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Saudi Aramco: Company General Use
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Assessment of Abqaiq Plant Water Treatment Program
Mohammed A. Al-Mugahwi & Mohammed S.AlajajiAbqaiq Plants, Saudi Aramco
Saudi Aramco: Company General Use
Overview
Saudi Aramco: Company General Use
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Saudi Aramco: Company General Use
Fin Fan
Boiler (10)HRSG (5)
Re-Boiler Re-Boiler
Steam Turbines
CondensateTank (6)
Deaerator (6)
CondensateWater
T=750 F
Steam (625 psig)
Steam (60 psig)
Return Condensate Water
Demin Water
T=310 F60 psig s steam
Raw WaterRODrinking Water
DWTank (2)
Cooling Water
400 Sample/day
1800Test/day
Abqaiq Plants Water Cycle
Saudi Aramco: Company General Use
Objectives
Saudi Aramco: Company General Use
A
B
C
Maintain Water / Steam Quality
Protect Assets Integrity
Avoid Waste Resources
Saudi Aramco: Company General Use
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Methodology
Saudi Aramco: Company General Use
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Established a team that consisted of SALD, APOD/UOD , APOE/I&CU , Chemical Supplier led by APOE/UU
Identified the references (SA Standards and International Standards ) :• SABP-A-026,028,029• Boiler Manufactures Association
(BMA) • National Electrical Manufacturers
Association (NEMA.)• American Society of Mechanical
Engineers ,Ch-13 (ASME)
Assessed the Water Treatment program• Identified the Required Tests to be
Conducted On Collected Samples.• Evaluated the SALD capability to
conduct the required test • Reviewed all the chemical ranges/ limits • Ensured all the chemicals ranges are
consistent for all the reperting methods ( OIMs,NALCO, Operation Log sheet)
Reviewed and Concurred the Results by Central Engineering
Saudi Aramco: Company General Use
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Results
Saudi Aramco: Company General Use
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A
B
C
Revised Water Treatment Program Control Ranges
Optimized Number of Field Samples
Optimized Number of LAB Tests Analysis
Saudi Aramco: Company General Use
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A Revised Water Treatment ProgramControl Ranges
Saudi Aramco: Company General Use
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B Optimized Number of Field Samples
Annual Number of Field Samples: 150 M 88 M
Saudi Aramco: Company General Use
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C Optimized Number of LAB Test Analysis
Annual Number of LAB Test Analysis: 660 M 230 M
Saudi Aramco: Company General Use
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Optimization Calculations
Financial Impacts
Saudi Aramco: Company General Use
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2018 2019
150 M
25 M
0.63 MM
88 M
15 M
0.41 MM
Total Number of Field Samples Points /yr
Total Operator Labor Hour/ yr (10 min/Sample Point)
Cost of Operator Labor $/ yr ( Employee Labor Cost $28 /hr)
Operational Cost Optimization
Saudi Aramco: Company General Use
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2018 2019
660 M
55 M
1.5 MM
230 M
20 M
0.5 MM
Total Number of LAB Tests Analysis /yr
Total Lab Scientist Labor Hour/ yr (5 min/Test )
Cost of Lab Scientist Labor $/ yr ( Employee Labor Cost $28 /hr)
Laboratory Cost Optimization
Saudi Aramco: Company General Use
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2018 2019
0.5 MM
33 M
0.13 MM
22 M
Cost of Chemicals Reagents $/yr ($1.25)
Cost of Water Bottles Samples $/yr (sample point/ weekly change )
Material Cost Optimization
Saudi Aramco: Company General Use
Lab Cost
Saving
($/yr)
$ 1 MM
Opera Cost
Saving
($/yr)
$ 0.22MM
Materials
Cost Saving
($/yr)
$ 0.36MM
$1.6 MM /Yr
Total Cost Optimization
Saudi Aramco: Company General Use
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Path-Forward
Saudi Aramco: Company General Use
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Monitor the assessment results
Develop Dashboard
IR 4.0
Monitor the assessment results and implement them in full scale by 2020.
Dashboard will enhance sample monitoring and timely corrective actions
Adapt IR 4.0 in order toenhance the water qualityand looking for moreenhancement such installingsmart Analyzers.
01 02 03
Saudi Aramco: Company General Use
Thank you!
