
Bid
Pac ka ge
Finalized
•M A C Bi d
Pac ka g e
•P EF S ’s re v A
•Units
•etc.
P P in cl u d es:
•Sys te m si zi ng a nd a rc hi te c tu re
•Im p le m en ta ti o n pl an & e xe cu t i on
Dur at io n ( W ee ks )
•Fun ct io na l D e si g n s pe cs
•Pro je ct st an d a rd s
•Site p lanning data
•N ew Q u ot at io n ( < Ce il i n g )
(Ceiling= Old Quote + /- Un its *
U ni t r at es + conting encies)
Work
Together
L ST K aw a rd
MAC
Bidding
MA C
Sel.
Quotation
•Pro je ct
LS co st
•Uni t r at es
•etc .
Sel ec ti o n
•Award for
W o rk on
P P Ph as e
Design Prep./
B as ic des ig n
Project Proposal phase
Imp leme ntation Phase
DBSP
Completed
PP
Com pl et e d
LSTK
BP
Design of
PAS
Strategy
Figure 2 MAC Project Timeline
Saleh Al-Qaffasis an Engineering Consultant with Process &
Control Systems Department. He holds a BS degree in
Electrical Engineerin from the Universsity of Pittsbirgh, USA
and an MBA degree from the university of Hull, UK. Saleh is
the Chairman of the Process Control Standards Committee
with Saudi Aramco and the Presidient of the Saudi Arabia
Section of the Instrumentation, Systems & Automation
Society (ISA).
33Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Oil and Gas Processor Goes Wireless on the LAN
Mohammed Al-Saeed, Soliman Al-Walaie,
and Majed Al-Subaie
ISA InTech Magazine, April 1, 200
Monitoring and Maintaining Multivariable
Constrained Controllers
Jim Anderson
Matrikon Users Summit 2007
Chicago, Illinois USA, May 9, 2007
Saudi Aramco Control Systems Design and Future
Trends,John Kinsley
Invensys Foxboro North America 2007 User’s Group
Meeting
Chicago, Illinois USA, July 18, 2007
Saudi Aramco Organization & Implementation of
DVR Technology for Performance & Energy
Consumption Optimization,Ashraf AlGhazzawi,
Antonio Fernandes and Amein Alsuezi, D.Sc.
16h Belsim User Meeting 2007, Barcelona, Spain
June 11, 2007
Centralized LIMS System at Saudi Aramco
Muhammad Shahid
Khursaniyah Gas Plant Project
London, United Kingdom, March 23, 2007
Application of Multi-Unit Optimization on a NGL Gas Plant,
Steve Wagner
Honeywell Profit Suite Strategic Users Forum 2007
Phoenix, Arizona USA, June 8, 2007
Industrial Wireless LAN Security for Oil & Gas Process
Automation Networks
Mohammed Al-Saeed
The 8th Annual Gas and Oil Exchange UK 2007
United Kingdom, November 30, 2007
Mohammed Al-Saeed, Soliman Al-Walaie,
and Majed Al-Subaie
ISA InTech Magazine, April 1, 200
Monitoring and Maintaining Multivariable
Constrained Controllers
Jim Anderson
Matrikon Users Summit 2007
Chicago, Illinois USA, May 9, 2007
Saudi Aramco Control Systems Design and Future
Trends,John Kinsley
Invensys Foxboro North America 2007 User’s Group
Meeting
Chicago, Illinois USA, July 18, 2007
Saudi Aramco Organization & Implementation of
DVR Technology for Performance & Energy
Consumption Optimization,Ashraf AlGhazzawi,
Antonio Fernandes and Amein Alsuezi, D.Sc.
16h Belsim User Meeting 2007, Barcelona, Spain
June 11, 2007
Centralized LIMS System at Saudi Aramco
Muhammad Shahid
Khursaniyah Gas Plant Project
London, United Kingdom, March 23, 2007
Application of Multi-Unit Optimization on a NGL Gas Plant,
Steve Wagner
Honeywell Profit Suite Strategic Users Forum 2007
Phoenix, Arizona USA, June 8, 2007
Industrial Wireless LAN Security for Oil & Gas Process
Automation Networks
Mohammed Al-Saeed
The 8th Annual Gas and Oil Exchange UK 2007
United Kingdom, November 30, 2007
Overview of Catalyst Management and Selection
Protocols at Saudi Aramco’s Refineries
Saeed Al-Alloush, Gene Yeh, and A. M. Aitani (KFUPM
Saudi Aramco Journal of Technology Fall 2006
Crude Column Optimization – Saudi Aramco
Rabigh Refinery case,Khalid S. Al-Otaibi,
Salem S Bolawi, Hamad A Sobhi
PETROTECH 2007
India, January 17, 2007
Foundation for Safety Instrumented Functions (SIF)
Patrick Flanders,KFUPM Workshop on Industrial Systems and
Control, Dhahran Saudi Arabia, May 21, 2007, ISA Saudi Arabia
Section,
Dhahran Saudi Arabia, June 25, 2007, Foundation
Fieldbus Conference,Abu Dhabi, UAE, Sept 10, 2007
The Effect of Biological and Polymeric Inhibitors on
Methane Gas Hydrate Growth Kinetics
S. Al-Adel, J. Dick, R. El-Ghafari and P. Servio
Eleventh International Conference on Properties and
Phase Equilibria for Product and Process Design,
Crete, Greece, May 23, 2007
Legacy Industrial Wireless and the SP100 in Oil and Gas
Process Control Systems – Design and Planning
Considerations,Author: Dr. Abdelghani Daraiseh.
Co-authors: Abdullah Al-Nufaii, Barrag Assaf from North
Shedgum Gas Plant, IEEE Gulf Conference, Manama,
Bahrain, November 12, 2007
Protocols at Saudi Aramco’s Refineries
Saeed Al-Alloush, Gene Yeh, and A. M. Aitani (KFUPM
Saudi Aramco Journal of Technology Fall 2006
Crude Column Optimization – Saudi Aramco
Rabigh Refinery case,Khalid S. Al-Otaibi,
Salem S Bolawi, Hamad A Sobhi
PETROTECH 2007
India, January 17, 2007
Foundation for Safety Instrumented Functions (SIF)
Patrick Flanders,KFUPM Workshop on Industrial Systems and
Control, Dhahran Saudi Arabia, May 21, 2007, ISA Saudi Arabia
Section,
Dhahran Saudi Arabia, June 25, 2007, Foundation
Fieldbus Conference,Abu Dhabi, UAE, Sept 10, 2007
The Effect of Biological and Polymeric Inhibitors on
Methane Gas Hydrate Growth Kinetics
S. Al-Adel, J. Dick, R. El-Ghafari and P. Servio
Eleventh International Conference on Properties and
Phase Equilibria for Product and Process Design,
Crete, Greece, May 23, 2007
Legacy Industrial Wireless and the SP100 in Oil and Gas
Process Control Systems – Design and Planning
Considerations,Author: Dr. Abdelghani Daraiseh.
Co-authors: Abdullah Al-Nufaii, Barrag Assaf from North
Shedgum Gas Plant, IEEE Gulf Conference, Manama,
Bahrain, November 12, 2007
VISION - To become leaders in process engineering and automation!
Advanced Multivariable & Regulatory Control
Performance Monitoring
A technical study was completed in early 2007 to identify, pilot, and evaluate
multivariable control (MVC
monitoring technologies for use in Saudi Aramco facilities.
A technical study was completed in early 2007 to identify,
pilot, and evaluate multivariable control (MVC) and
regulatory control (PID) advanced performance
monitoring technologies for use in Saudi Aramco
facilities. The monitoring tools are essential to be able to
fully and consistently capture the economic benefits that
such MVC applications bring. Currently, Saudi Aramco
uses MVC technologies from AspenTech, Honeywell, and
Yokagawa/Shell.
The Advanced Process Control Unit (APCU) of the Process
Control Division (PCD) of the Process & Control Systems
Department (P&CSD) obtained approval for a Technology
Item (PRA-02/04-T) for the purpose of identifying, piloting
and evaluating technical capabilities of the major vendors
that supply such systems and to recommend a limited
number of vendors that can provide best field proven
systems that meet all the requirements for Saudi Aramco
Refineries and Gas Plants. The core Evaluation Team was
formed to execute and complete the technologies
evaluation and was comprised of representatives from
P&CSD, Ras Tanura Refinery, Riyadh Refinery, Ju’aymah
Gas Plant and Yanbu‘ Refinery.
Evaluation Methodology
A Product Evaluation Program was developed to aid in
objectively assessing the various MVC performance
Figure 1
Matrikon’s ProcessDoctor uses an ergonomically designed interface that allows a single view of all MVC assets for an
entire plant with drill-down capability to easily and quickly detect, diagnose and correct control performance problems.
Authors: Jim Anderson, Mohammed Al-Zain, Dr. Rashid Ansari, Dr. Othman Taha, Abdullah Al-Garni, Khaled Al-Harbi
36 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Advanced Multivariable & Regulatory Control
Performance Monitoring
A technical study was completed in early 2007 to identify, pilot, and evaluate
multivariable control (MVC
monitoring technologies for use in Saudi Aramco facilities.
A technical study was completed in early 2007 to identify,
pilot, and evaluate multivariable control (MVC) and
regulatory control (PID) advanced performance
monitoring technologies for use in Saudi Aramco
facilities. The monitoring tools are essential to be able to
fully and consistently capture the economic benefits that
such MVC applications bring. Currently, Saudi Aramco
uses MVC technologies from AspenTech, Honeywell, and
Yokagawa/Shell.
The Advanced Process Control Unit (APCU) of the Process
Control Division (PCD) of the Process & Control Systems
Department (P&CSD) obtained approval for a Technology
Item (PRA-02/04-T) for the purpose of identifying, piloting
and evaluating technical capabilities of the major vendors
that supply such systems and to recommend a limited
number of vendors that can provide best field proven
systems that meet all the requirements for Saudi Aramco
Refineries and Gas Plants. The core Evaluation Team was
formed to execute and complete the technologies
evaluation and was comprised of representatives from
P&CSD, Ras Tanura Refinery, Riyadh Refinery, Ju’aymah
Gas Plant and Yanbu‘ Refinery.
Evaluation Methodology
A Product Evaluation Program was developed to aid in
objectively assessing the various MVC performance
Figure 1
Matrikon’s ProcessDoctor uses an ergonomically designed interface that allows a single view of all MVC assets for an
entire plant with drill-down capability to easily and quickly detect, diagnose and correct control performance problems.
Authors: Jim Anderson, Mohammed Al-Zain, Dr. Rashid Ansari, Dr. Othman Taha, Abdullah Al-Garni, Khaled Al-Harbi
36 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
monitoring technologies. This program was based on the
same principles of previous product evaluations
conducted by P&CSD which were approved by Law
Department and Contract Review & Cost Compliance
Department. This program is based on the Kepner-Tregoe
(K-T) Decision Analysis Method.
Results & Recommendations
Matrikon’s ProcessDocTM PID carries the highest rating
and is recommended for all operating facilities to monitor
performance of the regulatory control systems. In
addition, the Matrikon’s ProcessDocTM MPC and Tai-Ji are
recommended for operating facilities employing MVC
technologies from either Honeywell (Profit ControllerTM)
or AspenTech (DMCplusTM
ProcessDocTM MPC does not interface with the
Shell/Yokogawa SMOCTM controller. Matrikon has future
plans to incorporate the SMOCTM technology into its
monitoring product but there are no specific dates for
accomplishing this. Therefore, facilities which utilize
Shell/Yokogawa SMOCTM MVC controllers may use
Shell/Yokogawa’s monitoring product, MDPro, for those
applications.
AspenWatchTM package may be considered for very
complex DMCplusTM applications. Examples include
reactor processes or highly integrated MVC applications.
The reasoning for this recommendation is based on
AspenWatchTM being designed specifically for
DMCplusTM. Consequently, it has very detailed
knowledge of the inner workings and capabilities of
DMCplusTM.
Benefits
It is estimated that the MVC advanced performance
monitoring technology piloted as part of this study will
improve MVC performance by 10%. This performance
improvement is largely measured as increases in online
service time and controller effectiveness or utilization
resulting significant annual savings when used on all MVC
applications within Saudi Aramco. Preliminary data from
the installed pilots indicate that the estimated
improvement of 10% is achievable.
Implementation Steps
P&CSD issued preliminary recommendations to operating
facilities in 2006. As a result of the recommendations,
several operating facilities budgeted accordingly and
purchased site licenses for Matrikon’s – ProcessDocTM PID,
MPC & Tai-Ji. Ras Tanura Refinery purchased a site-wide
license and installed the technology at the end of 2006.
Yanbu‘ Refinery and Gas Plant have also completed site-
wide installations of ProcessDocTM PID and MPC in 2006
and 2007.
P&CSD was able to negotiate a favorable corporate
discounting structure in the Matrikon software contract
due to the large rollout of the product across the
Company. Nine (9
purchased site-wide licenses. Berri and Shedgum Gas
Plants have planned installations in 2007 while the others
are planning for 2008 and 2009. Upstream operations are
also planning installations in 2008.
Jim Andersonis a Control Consultant at Saudi Aramco. He
works in the Advanced Process Control Unit for P&CSD. He
has 30 years of industry experience in process controls.
Dr. Othman Tahais a Lead Process Control Engineer with
the Advanced Process Control Unit in P&CSD. He holds a PhD
in Chemical Engineering and PhD in Electrical Engineering,
with speciality APC control.
Abdullah Al-Garniis a Lead Process Control Engineer at
Saudi Aramco’s Ras Tanura Refinery where he works in the
Engineering Technical Support Unit.
Khaled Al-Harbiis a Process Control Engineer at Saudi
Aramco. He works in the Operations and Automation Unit
for Yanbu‘ Refinery. Dr. Rashid Ansariis a process Control Specialist at Saudi
Aramco’s Riyadh Refinery. He holds a PhD in Chemical
Engineering with specialization in multivariable control and
optimization.
Mohammed Al-Zainis a Lead Process Control Engineer at
Saudi Aramco. He works in the Advanced Process Control
Unit for Ju’aymah Gas Plant. is a Control Consultant at Saudi
Aramco. He works in the Advanced Process Control Unit for
P&CSD. He has 30 years of industry experience in process
controls.
37Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
monitoring technologies. This program was based on the
same principles of previous product evaluations
conducted by P&CSD which were approved by Law
Department and Contract Review & Cost Compliance
Department. This program is based on the Kepner-Tregoe
(K-T) Decision Analysis Method.
Results & Recommendations
Matrikon’s ProcessDocTM PID carries the highest rating
and is recommended for all operating facilities to monitor
performance of the regulatory control systems. In
addition, the Matrikon’s ProcessDocTM MPC and Tai-Ji are
recommended for operating facilities employing MVC
technologies from either Honeywell (Profit ControllerTM)
or AspenTech (DMCplusTM
ProcessDocTM MPC does not interface with the
Shell/Yokogawa SMOCTM controller. Matrikon has future
plans to incorporate the SMOCTM technology into its
monitoring product but there are no specific dates for
accomplishing this. Therefore, facilities which utilize
Shell/Yokogawa SMOCTM MVC controllers may use
Shell/Yokogawa’s monitoring product, MDPro, for those
applications.
AspenWatchTM package may be considered for very
complex DMCplusTM applications. Examples include
reactor processes or highly integrated MVC applications.
The reasoning for this recommendation is based on
AspenWatchTM being designed specifically for
DMCplusTM. Consequently, it has very detailed
knowledge of the inner workings and capabilities of
DMCplusTM.
Benefits
It is estimated that the MVC advanced performance
monitoring technology piloted as part of this study will
improve MVC performance by 10%. This performance
improvement is largely measured as increases in online
service time and controller effectiveness or utilization
resulting significant annual savings when used on all MVC
applications within Saudi Aramco. Preliminary data from
the installed pilots indicate that the estimated
improvement of 10% is achievable.
Implementation Steps
P&CSD issued preliminary recommendations to operating
facilities in 2006. As a result of the recommendations,
several operating facilities budgeted accordingly and
purchased site licenses for Matrikon’s – ProcessDocTM PID,
MPC & Tai-Ji. Ras Tanura Refinery purchased a site-wide
license and installed the technology at the end of 2006.
Yanbu‘ Refinery and Gas Plant have also completed site-
wide installations of ProcessDocTM PID and MPC in 2006
and 2007.
P&CSD was able to negotiate a favorable corporate
discounting structure in the Matrikon software contract
due to the large rollout of the product across the
Company. Nine (9
purchased site-wide licenses. Berri and Shedgum Gas
Plants have planned installations in 2007 while the others
are planning for 2008 and 2009. Upstream operations are
also planning installations in 2008.
Jim Andersonis a Control Consultant at Saudi Aramco. He
works in the Advanced Process Control Unit for P&CSD. He
has 30 years of industry experience in process controls.
Dr. Othman Tahais a Lead Process Control Engineer with
the Advanced Process Control Unit in P&CSD. He holds a PhD
in Chemical Engineering and PhD in Electrical Engineering,
with speciality APC control.
Abdullah Al-Garniis a Lead Process Control Engineer at
Saudi Aramco’s Ras Tanura Refinery where he works in the
Engineering Technical Support Unit.
Khaled Al-Harbiis a Process Control Engineer at Saudi
Aramco. He works in the Operations and Automation Unit
for Yanbu‘ Refinery. Dr. Rashid Ansariis a process Control Specialist at Saudi
Aramco’s Riyadh Refinery. He holds a PhD in Chemical
Engineering with specialization in multivariable control and
optimization.
Mohammed Al-Zainis a Lead Process Control Engineer at
Saudi Aramco. He works in the Advanced Process Control
Unit for Ju’aymah Gas Plant. is a Control Consultant at Saudi
Aramco. He works in the Advanced Process Control Unit for
P&CSD. He has 30 years of industry experience in process
controls.
37Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
38
VISION - To become leaders in process engineering and automation!
Yanbu‘ Gas Plant Dynamic Optimizer Implementation
This application is primarily
designed to optimize and
coordinate the feed rates to the NGL
fractionation trains subject to
ethane and local non-refrigerated
propane demands. This is the second
implementation of this specific type
of real-time dynamic optimization
technology at Saudi Aramco. It is the
first implementation with a process
scope that encompasses more than
P&CSD/APCU partnered with YG&TD
Engineering and Operations groups to
implement a dynamic multi-unit optimizer
application for NGL fractionation.
one operating area. The Yanbu‘ NGL application
incorporates operating objectives and constraints of
the process areas of three console operators.
Six advanced process control applications were
P&CSD/APCU partnered with YG&TD Engineering and Operations groups to
implement a dynamic multi-unit optimizer application for NGL fractionation.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Author: Steve Wagner
This application
is primarily
designed to
optimize and
coordinate the
feed rates to
the NGL
fractionation
trains subject to
ethane and local
non-
refrigerated
propane
demands.
VISION - To become leaders in process engineering and automation!
Yanbu‘ Gas Plant Dynamic Optimizer Implementation
This application is primarily
designed to optimize and
coordinate the feed rates to the NGL
fractionation trains subject to
ethane and local non-refrigerated
propane demands. This is the second
implementation of this specific type
of real-time dynamic optimization
technology at Saudi Aramco. It is the
first implementation with a process
scope that encompasses more than
P&CSD/APCU partnered with YG&TD
Engineering and Operations groups to
implement a dynamic multi-unit optimizer
application for NGL fractionation.
one operating area. The Yanbu‘ NGL application
incorporates operating objectives and constraints of
the process areas of three console operators.
Six advanced process control applications were
P&CSD/APCU partnered with YG&TD Engineering and Operations groups to
implement a dynamic multi-unit optimizer application for NGL fractionation.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Author: Steve Wagner
This application
is primarily
designed to
optimize and
coordinate the
feed rates to
the NGL
fractionation
trains subject to
ethane and local
non-
refrigerated
propane
demands.
39
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
implemented on the three fractionation columns in
Mod 3 and 4 in 2006. These control applications use
Honeywell’s control technology and were designed
with the subsequent addition of this tightly integrated
dynamic optimization technology in mind. The
optimizer application was developed in the first
quarter of 2007 and commissioning was completed at
Yanbu‘ in April. P&CSD handled most of the
engineering in-house.
Console operator interface training was a key concern
for this project. The application scope includes one
console area where personnel previously had no
experience with advanced control technologies. The
standard operating screens for these technologies can
include large amounts of data and require some
training and familiarization to be used effectively. An
example of just one of six standard screens for the
dynamic optimizer is shown below.
Since only a select few pieces if all this data are used by
the console operator for control YG&TD control
engineers designed a simpler, focused interface for the
console operators new to this technology. This step
provides a better operating tool and significantly
reduced the training required during commissioning.
The new custom graphic is shown below. It is tailored
to provide just the key control and related status
information.
Initial results of this application show the anticipated
reduction in variability of the feed to the NGL
fractionation trains and steadier supply to ethane
customers. The figures below show before and after
control performance for the ethane header pressure.
The following figures show the related change in the
control performance of the feed rates to the NGL
fractionation trains. These more gradual changes
translate into better control of key specification on the
individual fraction columns, especially the de-
ethanizers.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Stephen Wagneris an Engineering Specialist with the
Advanced Process Control Unit in P&CSD. He has 22 years
experience in the areas of process control and refining
operations. Stephen is a Chemical Engineer and has been
with Saudi Aramco since 2001. Prior to that, he worked in
several refineries in Canada with experience in process
control operations and process engineering.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
implemented on the three fractionation columns in
Mod 3 and 4 in 2006. These control applications use
Honeywell’s control technology and were designed
with the subsequent addition of this tightly integrated
dynamic optimization technology in mind. The
optimizer application was developed in the first
quarter of 2007 and commissioning was completed at
Yanbu‘ in April. P&CSD handled most of the
engineering in-house.
Console operator interface training was a key concern
for this project. The application scope includes one
console area where personnel previously had no
experience with advanced control technologies. The
standard operating screens for these technologies can
include large amounts of data and require some
training and familiarization to be used effectively. An
example of just one of six standard screens for the
dynamic optimizer is shown below.
Since only a select few pieces if all this data are used by
the console operator for control YG&TD control
engineers designed a simpler, focused interface for the
console operators new to this technology. This step
provides a better operating tool and significantly
reduced the training required during commissioning.
The new custom graphic is shown below. It is tailored
to provide just the key control and related status
information.
Initial results of this application show the anticipated
reduction in variability of the feed to the NGL
fractionation trains and steadier supply to ethane
customers. The figures below show before and after
control performance for the ethane header pressure.
The following figures show the related change in the
control performance of the feed rates to the NGL
fractionation trains. These more gradual changes
translate into better control of key specification on the
individual fraction columns, especially the de-
ethanizers.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Stephen Wagneris an Engineering Specialist with the
Advanced Process Control Unit in P&CSD. He has 22 years
experience in the areas of process control and refining
operations. Stephen is a Chemical Engineer and has been
with Saudi Aramco since 2001. Prior to that, he worked in
several refineries in Canada with experience in process
control operations and process engineering.
40
VISION - To become leaders in process engineering and automation!
Alarm System Improvement at AINDAR GOSP-2
This is the first project to improve a GOSP Alarm
Management System within Saudi Aramco. This article
describes the data collection setup, summarizes the
analysis results, and recommended resolutions for the
immediate alarm system performance improvement.
Data Collection Setup
The alarm and events messages from AINDAR GOSP-2 are
collected by using the Matrikon Collector via the ExaOPC
Server interfaced to the process automation system
(PAS),Yokogawa CS3000. The messages are parsed andDHA 00730-SQLT 01
ProcessGuard Archiver
Local
ProcessGuard
Server
Central
ProcessGuard
Server
Central D atabase
Server
ABQAIQ
AIN DAR GOSP -2
ProcessGuard
Analyzer
ProcessGuard
Web Repor ts
(MSDE )
Process
ExaQuantum
OPC Server
LEGEND
Process
Guard
Coll ector
DBTEMS 01
ProcessGuard
Excel Analysis
Reports
Internet
Explorer
ProcessGuard
Real Time Vie wer
ProcessGuard C lient Applica tions
Software Co mp onent
PC / Server
BC332172
BC312960
TCP 8541
TCP 8540 / 8543
TCP 80 TCP 854 2
ProcessGuard
Heal th M onitor
OPC 01 62
TCP 854 1
Process
Guard
Coll ector
Yokoga wa
ExaOPC
A&E Server
Local DB
( 2 GB Limit)
Guard
Archiver
Data stored loca lly and then
forwarded to a nother
collec tor from which i t is
sent to the central server
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Authors: Saad M. Al-Abbud, Bandar M. Al-Usaimi
Figure 1 ProcessGuard System Architecture
Using an Engineering Services Agreement (ESA
Department (P&CSD
(NGPD
improvement solutions, and recommended resolutions for fixing the top 10 bad
actors at AINDAR GOSP-2.
VISION - To become leaders in process engineering and automation!
Alarm System Improvement at AINDAR GOSP-2
This is the first project to improve a GOSP Alarm
Management System within Saudi Aramco. This article
describes the data collection setup, summarizes the
analysis results, and recommended resolutions for the
immediate alarm system performance improvement.
Data Collection Setup
The alarm and events messages from AINDAR GOSP-2 are
collected by using the Matrikon Collector via the ExaOPC
Server interfaced to the process automation system
(PAS),Yokogawa CS3000. The messages are parsed andDHA 00730-SQLT 01
ProcessGuard Archiver
Local
ProcessGuard
Server
Central
ProcessGuard
Server
Central D atabase
Server
ABQAIQ
AIN DAR GOSP -2
ProcessGuard
Analyzer
ProcessGuard
Web Repor ts
(MSDE )
Process
ExaQuantum
OPC Server
LEGEND
Process
Guard
Coll ector
DBTEMS 01
ProcessGuard
Excel Analysis
Reports
Internet
Explorer
ProcessGuard
Real Time Vie wer
ProcessGuard C lient Applica tions
Software Co mp onent
PC / Server
BC332172
BC312960
TCP 8541
TCP 8540 / 8543
TCP 80 TCP 854 2
ProcessGuard
Heal th M onitor
OPC 01 62
TCP 854 1
Process
Guard
Coll ector
Yokoga wa
ExaOPC
A&E Server
Local DB
( 2 GB Limit)
Guard
Archiver
Data stored loca lly and then
forwarded to a nother
collec tor from which i t is
sent to the central server
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Authors: Saad M. Al-Abbud, Bandar M. Al-Usaimi
Figure 1 ProcessGuard System Architecture
Using an Engineering Services Agreement (ESA
Department (P&CSD
(NGPD
improvement solutions, and recommended resolutions for fixing the top 10 bad
actors at AINDAR GOSP-2.
41
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
achieved on a local Archiver then forwarded to a central
server located at Abqaiq for remote alarm management
and analysis. The ProcessGuard System Architecture
installed for AINDAR GOSP-2 is illustrated below.
Alarm Data Analysis Results Summary
The alarm data were collected for more than a three
month period, from February 4, 2007 through May 13,
2007. The performance measured by using Key
Performance Indicators (KPIs) defined in Saudi Aramco
Engineering Report SAER-5895, Alarm Management
Guidelines for PAS.
Many of the performance deficiencies listed in the
findings below are due to an improper alarm system
design inherited from the designer, and inappropriate
configurations exercised by the PAS Vendor. Here is the
summary of the findings and recommendations:
Findings
•The tags of the top 20 bad actors have been identified.
More than 25% of these bad actors are caused by
instruments malfunction. Also, alarms on 69 tags have
been disabled/suppressed due to similar problems. It is
recommended that disabled alarms should be less than
30 at any time.
•The average of the configured alarms per analog tags
is 1.6, and the average of the configured alarms per
digital tags is 1.0. The recommended average for
analog tags is 1.0, and for digital tags is 0.4. The
existing configuration for the both tag types is
exciding the recommended average.
•About 96% of the alarms have MEDIUM (HIGH)
priority with no LOW priority alarms. This alarm
priority is not aligned with the best industry practices
as defined in SAER-5895, 5% Emergency, 15% High,
and 80% Low.
•The different alarm priorities are neither
distinguishable by color on the displays nor by audible
alarm tones. This severely impacts the operator’s
ability to focus on prioritizing his actions during
abnormal conditions.
•There is no Alarms Philosophy document available at
the site.
Recommendations
A workshop was held at AINDAR GOSP-2 attended by
representatives from P&CSD, NGPD, AINDAR GOSP-2
Operation, Engineering, and Maintenance. During the
workshop, proposed recommendations for fixing the top
20 bad actors and immediate performance improvement
solutions were discussed. The team agreed on the
following recommendations:
•The PAS Alarms need to be re-configured so that the
different priorities (Low, High, and Emergency) of the
alarms can be distinguishable to the console operator.
The alarm indication color should be based on priority
and be consistent through displays on all consoles. This
will play an important role especially in an upset
condition when the Operator can focus on prioritizing
his actions based on alarm priority.
•Immediate implementation of the recommended
resolutions of the top 20 bad actors should be
performed. This will improve the alarm management
system by 70%.
•An Alarm Philosophy Document for AINDAR GOSP-2
should be developed based on NGPD Management of
Change, and SAER-5895. The Alarm Philosophy
Document will serve as guidelines to provide
consistent methodology and criteria for the
development, implementation, and modification of
process alarms.
Saad M. Al-Abbudis the Alarm Management Optimization
(AMO) Lead Engineer at Saudi Aramco. He has active
participations in establishing Alarm Management System
Project Specification, and sites alarm system philosophy
Documents. Led many AMO projects.
Bandar M. Al-Usaimiworks in NGPD as a control system
engineer. He has participated in several SAOO control
system upgrade projects. Bandar is assigned to lead Alarm
Management System installation as a Pilot Testing and
develop a deployment plan to the rest of NGPD facilities.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
The performance measured by
using Key Performance
Indicators (KPIs) defined in Saudi
Aramco Engineering Report
SAER-5895, Alarm Management
Guidelines for PAS.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
achieved on a local Archiver then forwarded to a central
server located at Abqaiq for remote alarm management
and analysis. The ProcessGuard System Architecture
installed for AINDAR GOSP-2 is illustrated below.
Alarm Data Analysis Results Summary
The alarm data were collected for more than a three
month period, from February 4, 2007 through May 13,
2007. The performance measured by using Key
Performance Indicators (KPIs) defined in Saudi Aramco
Engineering Report SAER-5895, Alarm Management
Guidelines for PAS.
Many of the performance deficiencies listed in the
findings below are due to an improper alarm system
design inherited from the designer, and inappropriate
configurations exercised by the PAS Vendor. Here is the
summary of the findings and recommendations:
Findings
•The tags of the top 20 bad actors have been identified.
More than 25% of these bad actors are caused by
instruments malfunction. Also, alarms on 69 tags have
been disabled/suppressed due to similar problems. It is
recommended that disabled alarms should be less than
30 at any time.
•The average of the configured alarms per analog tags
is 1.6, and the average of the configured alarms per
digital tags is 1.0. The recommended average for
analog tags is 1.0, and for digital tags is 0.4. The
existing configuration for the both tag types is
exciding the recommended average.
•About 96% of the alarms have MEDIUM (HIGH)
priority with no LOW priority alarms. This alarm
priority is not aligned with the best industry practices
as defined in SAER-5895, 5% Emergency, 15% High,
and 80% Low.
•The different alarm priorities are neither
distinguishable by color on the displays nor by audible
alarm tones. This severely impacts the operator’s
ability to focus on prioritizing his actions during
abnormal conditions.
•There is no Alarms Philosophy document available at
the site.
Recommendations
A workshop was held at AINDAR GOSP-2 attended by
representatives from P&CSD, NGPD, AINDAR GOSP-2
Operation, Engineering, and Maintenance. During the
workshop, proposed recommendations for fixing the top
20 bad actors and immediate performance improvement
solutions were discussed. The team agreed on the
following recommendations:
•The PAS Alarms need to be re-configured so that the
different priorities (Low, High, and Emergency) of the
alarms can be distinguishable to the console operator.
The alarm indication color should be based on priority
and be consistent through displays on all consoles. This
will play an important role especially in an upset
condition when the Operator can focus on prioritizing
his actions based on alarm priority.
•Immediate implementation of the recommended
resolutions of the top 20 bad actors should be
performed. This will improve the alarm management
system by 70%.
•An Alarm Philosophy Document for AINDAR GOSP-2
should be developed based on NGPD Management of
Change, and SAER-5895. The Alarm Philosophy
Document will serve as guidelines to provide
consistent methodology and criteria for the
development, implementation, and modification of
process alarms.
Saad M. Al-Abbudis the Alarm Management Optimization
(AMO) Lead Engineer at Saudi Aramco. He has active
participations in establishing Alarm Management System
Project Specification, and sites alarm system philosophy
Documents. Led many AMO projects.
Bandar M. Al-Usaimiworks in NGPD as a control system
engineer. He has participated in several SAOO control
system upgrade projects. Bandar is assigned to lead Alarm
Management System installation as a Pilot Testing and
develop a deployment plan to the rest of NGPD facilities.
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
The performance measured by
using Key Performance
Indicators (KPIs) defined in Saudi
Aramco Engineering Report
SAER-5895, Alarm Management
Guidelines for PAS.
Automatic Valve Characterization –
Why didn’t we think of that?
Patrick S. Flandersis an Engineering Specialist within the
Instrumentation Unit of P&CSD. He is named on 6 patent
applications and is credited with the development of three
commercialized products. He is a registered professional
engineer in the State of South Dakota, USA.
Rienk Tuinis an Engineering Consultant within the
Instrumentation Unit of PID. He joined AOC in Holland in
1981 and then transferred to SAO in 1987. He is the
instructor for the control valve courses PCI-103 and PCI-204.
Author: Patrick S. Flanders, Rienk Tuin
Figure 1 AVC Valve Performance Correction Method
Figure 2 AVC Device Architecture
This problem has plagued the process control engineer since
automation was first implemented in continuous processing
facilities. Conventional attempts to address control valve
“non-linearities” involved manual adjustments known as
“characterization” within the valve controller or
mechanically through the selection and installation of special
valve internals.
Although possible in theory, the conventional approaches
proved impractical as they required manual readjustment to
control valve behavior every time the process changed
(entire process including the valve and all other equipment in
the loop). Matching the valve characteristic to the process
requirement was difficult enough but each time piping
modifications were made, pumps turned on or turned off,
product build up within the process piping or wear on
control valve internals changed the pressure drop seen at the
control valve, the process of valve re-characterization was
required again. If not re-adjusted, non-linearity would be
introduced with negative impact on the overall control loop
performance.
To address this problem, Process and Control Systems
Engineers, Patrick Flanders and Rienk Tuin proposed a new
innovative solution. They envisioned a new smart valve
controller that could perform the required corrections in real
time by combining the computing power of advanced smart
valve controllers, continuous feedback of valve stem
position, and process data available at the field level.
With the new Automatic Valve Characterization controller,
the installed valve flow characteristic would be modified to
provide a linear relationship between the input signal to the
positioner and the flow through the control valve (refer to
Fig. 1). Using this new approach difficult non-linear control
valve applications will be more easily tuned to provide safe
and robust automatic control (refer to Fig. 2).
The invention was documented in a Saudi Aramco patent
application entitled “Automatic Valve Characterization of
Digital Valve Positioners.” The patent was granted under US
Patent # US 7,178,783 on February 20, 2007. Two major
instrumentation and control system suppliers have shown
interest in developing a prototype device jointly with Saudi
Aramco. As testament to the innovative potential of Saudi
Aramco, one supplier commented,
“Where do you guys come up with such great ideas?”
Another stated, “Why didn’t we think of that?”
42
VISION - To become leaders in process engineering and automation!
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Control valves and their performance play a major role in the automation of Saudi
Aramco facilities. The need to adjust or correct the off-the-shelf flow characteristic
of a control valve to achieve linear control action once installed in the process is not
a new problem.Input Signal
Process
Measurement
(Flow or Differential
Pressure)
AVC provides a linear relationship between the input signal to the
positioner and the flow through the control valve.
Control Valve
Digital Valve Controller
Valve Position
Feedback
Pneumatic
Output
to Valve
AVC
AVC Device Architecture
Why didn’t we think of that?
Patrick S. Flandersis an Engineering Specialist within the
Instrumentation Unit of P&CSD. He is named on 6 patent
applications and is credited with the development of three
commercialized products. He is a registered professional
engineer in the State of South Dakota, USA.
Rienk Tuinis an Engineering Consultant within the
Instrumentation Unit of PID. He joined AOC in Holland in
1981 and then transferred to SAO in 1987. He is the
instructor for the control valve courses PCI-103 and PCI-204.
Author: Patrick S. Flanders, Rienk Tuin
Figure 1 AVC Valve Performance Correction Method
Figure 2 AVC Device Architecture
This problem has plagued the process control engineer since
automation was first implemented in continuous processing
facilities. Conventional attempts to address control valve
“non-linearities” involved manual adjustments known as
“characterization” within the valve controller or
mechanically through the selection and installation of special
valve internals.
Although possible in theory, the conventional approaches
proved impractical as they required manual readjustment to
control valve behavior every time the process changed
(entire process including the valve and all other equipment in
the loop). Matching the valve characteristic to the process
requirement was difficult enough but each time piping
modifications were made, pumps turned on or turned off,
product build up within the process piping or wear on
control valve internals changed the pressure drop seen at the
control valve, the process of valve re-characterization was
required again. If not re-adjusted, non-linearity would be
introduced with negative impact on the overall control loop
performance.
To address this problem, Process and Control Systems
Engineers, Patrick Flanders and Rienk Tuin proposed a new
innovative solution. They envisioned a new smart valve
controller that could perform the required corrections in real
time by combining the computing power of advanced smart
valve controllers, continuous feedback of valve stem
position, and process data available at the field level.
With the new Automatic Valve Characterization controller,
the installed valve flow characteristic would be modified to
provide a linear relationship between the input signal to the
positioner and the flow through the control valve (refer to
Fig. 1). Using this new approach difficult non-linear control
valve applications will be more easily tuned to provide safe
and robust automatic control (refer to Fig. 2).
The invention was documented in a Saudi Aramco patent
application entitled “Automatic Valve Characterization of
Digital Valve Positioners.” The patent was granted under US
Patent # US 7,178,783 on February 20, 2007. Two major
instrumentation and control system suppliers have shown
interest in developing a prototype device jointly with Saudi
Aramco. As testament to the innovative potential of Saudi
Aramco, one supplier commented,
“Where do you guys come up with such great ideas?”
Another stated, “Why didn’t we think of that?”
42
VISION - To become leaders in process engineering and automation!
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Control valves and their performance play a major role in the automation of Saudi
Aramco facilities. The need to adjust or correct the off-the-shelf flow characteristic
of a control valve to achieve linear control action once installed in the process is not
a new problem.Input Signal
Process
Measurement
(Flow or Differential
Pressure)
AVC provides a linear relationship between the input signal to the
positioner and the flow through the control valve.
Control Valve
Digital Valve Controller
Valve Position
Feedback
Pneumatic
Output
to Valve
AVC
AVC Device Architecture
43
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Key Elements for Oil & Gas Wireless Networks
With a globally distributed design/build process and
supply chain, a demand-driven market, the rapid needs to
deploy technologies such as wireless to enhance
networking capabilities. With the need for secure real-
time response across the process control and enterprise
networks, companies are facing difficult challenges and
complex integration.
A shift is taking place across all of the process automation
industries. Information itself is becoming the engine that
runs the operation. From product development
engineering to production operations and extended to
distribution, information from all domains must be
shared across the operation stages and lifecycle, and
throughout the enterprise networks.
To that extent, the SP100 (wireless for automation
systems) is expected to becoming a basic building block of
the plant networks and a means for carrying information
within and outside the oil and gas plant premises. This
article will tap on the wireless key elements for process
automation networks and show the coming industrial
wireless standards in addition to addressing the
requirements for oil and gas applications
ISA SP100
SP100 is a work group within ISA (Instrumentation,
Systems and Automation society) tasked with developing
a new wireless standard for process automation system.
The SP100 wireless standard for process automation
systems is applicable to industry such as oil & gas,
petrochemical and manufacturing. The standard of SP100
is under development and is intended to be used in 2.4
GHz band in the first release.
Key Elements for Wireless Plant
Networks:
The key factors of selecting wireless for an application are
single industrial standard, reliability of data, wireless
security, sensor battery life, and single network for many
applications as seen in the above figure.
In several wireless projects in Saudi Aramco, there are a number of
requirements in any future wireless system that should be factored
into connecting various plant equipment or systems, as follow:
•The wireless system should be certified to work in a hazardous
area.
•
Support mesh topology.
•
Low latency.
•
Operate in extreme environment “high temperature and
humidity.
•
Have a strong level of wireless security, as described in SP100.
•
Provision for device to be battery operated
•
Employ frequency hopping to reduce the effect of interference
and fading
•
Scalable for additional nodes
•
Can support different types of physical connections, e.g.,
Ethernet, serial, etc.
Conclusion
Wireless data reliability and security are the most critical
aspects of SP100 design, as seen by the users. Proper
wireless design practices, cost effectiveness, and business
needs mandate that a single wireless network with
multiple applications is used as a model for our plants. For
the first phase, we anticipate that most applications using
wireless will be for monitoring and alerting. There are
few plans in the market to eventually use wireless for
control. Many wireless applications are new – not
previously measured with wired devices.Factors Influencing Use of Wireless
Percentage
Abdullah Al-Nufaiiis a Communications Engineer within
CCNU of P&CSD. He joined Saudi Aramco in 1994 with more
than eleven years of experience. He has a Masters Degree in
Telecommunications and an SDP candidate.
Dr. Abdelghani Daraisehis an Engineering Specialist within
CCNU of P&CSD. He has 17 years of industrial experience in
wireless networks and security. Previous to joining Saudi
Aramco, he worked in the USA with Nortel Networks, and a
Center for Wireless R&D.
Author: Abdullah Al-Nufaii, Dr. Abdelghani Daraiseh
Most Oil & Gas companies today are exposed to one of the most complex and
diverse business environments in process automation history.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Key Elements for Oil & Gas Wireless Networks
With a globally distributed design/build process and
supply chain, a demand-driven market, the rapid needs to
deploy technologies such as wireless to enhance
networking capabilities. With the need for secure real-
time response across the process control and enterprise
networks, companies are facing difficult challenges and
complex integration.
A shift is taking place across all of the process automation
industries. Information itself is becoming the engine that
runs the operation. From product development
engineering to production operations and extended to
distribution, information from all domains must be
shared across the operation stages and lifecycle, and
throughout the enterprise networks.
To that extent, the SP100 (wireless for automation
systems) is expected to becoming a basic building block of
the plant networks and a means for carrying information
within and outside the oil and gas plant premises. This
article will tap on the wireless key elements for process
automation networks and show the coming industrial
wireless standards in addition to addressing the
requirements for oil and gas applications
ISA SP100
SP100 is a work group within ISA (Instrumentation,
Systems and Automation society) tasked with developing
a new wireless standard for process automation system.
The SP100 wireless standard for process automation
systems is applicable to industry such as oil & gas,
petrochemical and manufacturing. The standard of SP100
is under development and is intended to be used in 2.4
GHz band in the first release.
Key Elements for Wireless Plant
Networks:
The key factors of selecting wireless for an application are
single industrial standard, reliability of data, wireless
security, sensor battery life, and single network for many
applications as seen in the above figure.
In several wireless projects in Saudi Aramco, there are a number of
requirements in any future wireless system that should be factored
into connecting various plant equipment or systems, as follow:
•The wireless system should be certified to work in a hazardous
area.
•
Support mesh topology.
•
Low latency.
•
Operate in extreme environment “high temperature and
humidity.
•
Have a strong level of wireless security, as described in SP100.
•
Provision for device to be battery operated
•
Employ frequency hopping to reduce the effect of interference
and fading
•
Scalable for additional nodes
•
Can support different types of physical connections, e.g.,
Ethernet, serial, etc.
Conclusion
Wireless data reliability and security are the most critical
aspects of SP100 design, as seen by the users. Proper
wireless design practices, cost effectiveness, and business
needs mandate that a single wireless network with
multiple applications is used as a model for our plants. For
the first phase, we anticipate that most applications using
wireless will be for monitoring and alerting. There are
few plans in the market to eventually use wireless for
control. Many wireless applications are new – not
previously measured with wired devices.Factors Influencing Use of Wireless
Percentage
Abdullah Al-Nufaiiis a Communications Engineer within
CCNU of P&CSD. He joined Saudi Aramco in 1994 with more
than eleven years of experience. He has a Masters Degree in
Telecommunications and an SDP candidate.
Dr. Abdelghani Daraisehis an Engineering Specialist within
CCNU of P&CSD. He has 17 years of industrial experience in
wireless networks and security. Previous to joining Saudi
Aramco, he worked in the USA with Nortel Networks, and a
Center for Wireless R&D.
Author: Abdullah Al-Nufaii, Dr. Abdelghani Daraiseh
Most Oil & Gas companies today are exposed to one of the most complex and
diverse business environments in process automation history.
VISION - To become leaders in process engineering and automation!
Industrial Time Synchronization
For Oil and Gas Process Automation Networks
This will guarantee same clocking reference is used for
the various industrial process applications such as SCADA,
DCS, VMS, PMS, etc. Lack of a coordinated accurate time
stamping for recorded events makes any reconstruction
of a timeline difficult and time consuming, if not
impossible.
Time synchronization and accuracy might not be
important to some organizations especially those who
have mostly stand-a-alone and closed application servers.
For other organizations that depend on distributed and
interacted systems to automate their work such as oil
refineries and oil/gas plants, time synchronization is a key
issue that needs to be always maintained across all
applications and devices in PAN. There are different ways
to provide time synchronization over industrial data
networks. Two popular ways are Network Timing Protocol
(NTP) and the newly released IEEE protocol Precision
Timing Protocol (PTP).
The NTP (RFC1305) is a protocol for synchronizing
industrial equipment’s clocks across the network to
standard time. These equipments and devices should be
Ethernet-based, e.g. workstations, HMI, RTU, PLC,
Wireless Gateways, Switches, Routers etc.
NTP version 4 can provide time accuracy of 10 milliseconds
over the Internet but can maintain time accuracy of less
than 200 microseconds over Local Area Networks.
NTP architecture consists of hierarchical stratums levels
(fig.1), which defines the distance and accuracy from the
reference clock.
The primary stratum (stratum 0) consists of devices such as
GPS, atomic, or radio clocks. The next stratum level
(stratum 1) contains servers that are directly connected to
Figure 1 NTP timing architecture
Authors: Majed M. Al-Subaey, Soliman Al-Walaie, and Mohammed A. Al-Saeed
44 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Industrial communications and data networking equipment such as routers,
switches, wireless devices and access points are used to interconnect PAN
infrastructures. Because of the multiple systems and applications, it is very crucial
to use precise and common master time reference to synchronize all systems and
ensure accurate time stamping consistency for all Oil and Gas plants operations.
For other organizations that
depend on distributed and
interacted systems to automate
their work such as oil refineries
and oil/gas plants, time
synchronization is a key issue
that needs to be always
maintained across all
applications and devices in PAN.
Industrial Time Synchronization
For Oil and Gas Process Automation Networks
This will guarantee same clocking reference is used for
the various industrial process applications such as SCADA,
DCS, VMS, PMS, etc. Lack of a coordinated accurate time
stamping for recorded events makes any reconstruction
of a timeline difficult and time consuming, if not
impossible.
Time synchronization and accuracy might not be
important to some organizations especially those who
have mostly stand-a-alone and closed application servers.
For other organizations that depend on distributed and
interacted systems to automate their work such as oil
refineries and oil/gas plants, time synchronization is a key
issue that needs to be always maintained across all
applications and devices in PAN. There are different ways
to provide time synchronization over industrial data
networks. Two popular ways are Network Timing Protocol
(NTP) and the newly released IEEE protocol Precision
Timing Protocol (PTP).
The NTP (RFC1305) is a protocol for synchronizing
industrial equipment’s clocks across the network to
standard time. These equipments and devices should be
Ethernet-based, e.g. workstations, HMI, RTU, PLC,
Wireless Gateways, Switches, Routers etc.
NTP version 4 can provide time accuracy of 10 milliseconds
over the Internet but can maintain time accuracy of less
than 200 microseconds over Local Area Networks.
NTP architecture consists of hierarchical stratums levels
(fig.1), which defines the distance and accuracy from the
reference clock.
The primary stratum (stratum 0) consists of devices such as
GPS, atomic, or radio clocks. The next stratum level
(stratum 1) contains servers that are directly connected to
Figure 1 NTP timing architecture
Authors: Majed M. Al-Subaey, Soliman Al-Walaie, and Mohammed A. Al-Saeed
44 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Industrial communications and data networking equipment such as routers,
switches, wireless devices and access points are used to interconnect PAN
infrastructures. Because of the multiple systems and applications, it is very crucial
to use precise and common master time reference to synchronize all systems and
ensure accurate time stamping consistency for all Oil and Gas plants operations.
For other organizations that
depend on distributed and
interacted systems to automate
their work such as oil refineries
and oil/gas plants, time
synchronization is a key issue
that needs to be always
maintained across all
applications and devices in PAN.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
the primary stratum while stratum 2 consists of industrial
devices that send NTP requests to stratum 1 servers and so
on as shown on the following figure.
Ju‘aymah Gas Plant (JGP) expansion project is an example
where NTP is implemented for accurate and consistent
time stamping for all sequence of events (SOE) and
alarming. Time synchronization was accomplished by
employing NTP time sync approach for plant wide systems
and applications.
In JGP expansion project, NTP server with GPS antenna
receiver will be installed and configured to be connected
to Vnet/IP layer 2 switches. NTP server will act as a
common master clock server over the Vnet/IP network
while clients connected to the Vnet/IP network will be
equipped with SNTP client function to time synchronize
with NTP server on the same Vnet/IP network. Other
subsystems that are not on the Vnet/IP network can be
synchronized by directly connecting them to the NTP
server via LAN ports (Ethernet) or serial ports (RS232).
The main challenge with NTP is that its timing signals are
delayed by the Operating System (OS) since its packets go
through the physical and Data Link OSI Layers in the
network switch as any other data packets. Thus, this has
lead to the development Precision Timing Protocol (PTP
The PTP provides better timing accuracy by resolving the
NTP problem using hardware Time Stamping Unit (TSU
This unit is placed between the Data Link and physical
layers to monitor the packets over the inbound and
outbound traffics and issue a precision time stamp when
a PTP packet is recognized. PTP is applicable to be used in
applications that have high demands on accuracy and
using dedicated networks. NTP is used for applications
using Local Area Network, Wide Area Network, and
Internet.
In conclusion, both timing protocol standards (NTP and
PTP) can be deployed on PAN to provide precisely
accurate common timing for the various process
applications such as DCS, SCADA, PMS, TMS, etc. This
solution can be integrated seamlessly with the existing
network infrastructure as well as providing a robust and
efficient mechanism to support timing over IP
applications. Both NTP and PTP protocol can be extended
in any deployment by utilizing the Global Positioning
System (GPS). NTP and PTP with GPS are now widely used
in closely coupled real-time control systems that require
synchronization in the range of mili-to micro-seconds.
Furthermore, PTP is more used in motion control
automation systems such robotics, and other
manufacturing applications.
Soliman Al-Walaieis a communication engineer within the
communications Unit of P&CSD. He is a certified wireless
networks professional (CWNP) engineer and has twelve years
of experience. He is the instructor of Communication
Transmission Systems (CTR205
Mohammed A. Al-Saeed is working for Saudi Aramco in
Process & Control Systems Department/ Process Instru-
mentation Division. He graduated from King Saud University
in 1995 with a bachelor degree in Computer Science in
Information Systems. He first worked with Saudi Arabian
Texaco Inc. as a Network Specialist for six years. In 2001, he
joined Saudi Aramco in P&CSD as Industrial Computer
Engineer. He obtained a Master of Business Administration
(MBA) and five technical certifications, Certified Wireless
Security Professional (CWSP), Cisco Certified Design
Professional (CCDP), Advanced Wireless LAN Design Specialist
(AWLDS), Cisco Certified Design Associate (CCDA), Cisco
Certified Network Associate (CCNA). His specialty is Process
Plant Networking and Systems Engineering. He is a member
of ISA and IEEE professional societies.
Majed M. Al-Subaeyis a Computer Engineer working for
Saudi Aramco in Process & Control Systems Department/
Process Instrumentation Division. He graduated with a
Bachelor of Science degree in Computer Engineering from
KFUPM in 2000 and obtained a Master degree in IT University
of Liverpool, UK in 2005. Currently, he is pursuing Ph.D in
Nova Southeastern University, Florida, USA in Information
Systems, area of interest Information Security. He is an MCSE
since 2001 and a Sun Certified Programmer in Java since
(SCPJ) 2004.
45Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
The main challenge with NTP is
that its timing signals are
delayed by the Operating System
(OS) since its packets go through
the physical and Data Link OSI
Layers in the network switch as
any other data packets.
Furthermore, PTP is more used
in motion control automation
systems such robotics, and
other manufacturing
applications.
and professional services in process engineering and process automation!
the primary stratum while stratum 2 consists of industrial
devices that send NTP requests to stratum 1 servers and so
on as shown on the following figure.
Ju‘aymah Gas Plant (JGP) expansion project is an example
where NTP is implemented for accurate and consistent
time stamping for all sequence of events (SOE) and
alarming. Time synchronization was accomplished by
employing NTP time sync approach for plant wide systems
and applications.
In JGP expansion project, NTP server with GPS antenna
receiver will be installed and configured to be connected
to Vnet/IP layer 2 switches. NTP server will act as a
common master clock server over the Vnet/IP network
while clients connected to the Vnet/IP network will be
equipped with SNTP client function to time synchronize
with NTP server on the same Vnet/IP network. Other
subsystems that are not on the Vnet/IP network can be
synchronized by directly connecting them to the NTP
server via LAN ports (Ethernet) or serial ports (RS232).
The main challenge with NTP is that its timing signals are
delayed by the Operating System (OS) since its packets go
through the physical and Data Link OSI Layers in the
network switch as any other data packets. Thus, this has
lead to the development Precision Timing Protocol (PTP
The PTP provides better timing accuracy by resolving the
NTP problem using hardware Time Stamping Unit (TSU
This unit is placed between the Data Link and physical
layers to monitor the packets over the inbound and
outbound traffics and issue a precision time stamp when
a PTP packet is recognized. PTP is applicable to be used in
applications that have high demands on accuracy and
using dedicated networks. NTP is used for applications
using Local Area Network, Wide Area Network, and
Internet.
In conclusion, both timing protocol standards (NTP and
PTP) can be deployed on PAN to provide precisely
accurate common timing for the various process
applications such as DCS, SCADA, PMS, TMS, etc. This
solution can be integrated seamlessly with the existing
network infrastructure as well as providing a robust and
efficient mechanism to support timing over IP
applications. Both NTP and PTP protocol can be extended
in any deployment by utilizing the Global Positioning
System (GPS). NTP and PTP with GPS are now widely used
in closely coupled real-time control systems that require
synchronization in the range of mili-to micro-seconds.
Furthermore, PTP is more used in motion control
automation systems such robotics, and other
manufacturing applications.
Soliman Al-Walaieis a communication engineer within the
communications Unit of P&CSD. He is a certified wireless
networks professional (CWNP) engineer and has twelve years
of experience. He is the instructor of Communication
Transmission Systems (CTR205
Mohammed A. Al-Saeed is working for Saudi Aramco in
Process & Control Systems Department/ Process Instru-
mentation Division. He graduated from King Saud University
in 1995 with a bachelor degree in Computer Science in
Information Systems. He first worked with Saudi Arabian
Texaco Inc. as a Network Specialist for six years. In 2001, he
joined Saudi Aramco in P&CSD as Industrial Computer
Engineer. He obtained a Master of Business Administration
(MBA) and five technical certifications, Certified Wireless
Security Professional (CWSP), Cisco Certified Design
Professional (CCDP), Advanced Wireless LAN Design Specialist
(AWLDS), Cisco Certified Design Associate (CCDA), Cisco
Certified Network Associate (CCNA). His specialty is Process
Plant Networking and Systems Engineering. He is a member
of ISA and IEEE professional societies.
Majed M. Al-Subaeyis a Computer Engineer working for
Saudi Aramco in Process & Control Systems Department/
Process Instrumentation Division. He graduated with a
Bachelor of Science degree in Computer Engineering from
KFUPM in 2000 and obtained a Master degree in IT University
of Liverpool, UK in 2005. Currently, he is pursuing Ph.D in
Nova Southeastern University, Florida, USA in Information
Systems, area of interest Information Security. He is an MCSE
since 2001 and a Sun Certified Programmer in Java since
(SCPJ) 2004.
45Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
The main challenge with NTP is
that its timing signals are
delayed by the Operating System
(OS) since its packets go through
the physical and Data Link OSI
Layers in the network switch as
any other data packets.
Furthermore, PTP is more used
in motion control automation
systems such robotics, and
other manufacturing
applications.
VISION - To become leaders in process engineering and automation!
Trim Integrity for Compressor Anti-surge Valves
Process Challenges
Valve trim parts are expected to continue in operation
(with minimum wear and tear) until the next plant or
equipment turndown. They have to be selected to be
capable of handling the following process challenges:
•flow induced noise and vibration
•sudden flow gust
•high energy dissipation
•spare flowing capacity
•seating area leakage
•low travel throttling
Analysis
I) Plug Designs
1. The Solid Plug Design
The solid plug design is rugged, less susceptible to
vibration and friendly to machining. Its excessive weight,
however, makes it economically unattractive.
2. The Skirt Plug Design (Figure 1)
The skirt plug design overcomes plug weight concerns
and therefore helps achieving better stroke speeds. The
design however is more susceptible to vibration.
3. The Spoked Plug Design (Figure 2)
The spoked plug design is considered the optimal plug
design. Weight and susceptibility to vibration are top-
quality. Because of its difficult geometry, this design faces
manufacturing challenges.
II) Plug/Stem Connection Methods
1. The Screw & Pin Method (Figure 3)
Because of its simplicity and suitability to sour and sweet
Figure 1 The Skirt Plug Design
Figure 2
The Spoked
Plug Design
Figure 3 The Screw & Pin Stem/Plug Connection Method
Author: Mohammed Al-Juaib
Recently, performance analysis of anti-surge valves is focused on the quality of
response (speed, overshoot, set point tracking, etc.
the above, is predominantly concerned with the actuating system (actuator,
positioner, boosters, etc), with very little or no emphasis on the selection of the
valve internal components (mainly the trim parts
vibration, noise, trim damage, plug jam and loss of the tight shutoff, need to be
addressed and resolved. Drilled
46 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Trim Integrity for Compressor Anti-surge Valves
Process Challenges
Valve trim parts are expected to continue in operation
(with minimum wear and tear) until the next plant or
equipment turndown. They have to be selected to be
capable of handling the following process challenges:
•flow induced noise and vibration
•sudden flow gust
•high energy dissipation
•spare flowing capacity
•seating area leakage
•low travel throttling
Analysis
I) Plug Designs
1. The Solid Plug Design
The solid plug design is rugged, less susceptible to
vibration and friendly to machining. Its excessive weight,
however, makes it economically unattractive.
2. The Skirt Plug Design (Figure 1)
The skirt plug design overcomes plug weight concerns
and therefore helps achieving better stroke speeds. The
design however is more susceptible to vibration.
3. The Spoked Plug Design (Figure 2)
The spoked plug design is considered the optimal plug
design. Weight and susceptibility to vibration are top-
quality. Because of its difficult geometry, this design faces
manufacturing challenges.
II) Plug/Stem Connection Methods
1. The Screw & Pin Method (Figure 3)
Because of its simplicity and suitability to sour and sweet
Figure 1 The Skirt Plug Design
Figure 2
The Spoked
Plug Design
Figure 3 The Screw & Pin Stem/Plug Connection Method
Author: Mohammed Al-Juaib
Recently, performance analysis of anti-surge valves is focused on the quality of
response (speed, overshoot, set point tracking, etc.
the above, is predominantly concerned with the actuating system (actuator,
positioner, boosters, etc), with very little or no emphasis on the selection of the
valve internal components (mainly the trim parts
vibration, noise, trim damage, plug jam and loss of the tight shutoff, need to be
addressed and resolved. Drilled
46 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Drilled Hole Cage (inwards tapered)
Flow in
Flow in
Drilled Hole Cage (o utwards tapered) MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
process conditions, the screw & pin method is the most
favorable plug/stem connection method. Designers are
cautioned when specifying this method for high
Differential pressure (DP) applications as the screw & pins
integrity degrades significantly.
2. Welding Method
Welding the stem to the plug is a more robust connection
method. It is limited to sweet services since welding
introduces complications with the corrosion resistance of
the base metal.
III) Plug to Cage Clearance
Minimum clearance (between the plug and the cage) is
required to ensure negligible frication and to keep
clearance flow to minimum. Clearance flow (Figure 4)
causes series trim damage particularly in high DP
applications as it causes plug vibration and rotation. This
can be eliminated using tighter clearances or if plug
modifications, like including a lower piston ring, are
implemented.
(IV) Cage Design
Cage design primarily addresses noise reduction and
energy dissipation. In a typical drilled-hole cage design,
the size and spacing of the holes impact valve capacity
and noise in the following manner:
•Small hole sizes reduce noise better than large ones
but reduce capacity. Smaller holes introduce higher
frequency jets which are harmless to the valve and its
surroundings (piping/structure).
•Large hole spacing reduces noise better than small
hole spacing but reduces capacity. Larger hole spacing
minimizes the probability of jet interactions. When
jets interact, they produce combined jets that vibrate
at the low frequency spectrum.
•Tapered outwards (Figure 5
higher frequencies but minimize capacity. Tapered
inwards holes have exactly the opposite effect.
Conclusion
It is essentially important to:
•carefully verify process conditions
•thoroughly review vendor proposal(s)
•communicate with vendors to resolve design
uncertainties
•before shipment, conduct necessary factory testing
and inspection to validate selection
•conduct online site testing, monitor performance and
log deficienciesCage
PLUG
Pi
Seat
Figure 4 The Effect of Clearance Flow
Mohammed Al-Juaibis an instrumentation engineer with
the Instrumentation Unit/PID. He has 13 years experience
with Saudi Aramco. He worked as an instrumentation
engineer in Ju‘aymah Gas Plant, Riyadh Refinery and
Haradh Gas Plant.
47Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Figure 5 A Typical Drilled-Hole Cage Design
Flow in
Flow in
Drilled Hole Cage (o utwards tapered) MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
process conditions, the screw & pin method is the most
favorable plug/stem connection method. Designers are
cautioned when specifying this method for high
Differential pressure (DP) applications as the screw & pins
integrity degrades significantly.
2. Welding Method
Welding the stem to the plug is a more robust connection
method. It is limited to sweet services since welding
introduces complications with the corrosion resistance of
the base metal.
III) Plug to Cage Clearance
Minimum clearance (between the plug and the cage) is
required to ensure negligible frication and to keep
clearance flow to minimum. Clearance flow (Figure 4)
causes series trim damage particularly in high DP
applications as it causes plug vibration and rotation. This
can be eliminated using tighter clearances or if plug
modifications, like including a lower piston ring, are
implemented.
(IV) Cage Design
Cage design primarily addresses noise reduction and
energy dissipation. In a typical drilled-hole cage design,
the size and spacing of the holes impact valve capacity
and noise in the following manner:
•Small hole sizes reduce noise better than large ones
but reduce capacity. Smaller holes introduce higher
frequency jets which are harmless to the valve and its
surroundings (piping/structure).
•Large hole spacing reduces noise better than small
hole spacing but reduces capacity. Larger hole spacing
minimizes the probability of jet interactions. When
jets interact, they produce combined jets that vibrate
at the low frequency spectrum.
•Tapered outwards (Figure 5
higher frequencies but minimize capacity. Tapered
inwards holes have exactly the opposite effect.
Conclusion
It is essentially important to:
•carefully verify process conditions
•thoroughly review vendor proposal(s)
•communicate with vendors to resolve design
uncertainties
•before shipment, conduct necessary factory testing
and inspection to validate selection
•conduct online site testing, monitor performance and
log deficienciesCage
PLUG
Pi
Seat
Figure 4 The Effect of Clearance Flow
Mohammed Al-Juaibis an instrumentation engineer with
the Instrumentation Unit/PID. He has 13 years experience
with Saudi Aramco. He worked as an instrumentation
engineer in Ju‘aymah Gas Plant, Riyadh Refinery and
Haradh Gas Plant.
47Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Figure 5 A Typical Drilled-Hole Cage Design
VISION - To become leaders in process engineering and automation!
Industrial Wireless LAN Security
For Oil & Gas Process Automation Networks
While security remains to be the major concern, it should
be robust following a well defined standard and meeting
the industrial safety and security regulations including
premises protection and detection of rogue nodes.
Industrial WLAN technologies include four main suites
namely IEEE802.11a, b, g and n (known as WiFi).
Currently, there are three dominant WLAN standards in
the market 802.11a, b, and g as shown in Fig.1. On the
other hand, IEEE802.11n is a newly developed standard
“final approval stage” that will boost WLAN capacity to
200Mbps and above. WLAN is an open standard solution
and can be considered as “Wireless Ethernet” since it uses
pretty similar to the original Ethernet access mechanism
“CSMA/CA.”
Since WLAN broadcast data into the air using “radio
signals,” securing WLAN networks becomes very crucial
for process automation networks and systems.
The three key wireless security factors are authentication,
encryption and data integrity.
Wireless Access Authentication
Authentication is a process of verifying users or devices
identity and credentials. Users or devices should present
credentials such as passwords or digital certificates to for
verification. Media Access Control (MAC) address is
considered as a weak verification identity since it can be
spoofed and changed easily.
Successful authentication of user and device would result
in authorizing that specific user or device to grant access
to network resources and services. (Fig.2)
Encryption and Data Integrity
Data confidentiality and integrity of transmitted data
over the air can be achieved by applying encryption
techniques.
There are two main encryption mechanisms in Wireless
LAN solution which are:
•Rivest’s Cipher (RC
Equivalency Privacy (WEP
Integrity Protocol (TKIP
encryption weakness, WEP encryption algorithm did
not provide the level of security necessary for
corporate and critical process automation applications.
•Advanced Encryption Standard (AES) which provides a
robust enhancement to the aforementioned TKIP and
its RC encryption. AES encryption algorithm performs
hashing as well as advanced encryption.
The new IEEE802.11i WLAN security standard was
approved in June 2004 and addresses robust security
protocols and encryption algorithm (AES). This resulted in
Several remote facilities, processes and field operations
may utilize this connectivity to access a PAN which would
result in improving productivity, less downtime, faster
and more accurate data analysis and reduced capital and
operating expenditures. This technology is the most
extensive deployment in the industrial environment and
has a potential to be deployed more in the future. Due to
its flexibility, fast deployment, cost reduction, and
simplicity, it is considered to be an attractive solution to
industry.
Security Threats in Industrial WLAN
Securing and protecting industrial networks and systems
is very critical. First of all, these systems are mission-critical
and should be up and running round-the-clock. Also, the
new technologies are changing rapidly as well as moving
to open standard in terms of protocols and operating
systems. In addition, recent studies reported a significant
increase in virus attacks and hacking incidents over the
Internet.
802.11a 802.11b 802.11g 802.11n
IEEE Ratification 1999 1999 2003 2008
RF Technology OFDM DSSS DSSS/OFDM DSSS/OFDM
Max Data Rate 54 Mbps 11 Mbps 54 Mbps 200+Mbps
Frequency 5 GHz 2.4 GHz 2.4 GHz 2.4/5 GHz
Author: Soliman Al-Walaie, Mohammed A. Al-Saeed,Majed M. Al-Subaey
48 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Industrial Wireless Technology can be applied in several process automation
applications such as oil/gas well heads automation and vibration monitoring
system. This solution must ensure security, interoperability, coexistence, quality of
service, reliably and scalability.
Industrial Wireless LAN Security
For Oil & Gas Process Automation Networks
While security remains to be the major concern, it should
be robust following a well defined standard and meeting
the industrial safety and security regulations including
premises protection and detection of rogue nodes.
Industrial WLAN technologies include four main suites
namely IEEE802.11a, b, g and n (known as WiFi).
Currently, there are three dominant WLAN standards in
the market 802.11a, b, and g as shown in Fig.1. On the
other hand, IEEE802.11n is a newly developed standard
“final approval stage” that will boost WLAN capacity to
200Mbps and above. WLAN is an open standard solution
and can be considered as “Wireless Ethernet” since it uses
pretty similar to the original Ethernet access mechanism
“CSMA/CA.”
Since WLAN broadcast data into the air using “radio
signals,” securing WLAN networks becomes very crucial
for process automation networks and systems.
The three key wireless security factors are authentication,
encryption and data integrity.
Wireless Access Authentication
Authentication is a process of verifying users or devices
identity and credentials. Users or devices should present
credentials such as passwords or digital certificates to for
verification. Media Access Control (MAC) address is
considered as a weak verification identity since it can be
spoofed and changed easily.
Successful authentication of user and device would result
in authorizing that specific user or device to grant access
to network resources and services. (Fig.2)
Encryption and Data Integrity
Data confidentiality and integrity of transmitted data
over the air can be achieved by applying encryption
techniques.
There are two main encryption mechanisms in Wireless
LAN solution which are:
•Rivest’s Cipher (RC
Equivalency Privacy (WEP
Integrity Protocol (TKIP
encryption weakness, WEP encryption algorithm did
not provide the level of security necessary for
corporate and critical process automation applications.
•Advanced Encryption Standard (AES) which provides a
robust enhancement to the aforementioned TKIP and
its RC encryption. AES encryption algorithm performs
hashing as well as advanced encryption.
The new IEEE802.11i WLAN security standard was
approved in June 2004 and addresses robust security
protocols and encryption algorithm (AES). This resulted in
Several remote facilities, processes and field operations
may utilize this connectivity to access a PAN which would
result in improving productivity, less downtime, faster
and more accurate data analysis and reduced capital and
operating expenditures. This technology is the most
extensive deployment in the industrial environment and
has a potential to be deployed more in the future. Due to
its flexibility, fast deployment, cost reduction, and
simplicity, it is considered to be an attractive solution to
industry.
Security Threats in Industrial WLAN
Securing and protecting industrial networks and systems
is very critical. First of all, these systems are mission-critical
and should be up and running round-the-clock. Also, the
new technologies are changing rapidly as well as moving
to open standard in terms of protocols and operating
systems. In addition, recent studies reported a significant
increase in virus attacks and hacking incidents over the
Internet.
802.11a 802.11b 802.11g 802.11n
IEEE Ratification 1999 1999 2003 2008
RF Technology OFDM DSSS DSSS/OFDM DSSS/OFDM
Max Data Rate 54 Mbps 11 Mbps 54 Mbps 200+Mbps
Frequency 5 GHz 2.4 GHz 2.4 GHz 2.4/5 GHz
Author: Soliman Al-Walaie, Mohammed A. Al-Saeed,Majed M. Al-Subaey
48 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Industrial Wireless Technology can be applied in several process automation
applications such as oil/gas well heads automation and vibration monitoring
system. This solution must ensure security, interoperability, coexistence, quality of
service, reliably and scalability.
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
overcoming attacks on privacy , integrity, and
authentication.
Conclusions
Modern Industrial WLAN security has matured by
combining data confidentiality and integrity,
authentication and access control as well as intrusion
detection and protection mechanisms. The security
methods used by the original 802.11 standard proved to
be relatively weak. The 802.1X standard was adapted for
802.11 wireless networks to provide much stronger
authentication and automated encryption key
management. It is recommended to use WPA2 product
certification for the security features of the IEEE 802.11i
standard. That includes mandatory use of AES for
encryption and data integrity.
Figure 2 WLAN Authentication architecture
Mohammed A. Al-Saeed is working for Saudi Aramco in
Process & Control Systems Department/ Process Instru-
mentation Division. He graduated from King Saud University
in 1995 with a bachelor degree in Computer Science in
Information Systems. He first worked with Saudi Arabian
Texaco Inc. as a Network Specialist for six years. In 2001, he
joined Saudi Aramco in P&CSD as Industrial Computer
Engineer. He obtained a Master of Business Administration
(MBA) and five technical certifications, Certified Wireless
Security Professional (CWSP), Cisco Certified Design
Professional (CCDP), Advanced Wireless LAN Design Specialist
(AWLDS), Cisco Certified Design Associate (CCDA
Certified Network Associate (CCNA). His specialty is Process
Plant Networking and Systems Engineering. He is a member
of ISA and IEEE professional societies.
Soliman Al-Walaieis a communication engineer in
P&CSD/CCNU. He is a certified wireless networks professional
(CWNP) engineer and has twelve years of experience. He is
the instructor of Communication Transmission Systems
(CTR205).
Majed Al-Subaeyis a Computer Engineer working in
PID/CCNU. He graduated with a Bachelor of Science degree in
Computer Engineering from King Fahd University of
Petroleum and Minerals in 2000 and obtained a Masters
degree in Information Technology from the University of
Liverpool, UK in 2005. Currently, he is pursuing his Ph.D in
Nova Southeastern University, Florida, USA in Information
Systems, area of interest Information Security. He is a
Microsoft Certified Systems Engineer (MCSE) since 2001 and
a Sun Certified Programmer in Java since (SCPJ) 2004.
49Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
WLAN is an open standard
solution and can be considered
as “Wireless Ethernet” since it
uses pretty similar to the
original Ethernet access
mechanism “CSMA/CA.”
and professional services in process engineering and process automation!
overcoming attacks on privacy , integrity, and
authentication.
Conclusions
Modern Industrial WLAN security has matured by
combining data confidentiality and integrity,
authentication and access control as well as intrusion
detection and protection mechanisms. The security
methods used by the original 802.11 standard proved to
be relatively weak. The 802.1X standard was adapted for
802.11 wireless networks to provide much stronger
authentication and automated encryption key
management. It is recommended to use WPA2 product
certification for the security features of the IEEE 802.11i
standard. That includes mandatory use of AES for
encryption and data integrity.
Figure 2 WLAN Authentication architecture
Mohammed A. Al-Saeed is working for Saudi Aramco in
Process & Control Systems Department/ Process Instru-
mentation Division. He graduated from King Saud University
in 1995 with a bachelor degree in Computer Science in
Information Systems. He first worked with Saudi Arabian
Texaco Inc. as a Network Specialist for six years. In 2001, he
joined Saudi Aramco in P&CSD as Industrial Computer
Engineer. He obtained a Master of Business Administration
(MBA) and five technical certifications, Certified Wireless
Security Professional (CWSP), Cisco Certified Design
Professional (CCDP), Advanced Wireless LAN Design Specialist
(AWLDS), Cisco Certified Design Associate (CCDA
Certified Network Associate (CCNA). His specialty is Process
Plant Networking and Systems Engineering. He is a member
of ISA and IEEE professional societies.
Soliman Al-Walaieis a communication engineer in
P&CSD/CCNU. He is a certified wireless networks professional
(CWNP) engineer and has twelve years of experience. He is
the instructor of Communication Transmission Systems
(CTR205).
Majed Al-Subaeyis a Computer Engineer working in
PID/CCNU. He graduated with a Bachelor of Science degree in
Computer Engineering from King Fahd University of
Petroleum and Minerals in 2000 and obtained a Masters
degree in Information Technology from the University of
Liverpool, UK in 2005. Currently, he is pursuing his Ph.D in
Nova Southeastern University, Florida, USA in Information
Systems, area of interest Information Security. He is a
Microsoft Certified Systems Engineer (MCSE) since 2001 and
a Sun Certified Programmer in Java since (SCPJ) 2004.
49Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
WLAN is an open standard
solution and can be considered
as “Wireless Ethernet” since it
uses pretty similar to the
original Ethernet access
mechanism “CSMA/CA.”
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
Process Automation Focus Team Update
The Process Automation Focus Team (PAFT) has been
active this year. One significant technology item,
Advanced MVC/PID Performance Monitoring, was
successfully implemented and closed in February. The
results and recommendations have been published as
SAER 6166. In addition, four new technology items have
already been approved in 2007 with another item in the
final stages of approval. This represents a significant
upswing in technology program activity and underlines
the emphasis that management has placed on technology
development and implementation.
The Process Automation Focus Team (PAFT) actively
identifies and sponsors new process automation
technologies that can be successfully implemented in
partnership with operating organizations throughout
Saudi Aramco. All new technology items are led by a team
of engineers from both P&CSD and partnering operating
organizations. Funding and logistical support for
technology items is provided by the Engineering Services
technology program.
Currently there are 12 active process automation
technologies and PAFT is actively seeking to identify new
technologies that have the potential for high potential to
improve economic or safety performance of our
operations.
Figure 1. Active Process Automation Technology Items
PRA-01-/03-T
PRA-01/04-T
PRA-01/05-T
PRA-02/05-T
PRA-01/07-T
PRA-02/07-T
PRA-03/07-T
PR-05/07-T
PCD-04/04-T
PCD-06/04-T
PCD-01/02-J
PCD-02/03-3
Programming for Commercialization of
PAS Obsolescence (SAEP135
Local Emergency Isolation Valve
Controller with FF-S15 Communications
Natural Gas Liquids Recovery
Improvement via Empirical Experimental
Method
Automating Gas Custody Transfer
Measurement Systems
Online Mercury in Natural Gas Analyzer
Welhead Flowing Protection System with
Automatic Testing and Diagnostics
Evaluation of Nanotechnology Metal
Oxide Semiconductor (NTMOS) H
2S Gas
Detector
On-line Oxygen Analyzer for Thermal
Oxidizer
High Speed Digital Subscriber Loop
(HDSL)/Wireless Remote Monitoring for
Ultrasonic Liquid Flow Sensing Meter
Field Mounted Gas Chromatograph
Standards and Deployment of Wireless
Local Area Networks
Packet Communications
9/30/2007
9/30/2008
6/30/2008
6/30/2008
6/30/2008
12/31/2010
3/31/2008
6/30/2008
6/30/2007
12/31/2007
3/31/2007
12/31/2007
Nasser Y. Assiry, Deraid Herling, John
Grainger, Gregg Skinner, Others
Patrick S. Flanders
Othman Taha, Salah A. Al-Ali, Henry
H. Chan.,
Mohammed Salim, Abdelghani A.
Daraiseh, Hassan A. Amer, Abdullatif
A. Saadoun.
Suryanarayana Vedula, Khali
Jehairan
Patrick S. Flanders, Mohmmed K. Al-
Juai, AbdulJail A. Al-Hawai
Saeed M. Al-Abeediah, Saad Al-Ali
Suryanarayana Vadula, Riyadh H.
Fares
Soliman M. Aimadi, Soliman A. Al-
Walaie, Mohammed Salim, D.W.
Burkel/S. Al-Twaijri
Suryanarayan Vedula, James L.
Spranque
Abdelghani Daraiseh, Rushdi H.
Muammar, Khalid S. Al-Ghamdi,
Abdullah S. Nufail
Soliman M. Almadi, Soliman A. Al-
Walaie, Hussain A. Al-Salem, Fouad
M. Khabbaz
Item Number Technology Title End Date Team Members
Douglas S. Esplinis a registered Professional Engineer in the
state of Utah and has 25 years of process control experience.
He has been with Saudi Aramco for a total of 13 years
working in the RT Refinery and P&CSD. He is an Engineering
Consultant with the Process Automation Systems Unit in
P&CSD and the leader of the Process Automation Focus
Team.
Author: Douglas S. Esplin
51Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
Process Automation Focus Team Update
The Process Automation Focus Team (PAFT) has been
active this year. One significant technology item,
Advanced MVC/PID Performance Monitoring, was
successfully implemented and closed in February. The
results and recommendations have been published as
SAER 6166. In addition, four new technology items have
already been approved in 2007 with another item in the
final stages of approval. This represents a significant
upswing in technology program activity and underlines
the emphasis that management has placed on technology
development and implementation.
The Process Automation Focus Team (PAFT) actively
identifies and sponsors new process automation
technologies that can be successfully implemented in
partnership with operating organizations throughout
Saudi Aramco. All new technology items are led by a team
of engineers from both P&CSD and partnering operating
organizations. Funding and logistical support for
technology items is provided by the Engineering Services
technology program.
Currently there are 12 active process automation
technologies and PAFT is actively seeking to identify new
technologies that have the potential for high potential to
improve economic or safety performance of our
operations.
Figure 1. Active Process Automation Technology Items
PRA-01-/03-T
PRA-01/04-T
PRA-01/05-T
PRA-02/05-T
PRA-01/07-T
PRA-02/07-T
PRA-03/07-T
PR-05/07-T
PCD-04/04-T
PCD-06/04-T
PCD-01/02-J
PCD-02/03-3
Programming for Commercialization of
PAS Obsolescence (SAEP135
Local Emergency Isolation Valve
Controller with FF-S15 Communications
Natural Gas Liquids Recovery
Improvement via Empirical Experimental
Method
Automating Gas Custody Transfer
Measurement Systems
Online Mercury in Natural Gas Analyzer
Welhead Flowing Protection System with
Automatic Testing and Diagnostics
Evaluation of Nanotechnology Metal
Oxide Semiconductor (NTMOS) H
2S Gas
Detector
On-line Oxygen Analyzer for Thermal
Oxidizer
High Speed Digital Subscriber Loop
(HDSL)/Wireless Remote Monitoring for
Ultrasonic Liquid Flow Sensing Meter
Field Mounted Gas Chromatograph
Standards and Deployment of Wireless
Local Area Networks
Packet Communications
9/30/2007
9/30/2008
6/30/2008
6/30/2008
6/30/2008
12/31/2010
3/31/2008
6/30/2008
6/30/2007
12/31/2007
3/31/2007
12/31/2007
Nasser Y. Assiry, Deraid Herling, John
Grainger, Gregg Skinner, Others
Patrick S. Flanders
Othman Taha, Salah A. Al-Ali, Henry
H. Chan.,
Mohammed Salim, Abdelghani A.
Daraiseh, Hassan A. Amer, Abdullatif
A. Saadoun.
Suryanarayana Vedula, Khali
Jehairan
Patrick S. Flanders, Mohmmed K. Al-
Juai, AbdulJail A. Al-Hawai
Saeed M. Al-Abeediah, Saad Al-Ali
Suryanarayana Vadula, Riyadh H.
Fares
Soliman M. Aimadi, Soliman A. Al-
Walaie, Mohammed Salim, D.W.
Burkel/S. Al-Twaijri
Suryanarayan Vedula, James L.
Spranque
Abdelghani Daraiseh, Rushdi H.
Muammar, Khalid S. Al-Ghamdi,
Abdullah S. Nufail
Soliman M. Almadi, Soliman A. Al-
Walaie, Hussain A. Al-Salem, Fouad
M. Khabbaz
Item Number Technology Title End Date Team Members
Douglas S. Esplinis a registered Professional Engineer in the
state of Utah and has 25 years of process control experience.
He has been with Saudi Aramco for a total of 13 years
working in the RT Refinery and P&CSD. He is an Engineering
Consultant with the Process Automation Systems Unit in
P&CSD and the leader of the Process Automation Focus
Team.
Author: Douglas S. Esplin
51Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
Engineering the Future
Authors: Saleh Al-Qaffas, Luay Al Awami, John Kinsley, Patrick Flanders
Process & Controls Systems Department recently
participated in the first ISA-KFUPM Student Project
Competition. The event was held on May 21 during
KFUPM's Workshop on Industrial Systems and Control
(WISC-2007) and was attended by more than 300
professionals. The event was coordinated between the
Systems Engineering Department of King Fahd University
of Petroleum and Minerals (KFUPM) and the
Instrumentation, Systems and Automation society (ISA).
P&CSD engineers from the Process Instrumentation
Division and the Process Controls Division serve as board
members of the local Saudi Arabian section of ISA and
were responsible for organizing the event. Saudi Aramco
was one of six sponsor companies which generously
provided funding for the competition. SABIC, Yokogawa,
Invensys, Honeywell and Emerson also participated in
sponsoring the event.
The competition enabled the students to put their
theoretical studies to work solving real world industrial
problems. The focus of their work was to apply the
principles of industrial control and automation to
enhance industrial processes. As part of the mandatory
engineering curriculum, students are required to
complete a project in their field of study. These projects
served as the basis for the competition which featured a
demonstration and presentation of six student projects.
Projects were pre-selected by the KFUPM faculty prior to
the competition. Dr. Fouad Al Sunni and Moustafa El-
Shafei from the Systems Engineering department were
responsible for pre-selecting the six projects. During the
competition, each student provided a demonstration of
his project and was required to give a 15 minute
presentation to discuss the nature of his work. Projects
were judged based on technical content and
presentation. A panel of judges scored each project and
winners were chosen in two categories; Applied
Automation and Innovation. A representative from each
of the sponsor companies was selected to serve on the
Judge's Panel. P&CSD manager, Saleh Al Zaid represented
Saudi Aramco on the judge's panel. Other members of the
judge’s panel included: Mr. Abdulaziz Al-Najim, Manager,
Engineering and Project Management Department,
SABIC; Mr. Toshiaki Shirai San, Vice President, Research &
Development, Yokogawa; Mr. Salem Al Khaldi, Business
Development Manager, Invensys Saudi Arabia; Mr. Abbas
Alelg, Senior Engineer, Honeywell Advanced Process
Solutions; and Andrew Dennant, Technical Manager,
Emerson Process Systems.
All of the students worked very hard on their projects and
produced excellent work. The judges had a challenging
time selecting the best from the six projects presented.
Each student was presented with a plaque for their
participation and the winners received a trophy and gift.
The winner in the category of Innovation was Ashraf
Dasah for his project on "Inherent Flow Characteristics."
He developed a method to programmatically adjust flow
characteristics of a control valve. The system monitored
line pressure and automatically adjusted the valve
signature curve to compensate for fluctuations. This
enables the valve and therefore the control system to
maintain accurate flow control over a wide range of line
pressures. KFUPM has filed for a patent with the U.S.
Patent and Trademark Office to obtain intellectual
property rights for that idea. The university is hoping to
partner with local manufacturers in the commercial
KFUPM students gather with other event participants
for a group photo.
Ashraf Dasah explains the benefits of his project to
ISA section President Saleh Al-Qaffas and Saudi
Aramco, Process & Controls Systems Department
Manager Saleh A. Al-Zaid.
Luay Al Awami, left, Vice President of the
Instrumentation, Systems and Automation Society,
presents the award in the category of Applied
Automation to Mohamed Khan.
Prepare the workforce
for the Future
52 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Engineering the Future
Authors: Saleh Al-Qaffas, Luay Al Awami, John Kinsley, Patrick Flanders
Process & Controls Systems Department recently
participated in the first ISA-KFUPM Student Project
Competition. The event was held on May 21 during
KFUPM's Workshop on Industrial Systems and Control
(WISC-2007) and was attended by more than 300
professionals. The event was coordinated between the
Systems Engineering Department of King Fahd University
of Petroleum and Minerals (KFUPM) and the
Instrumentation, Systems and Automation society (ISA).
P&CSD engineers from the Process Instrumentation
Division and the Process Controls Division serve as board
members of the local Saudi Arabian section of ISA and
were responsible for organizing the event. Saudi Aramco
was one of six sponsor companies which generously
provided funding for the competition. SABIC, Yokogawa,
Invensys, Honeywell and Emerson also participated in
sponsoring the event.
The competition enabled the students to put their
theoretical studies to work solving real world industrial
problems. The focus of their work was to apply the
principles of industrial control and automation to
enhance industrial processes. As part of the mandatory
engineering curriculum, students are required to
complete a project in their field of study. These projects
served as the basis for the competition which featured a
demonstration and presentation of six student projects.
Projects were pre-selected by the KFUPM faculty prior to
the competition. Dr. Fouad Al Sunni and Moustafa El-
Shafei from the Systems Engineering department were
responsible for pre-selecting the six projects. During the
competition, each student provided a demonstration of
his project and was required to give a 15 minute
presentation to discuss the nature of his work. Projects
were judged based on technical content and
presentation. A panel of judges scored each project and
winners were chosen in two categories; Applied
Automation and Innovation. A representative from each
of the sponsor companies was selected to serve on the
Judge's Panel. P&CSD manager, Saleh Al Zaid represented
Saudi Aramco on the judge's panel. Other members of the
judge’s panel included: Mr. Abdulaziz Al-Najim, Manager,
Engineering and Project Management Department,
SABIC; Mr. Toshiaki Shirai San, Vice President, Research &
Development, Yokogawa; Mr. Salem Al Khaldi, Business
Development Manager, Invensys Saudi Arabia; Mr. Abbas
Alelg, Senior Engineer, Honeywell Advanced Process
Solutions; and Andrew Dennant, Technical Manager,
Emerson Process Systems.
All of the students worked very hard on their projects and
produced excellent work. The judges had a challenging
time selecting the best from the six projects presented.
Each student was presented with a plaque for their
participation and the winners received a trophy and gift.
The winner in the category of Innovation was Ashraf
Dasah for his project on "Inherent Flow Characteristics."
He developed a method to programmatically adjust flow
characteristics of a control valve. The system monitored
line pressure and automatically adjusted the valve
signature curve to compensate for fluctuations. This
enables the valve and therefore the control system to
maintain accurate flow control over a wide range of line
pressures. KFUPM has filed for a patent with the U.S.
Patent and Trademark Office to obtain intellectual
property rights for that idea. The university is hoping to
partner with local manufacturers in the commercial
KFUPM students gather with other event participants
for a group photo.
Ashraf Dasah explains the benefits of his project to
ISA section President Saleh Al-Qaffas and Saudi
Aramco, Process & Controls Systems Department
Manager Saleh A. Al-Zaid.
Luay Al Awami, left, Vice President of the
Instrumentation, Systems and Automation Society,
presents the award in the category of Applied
Automation to Mohamed Khan.
Prepare the workforce
for the Future
52 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
development of the technology and eventually market
the idea to petrochemical companies, including Saudi
Aramco.
The winner in the category of Applied Automation went
to a project that involved automation of an assembly line.
This project was developed by Munir Kulaib and
Mohamed Khan, based on work done during an
internship assignment with Al-Zamil Company at an air
conditioner manufacturing facility. The students
developed a system to automate tracking and quality
assurance checks during the assembly process. This work
was being recorded manually by workers at the
manufacturing plant. Individual components were
scanned as they entered the assembly line and monitored
as they moved through the assembly line. Quality checks
done during the assembly process were automatically
logged into the system and stored in a database against
the actual part. This enabled a complete record of each
air conditioner to be automatically recorded during the
assembly process and automatic generation of shift
production reports. The students estimated that there
would be a net gain of 7% in production efficiency by
implementing the system while minimizing the potential
for human error. Based on this work, Zamil decided to go
ahead and implement the system at their actual
manufacturing plant.
Other projects which were not selected included
"Multivariable Controller of Single Screw Extruder for
Polymer Applications,” developed by Waleed Abdul-Ate.
He developed a multi-loop control algorithm to control
extruder temperature. A mini-extruder was built using
electric heaters fixed to the screw in three stages. Waleed
implemented a feed-forward algorithm enable final exit
temperature to be more precisely controlled. This type of
control could potentially be used by SABIC and other
petrochemical companies.
Another student developed a system to monitor vibration
levels in rotating equipment. The system used a simulator
which enabled him to manually manipulate vibrations on
a rotating shaft. Input sensors captured the vibration
signatures at various levels and were stored at in the
system. Once vibration signatures were captured at
several levels, the system then compared the real-time
levels against those stored in the database. The system
then produced a alarm to alert the operator when
vibration levels exceeded preset values.
Another project involved a simulated heat exchanger
system and was developed by a team of four students.
The system utilized a cascade control scheme which used
tank temperature as the primary control variable. The
primary temperature control was tied to a flow controller,
which adjusted the flow of hot water running through a
tube submersed in the tank. The equipment and control
algorithm were designed and built by the students.
The final project was an automatic syringe for chemical
applications. This project was developed by Wael Khalid
Zaitouni and Abdelrahman Shbair. The system automated
the measurement of very small and precise quantities of
liquid using a syringe. The operator enters the quantity of
liquid material desired into a computer system. The
computer then automatically controlled the amount of
fluid drawn into the syringe and then applied the fluid to
a vessel.
ISA is a worldwide professional society for
Instrumentation and Controls professionals. There are
over 30,000 ISA members worldwide. The Saudi Arabian
section or ISA has over 250 members from many different
companies across the Kingdom as well as KFUPM faculty
members. P&CSD engineers from both the
Instrumentation and Controls Divisions are board
members for the Saudi Arabian section of ISA. They are
responsible for organizing monthly technical meetings
for ISA members across the Kingdom. Board members of
the ISA Saudi Arabia section include: Saleh Al-Qaffas,
President; Luay Al Awami, Vice President; John Kinsley,
Secretary ;and Patrick Flanders, Treasurer. The
competition was organized to try to build a stronger
bond between industry and academia. The event was
successful in accomplishing this goal and ISA is planning
to continue this event on a yearly basis.
Saleh Al-Qaffasis an Engineering Consultant with Process &
Control Systems Department. He holds a BS degree in
Electrical Engineerin from the Universsity of Pittsbirgh, USA
and an MBA degree from the university of Hull, UK. Saleh is
the Chairman of the Process Control Standards Committee
with Saudi Aramco and the Presidient of the Saudi Arabia
Section of the Instrumentation, Systems & Automation
Society (ISA).
Luay Al Awami is an Engineering Specialist with the
Instrumentation Unit of P&CSD. He is also the Vice President
of the Saudi Arabian section of the Instrumentation, Systems
and Automation Society.
John Kinsleyis an Engineer with the Process Automation
Systems Unit of P&CSD. He is also the Secretary of the Saudi
Arabian section of the Instrumentation, Systems and
Automation Society.
Patrick Flandersis an Engineering Specialist with the
Instrumentation Unit of P&CSD. He is also the Treasurer of
the Saudi Arabian section of the Instrumentation, Systems
and Automation Society.
5353Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
development of the technology and eventually market
the idea to petrochemical companies, including Saudi
Aramco.
The winner in the category of Applied Automation went
to a project that involved automation of an assembly line.
This project was developed by Munir Kulaib and
Mohamed Khan, based on work done during an
internship assignment with Al-Zamil Company at an air
conditioner manufacturing facility. The students
developed a system to automate tracking and quality
assurance checks during the assembly process. This work
was being recorded manually by workers at the
manufacturing plant. Individual components were
scanned as they entered the assembly line and monitored
as they moved through the assembly line. Quality checks
done during the assembly process were automatically
logged into the system and stored in a database against
the actual part. This enabled a complete record of each
air conditioner to be automatically recorded during the
assembly process and automatic generation of shift
production reports. The students estimated that there
would be a net gain of 7% in production efficiency by
implementing the system while minimizing the potential
for human error. Based on this work, Zamil decided to go
ahead and implement the system at their actual
manufacturing plant.
Other projects which were not selected included
"Multivariable Controller of Single Screw Extruder for
Polymer Applications,” developed by Waleed Abdul-Ate.
He developed a multi-loop control algorithm to control
extruder temperature. A mini-extruder was built using
electric heaters fixed to the screw in three stages. Waleed
implemented a feed-forward algorithm enable final exit
temperature to be more precisely controlled. This type of
control could potentially be used by SABIC and other
petrochemical companies.
Another student developed a system to monitor vibration
levels in rotating equipment. The system used a simulator
which enabled him to manually manipulate vibrations on
a rotating shaft. Input sensors captured the vibration
signatures at various levels and were stored at in the
system. Once vibration signatures were captured at
several levels, the system then compared the real-time
levels against those stored in the database. The system
then produced a alarm to alert the operator when
vibration levels exceeded preset values.
Another project involved a simulated heat exchanger
system and was developed by a team of four students.
The system utilized a cascade control scheme which used
tank temperature as the primary control variable. The
primary temperature control was tied to a flow controller,
which adjusted the flow of hot water running through a
tube submersed in the tank. The equipment and control
algorithm were designed and built by the students.
The final project was an automatic syringe for chemical
applications. This project was developed by Wael Khalid
Zaitouni and Abdelrahman Shbair. The system automated
the measurement of very small and precise quantities of
liquid using a syringe. The operator enters the quantity of
liquid material desired into a computer system. The
computer then automatically controlled the amount of
fluid drawn into the syringe and then applied the fluid to
a vessel.
ISA is a worldwide professional society for
Instrumentation and Controls professionals. There are
over 30,000 ISA members worldwide. The Saudi Arabian
section or ISA has over 250 members from many different
companies across the Kingdom as well as KFUPM faculty
members. P&CSD engineers from both the
Instrumentation and Controls Divisions are board
members for the Saudi Arabian section of ISA. They are
responsible for organizing monthly technical meetings
for ISA members across the Kingdom. Board members of
the ISA Saudi Arabia section include: Saleh Al-Qaffas,
President; Luay Al Awami, Vice President; John Kinsley,
Secretary ;and Patrick Flanders, Treasurer. The
competition was organized to try to build a stronger
bond between industry and academia. The event was
successful in accomplishing this goal and ISA is planning
to continue this event on a yearly basis.
Saleh Al-Qaffasis an Engineering Consultant with Process &
Control Systems Department. He holds a BS degree in
Electrical Engineerin from the Universsity of Pittsbirgh, USA
and an MBA degree from the university of Hull, UK. Saleh is
the Chairman of the Process Control Standards Committee
with Saudi Aramco and the Presidient of the Saudi Arabia
Section of the Instrumentation, Systems & Automation
Society (ISA).
Luay Al Awami is an Engineering Specialist with the
Instrumentation Unit of P&CSD. He is also the Vice President
of the Saudi Arabian section of the Instrumentation, Systems
and Automation Society.
John Kinsleyis an Engineer with the Process Automation
Systems Unit of P&CSD. He is also the Secretary of the Saudi
Arabian section of the Instrumentation, Systems and
Automation Society.
Patrick Flandersis an Engineering Specialist with the
Instrumentation Unit of P&CSD. He is also the Treasurer of
the Saudi Arabian section of the Instrumentation, Systems
and Automation Society.
5353Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
Safety of the Issue
Relief valve relieving rates are based on several criteria
that lead to overpressure in vessels. The cause of
overpressure without going into detail can be attributed
for example to: reflux failure, utility failure like electrical
power, cooling water, instrument air, failure due to
accidental fires outside vessels, etc. The relieving load for
an individual relief valve is then based on any one or
combination of the above cases that is controlling; in
some cases the fire case (fire outside vessel) is the
controlling case.
This paper suggests engineers to be
cautious about how though the limiting case may be the
fire case, the relief valve could still be ineffective to
protect the vessel as designed, and the vessel may fail
prematurely to everyone’s surprise.
Accidental fires outside vessels
In a plant a pressure vessel may be exposed to external
fire due to ignition of hydrocarbons that leaked in the
area. The heat released from the open free burning fire
will be absorbed by the vessel by radiation or by direct
impingement of flame/hot gases on the vessel wall.
Caution on relief valve design for fire case
Are we safe?
The answer depends on the design engineer on how he
applies the Standard (SAES/API). When reviewing design,
one must exercise caution as follows:
Caution:
Many a times simulation calculations will show some
liquid being knocked off in the separator vessel; typically
based on the simulation, design contractor will assume a
wetted surface (liquid level in the vessel) within 25 ft
elevation from grade, irrespective of the rate at which
liquid builds up in the vessel; but in reality the vessel in
some cases may have negligible or no liquid, so in short
there is no wetted surface1 inside the vessel. The relieving
rate for the relief valve (RV) is then calculated for fire case
as if there was liquid in the vessel and this rate is used for
RV design if it is the controlling case; consequently the
vessel is designed with no external fire protection as
wetted surface is assumed.
Let us assume that we have an non-insulated KO drum
that is subject to accidental fire outside the vessel. The
heat released will be absorbed by the vessel and wall
temperature will begin to rise.
If there is liquid in the vessel as assumed in the design,
then we have a wetted surface that will ensure the vessel
wall temperature does not rise excessively as liquid inside
the vessel evaporates. This however will increase vapor
rate in the vessel leading to increased pressure in the
vessel. If we have a control system it will relieve excess
pressure to the flare, but if pressure keeps rising the RV
will pop eventually and relieve the pressure. The system
will be protected. The above scenario is what is normally
envisaged by the designer based on assumptions that
there will be liquid level inside the vessel. If the vessel had
negligible or no liquid in it, the vessel wall temperature
will rise and temperatures could soon reach above 1000˚ F,
consequently the vessel wall will not be able to contain
the stress from the normal operating pressure and could
have a
catastrophic failure at operating pressure.
To explain this further let us look at an example- refer to
Figure 1:
Vessel size: 78 in (d
Vessel wall: 1.1875 in thick.
Design Pressure: 440 psig
Operating Pressure: 330 psig
Design Temp: 200F
RV set at 440 psig.
Service: Fuel Gas
Vessel has no insulation. HOT SPOT
Figure 1 Vessel Drum
Author: Gabriel T. Fernandez
Caution on relief valve design for fire incidents Are we safe?
54 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Safety of the Issue
Relief valve relieving rates are based on several criteria
that lead to overpressure in vessels. The cause of
overpressure without going into detail can be attributed
for example to: reflux failure, utility failure like electrical
power, cooling water, instrument air, failure due to
accidental fires outside vessels, etc. The relieving load for
an individual relief valve is then based on any one or
combination of the above cases that is controlling; in
some cases the fire case (fire outside vessel) is the
controlling case.
This paper suggests engineers to be
cautious about how though the limiting case may be the
fire case, the relief valve could still be ineffective to
protect the vessel as designed, and the vessel may fail
prematurely to everyone’s surprise.
Accidental fires outside vessels
In a plant a pressure vessel may be exposed to external
fire due to ignition of hydrocarbons that leaked in the
area. The heat released from the open free burning fire
will be absorbed by the vessel by radiation or by direct
impingement of flame/hot gases on the vessel wall.
Caution on relief valve design for fire case
Are we safe?
The answer depends on the design engineer on how he
applies the Standard (SAES/API). When reviewing design,
one must exercise caution as follows:
Caution:
Many a times simulation calculations will show some
liquid being knocked off in the separator vessel; typically
based on the simulation, design contractor will assume a
wetted surface (liquid level in the vessel) within 25 ft
elevation from grade, irrespective of the rate at which
liquid builds up in the vessel; but in reality the vessel in
some cases may have negligible or no liquid, so in short
there is no wetted surface1 inside the vessel. The relieving
rate for the relief valve (RV) is then calculated for fire case
as if there was liquid in the vessel and this rate is used for
RV design if it is the controlling case; consequently the
vessel is designed with no external fire protection as
wetted surface is assumed.
Let us assume that we have an non-insulated KO drum
that is subject to accidental fire outside the vessel. The
heat released will be absorbed by the vessel and wall
temperature will begin to rise.
If there is liquid in the vessel as assumed in the design,
then we have a wetted surface that will ensure the vessel
wall temperature does not rise excessively as liquid inside
the vessel evaporates. This however will increase vapor
rate in the vessel leading to increased pressure in the
vessel. If we have a control system it will relieve excess
pressure to the flare, but if pressure keeps rising the RV
will pop eventually and relieve the pressure. The system
will be protected. The above scenario is what is normally
envisaged by the designer based on assumptions that
there will be liquid level inside the vessel. If the vessel had
negligible or no liquid in it, the vessel wall temperature
will rise and temperatures could soon reach above 1000˚ F,
consequently the vessel wall will not be able to contain
the stress from the normal operating pressure and could
have a
catastrophic failure at operating pressure.
To explain this further let us look at an example- refer to
Figure 1:
Vessel size: 78 in (d
Vessel wall: 1.1875 in thick.
Design Pressure: 440 psig
Operating Pressure: 330 psig
Design Temp: 200F
RV set at 440 psig.
Service: Fuel Gas
Vessel has no insulation. HOT SPOT
Figure 1 Vessel Drum
Author: Gabriel T. Fernandez
Caution on relief valve design for fire incidents Are we safe?
54 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
MISSION - We innovate and optimize operations for improved performance through leadership
and professional services in process engineering and process automation!
In the event of an accidental fire outside the vessel, the
heat released will be absorbed by radiation or by direct
impingement of flame/hot gases on the vessel wall. With
no liquid inside the vessel (no wetted surface), wall
temperature will begin to rise with negligible effect on
the vessel pressure. Figure 2 shows the allowable vessel
pressure vs wall temperature.
We notice that beyond 650˚F the allowable vessel
pressure drops very steeply. At 1000˚F the vessel cannot
operate above 75 psig, this implies that if the process
continues to operate at normal operating pressure of 330
psig it could have a catastrophic failure once the wall
temperature exceeds 800˚F. Referenced Standards data
shows this could happen in less than 10 minutes.
To avoid such lapses in design, the reviewing/
design engineer must verify if the vessel designed for a
fire incident will contain liquid under normal operations,
and this is based on experience. If it does not contain a
wetted surface then ensure the following for a safe
design.
•Design should include remotely controlled depres-
surizing control besides an inlet ZV.
•Providing insulation on vessels such that the
insulation will not be removed from the surface due
to fire. This will effectively limit heat input.
•If no insulation was provided then ensure that the
vessel can be cooled with water either from properly
placed fire monitors or deluge/spray systems.
•Ensure drainage is provided, and it must be away
from the vessel such that there is no accumulation
under the vessel.
•It is important to verify these points early in the
design to avoid future compromise solutions and
schedule/cost impact.
Though information regarding proper design is available
in Saudi Aramco and API standards
Ref
, the designers
interpretation may not necessarily meet the intent of the
standards. The above caution is intended to focus the
attention of the design review team to such lapses.
The article was prompted from the review of several designs made
by reputed design contractors that missed such analysis to ensure
protection was indeed guaranteed. Please refer your concerns to
Flare and Relief Systems Unit.
1
Wetted surface of a bare vessel is where the liquid content lies
against the inside surface of the outer wall of the vessel.
References: for further information;
• SAES-J-600
•
SAES-B-006 Section 6
•
API 521 5th edition; Section 5.15.0
0
100
200
300
400
500
600
100 200 300 400 500 600 700 800 900 1000 1100
Vessel wall temp vs Max internal pressure
temp F
pressure psig
Gabriel T. Fernandezis a Professional Engineer working as a
Process Engineering Specialist in the Upstream Process
Engineering Division of P&CSD. He holds a Bachelors degree
in Chemical Engineering from IIT Kanpur , and has a
Professional Engineers license from Alberta, Canada
(APEGGA).
His 30 years of experience has been in design/plant
engineering and operations of Crude Oil processing, Oil
sands, Lube Refining, Utilities & Offsites, and Process
engineering with Engineering Company.
Figure 2 The allowable vessel pressure vs wall temperature
55Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
and professional services in process engineering and process automation!
In the event of an accidental fire outside the vessel, the
heat released will be absorbed by radiation or by direct
impingement of flame/hot gases on the vessel wall. With
no liquid inside the vessel (no wetted surface), wall
temperature will begin to rise with negligible effect on
the vessel pressure. Figure 2 shows the allowable vessel
pressure vs wall temperature.
We notice that beyond 650˚F the allowable vessel
pressure drops very steeply. At 1000˚F the vessel cannot
operate above 75 psig, this implies that if the process
continues to operate at normal operating pressure of 330
psig it could have a catastrophic failure once the wall
temperature exceeds 800˚F. Referenced Standards data
shows this could happen in less than 10 minutes.
To avoid such lapses in design, the reviewing/
design engineer must verify if the vessel designed for a
fire incident will contain liquid under normal operations,
and this is based on experience. If it does not contain a
wetted surface then ensure the following for a safe
design.
•Design should include remotely controlled depres-
surizing control besides an inlet ZV.
•Providing insulation on vessels such that the
insulation will not be removed from the surface due
to fire. This will effectively limit heat input.
•If no insulation was provided then ensure that the
vessel can be cooled with water either from properly
placed fire monitors or deluge/spray systems.
•Ensure drainage is provided, and it must be away
from the vessel such that there is no accumulation
under the vessel.
•It is important to verify these points early in the
design to avoid future compromise solutions and
schedule/cost impact.
Though information regarding proper design is available
in Saudi Aramco and API standards
Ref
, the designers
interpretation may not necessarily meet the intent of the
standards. The above caution is intended to focus the
attention of the design review team to such lapses.
The article was prompted from the review of several designs made
by reputed design contractors that missed such analysis to ensure
protection was indeed guaranteed. Please refer your concerns to
Flare and Relief Systems Unit.
1
Wetted surface of a bare vessel is where the liquid content lies
against the inside surface of the outer wall of the vessel.
References: for further information;
• SAES-J-600
•
SAES-B-006 Section 6
•
API 521 5th edition; Section 5.15.0
0
100
200
300
400
500
600
100 200 300 400 500 600 700 800 900 1000 1100
Vessel wall temp vs Max internal pressure
temp F
pressure psig
Gabriel T. Fernandezis a Professional Engineer working as a
Process Engineering Specialist in the Upstream Process
Engineering Division of P&CSD. He holds a Bachelors degree
in Chemical Engineering from IIT Kanpur , and has a
Professional Engineers license from Alberta, Canada
(APEGGA).
His 30 years of experience has been in design/plant
engineering and operations of Crude Oil processing, Oil
sands, Lube Refining, Utilities & Offsites, and Process
engineering with Engineering Company.
Figure 2 The allowable vessel pressure vs wall temperature
55Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
VISION - To become leaders in process engineering and automation!
Viewpoint
I recently had the opportunity to get to know a strong group of
professionals when asked to cover the Manager position for
three months. Although I have been with the Company for 14
years, many of the technology areas within P&CSD were
unknown to me. Actually, what I realized is that frequently
P&CSD operate in the background by providing support to other
departments. The heart of our plant operations is composed of
processes and control systems, and P&CSD is charged with the
responsibility of ensuring that the Engineering Standards are
kept up to date and are at the leading edge of technology,
especially in the arena of control systems.
The wealth of knowledge in P&CSD far surpassed my
expectations, this department truly has talented individuals.
Their experience has been gained through plant operations in
oil production, gas processing and refining. One of the key
support functions is toward capital programs, by working with
Facilities Planning and Project Management. With the size of
the current capital program, P&CSD is vital to the success of all
of these projects.
I not only gained knowledge during my assignment, but also
increased my network of experts within the Company. It was a
privilege to work with the professionals that comprise P&CSD,
but also the overall Engineering Services of the Company.
Roy A. Debellefeuille
“The wealth of
knowledge in
P&CSD far
surpassed my
expectations,
this department
truly has
talented
individuals.
”
56 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Viewpoint
I recently had the opportunity to get to know a strong group of
professionals when asked to cover the Manager position for
three months. Although I have been with the Company for 14
years, many of the technology areas within P&CSD were
unknown to me. Actually, what I realized is that frequently
P&CSD operate in the background by providing support to other
departments. The heart of our plant operations is composed of
processes and control systems, and P&CSD is charged with the
responsibility of ensuring that the Engineering Standards are
kept up to date and are at the leading edge of technology,
especially in the arena of control systems.
The wealth of knowledge in P&CSD far surpassed my
expectations, this department truly has talented individuals.
Their experience has been gained through plant operations in
oil production, gas processing and refining. One of the key
support functions is toward capital programs, by working with
Facilities Planning and Project Management. With the size of
the current capital program, P&CSD is vital to the success of all
of these projects.
I not only gained knowledge during my assignment, but also
increased my network of experts within the Company. It was a
privilege to work with the professionals that comprise P&CSD,
but also the overall Engineering Services of the Company.
Roy A. Debellefeuille
“The wealth of
knowledge in
P&CSD far
surpassed my
expectations,
this department
truly has
talented
individuals.
”
56 Process & Control Systems DepartmentIssue No. 8 – Special Edition 2007
Answer to last Quiz
Ibrahim M. Orainy from the Marine Department is the winner of the last P&CSD News Letter Quiz. His entry was randomly selected
from among four correct answers submitted.
The question asked whether a process operating in a cycle could produce a net positive amount of work by applying energy to a fluid
and then extracting more energy than had been put in and repeating this in a cycle.
This violates the first and second laws of thermodynamics and therefore any claim to have invented a process to do this is impossible.
The Quiz Master
Ibrahim M. Orainy from the Marine Department is the winner of the last P&CSD News Letter Quiz. His entry was randomly selected
from among four correct answers submitted.
The question asked whether a process operating in a cycle could produce a net positive amount of work by applying energy to a fluid
and then extracting more energy than had been put in and repeating this in a cycle.
This violates the first and second laws of thermodynamics and therefore any claim to have invented a process to do this is impossible.
The Quiz Master
Altraiki P. Press
–Fax: 8471412
“Not all innovation is technology; yet technology is a
result of innovation. Both must produce tangible results. Just
look around yourself and imagine the vast number of prod-
ucts and their manufacturing processes that transform one or
a multitude of raw materials into a very different, useful prod-
ucts.
Either the end or the intermediate products, or their
production steps are likely the subject of a ‘patent’ at some-
time in their life span. To secure a patent, an inventor must
prove that the invention is not only novel, reproducible and
useful, but it is also not obvious to a person skilled in the
understanding of all related prior knowledge (published,
patented or practiced). The distinct ‘unobviousness’ require-
ment places an inventor on a higher plateau than securing
a PhD… hence the personal satisfaction of achievement and
recognition.
Inventing is easy; but it requires self-confidence and
discipline, true willingness to learn and respect others’ knowl-
edge, and an intense curiosity for in-depth understanding of
the problem before seeking a solution.
Quote of the issue
On Innovation & Technology…
Inv. Yuv R. Mehra, LPE, P&CSD …holder of 28 US
Patents related to processing of natural gas,
refining and petrochemicals & polymers. About
40% of Mehra’s patents are in commercial use in
three segments of the hydrocarbon processing
industry, including Saudi Aramco.
–Fax: 8471412
“Not all innovation is technology; yet technology is a
result of innovation. Both must produce tangible results. Just
look around yourself and imagine the vast number of prod-
ucts and their manufacturing processes that transform one or
a multitude of raw materials into a very different, useful prod-
ucts.
Either the end or the intermediate products, or their
production steps are likely the subject of a ‘patent’ at some-
time in their life span. To secure a patent, an inventor must
prove that the invention is not only novel, reproducible and
useful, but it is also not obvious to a person skilled in the
understanding of all related prior knowledge (published,
patented or practiced). The distinct ‘unobviousness’ require-
ment places an inventor on a higher plateau than securing
a PhD… hence the personal satisfaction of achievement and
recognition.
Inventing is easy; but it requires self-confidence and
discipline, true willingness to learn and respect others’ knowl-
edge, and an intense curiosity for in-depth understanding of
the problem before seeking a solution.
Quote of the issue
On Innovation & Technology…
Inv. Yuv R. Mehra, LPE, P&CSD …holder of 28 US
Patents related to processing of natural gas,
refining and petrochemicals & polymers. About
40% of Mehra’s patents are in commercial use in
three segments of the hydrocarbon processing
industry, including Saudi Aramco.
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