Best Practice

SABP-A-011 12 June 2006 Energy Conservation Requirements in Saudi Aramco Engineering Standards and Materials System Specifications Document Responsibility: Consulting Services Department

Previous Issue: New

Next Planned Update: 12 June 2011 Page 1 of 27

Primary contact: ali.qureisha@aramco.com, phone 873-0969 CopyrightSaudi Aramco 2005. All rights reserved.

Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 12 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 12 June 2011 Engineering Standards and Materials System Specifications

Table of Contents
Page 1 Introduction . 1.1 1.2 1.3 2 Definitions . Purpose and Scope Intended Users .. 3 3 3 3 4 5 5 8 14 18 18 20 21 25 25 26 26

General ................ 2.1 List of Energy Requirements in SAESs and SAMSSs 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.2 Heat Transfer Equipment . HVAC and Utilities Compressors, Gears and Steam Turbines ... Gas Turbines and Diesel Engines . Electrical System Design and Automation ...... UPS, DC Systems and Power Design & Automation .. Motors and Generators .. Onshore Structures Flare Systems .. Instrumentation ..

List of Energy Requirements in Saudi Aramco Engineering Procedures (SAEP).

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

Introduction Detailed energy assessments are conducted using Pinch Analysis method and Combined Heat and Power (CHP) method. In each function the target is to minimize energy consumption and maximize the efficiency. Equipment/system directly use energy or indirectly affect the use of energy in other equipment, hence, equipment efficiency optimization is extremely important in energy generation, energy distribution, and energy utilization in our plants. This Best Practice is a step in this direction. Through standards we make sure that equipment are energy efficient which is a major contributor in energy saving in industry. 1.1 Definitions Pinch Analysis: refers to a well-proven methodology to improve the efficient use of energy. It establishes the minimum energy consumption targets for a given process plant which enables us to identify the maximum potential for improvement. This approach can be applied on the existing plants or during the design stage. Combined Heat and Power (CHP): refers to the simulation model for the actual facilitys heat and power production and demand. This tool is used to develop basis for the process energy optimization. 1.2 Purpose and Scope This Best Practice document enlists all Saudi Aramco Engineering Standards and Material Specifications contents that are related to Energy Conservation. It is intended to: Ensure continuous update of the energy conservation requirements in all engineering standards and Material Specifications documents. Be used as a quick reference for facilities design requirements and operation conditions that affect energy consumption. Document energy saving impeded in our standard & Material Specifications standards. 1.3 Intended Users This Best Practice manual is intended for use by energy engineers in Saudi Aramco facilities as well as design and planning engineers.

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

General All Saudi Aramco Engineering Standards (SAESs) and Materials System Specifications (SAMSSs) as well as Engineering Procedures (SAEPs) were searched to address their contents related to energy conservation. Energy requirements in SAESs and SAMSSs are tabulated in the following sections under their respective Standards Committees. Engineering Procedures (SAEPs) are listed in a separate section as they do not belong to a specific Standards Committee. 2.1 List of All Energy Requirements in SAESs and SAMSSs 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 2.1.9 2.1.10 2.2 Heat Transfer Equipment HVAC/Utilities Compressors, Gears and Steam Turbines Gas Turbines and Diesel Engines Electrical System Design & Automation UPS, DC Systems and Power Design & Automation Motors and Generators Onshore Structures Flare Systems Design Instrumentation

List of Energy Requirements in Saudi Aramco Engineering Procedures (SAEPs)

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

2.1

List of All Energy Requirements in SAESs and SAMSSs

2.1.1 Heat Transfer Equipment
SAES/SAMSS TITLE Manufacture of Industrial Boilers PARAGRAPH COMMENTS Refractory of gas directing baffles shall be designed carefully to prevent gas bypassing, which results in lower efficiency. Achieving lower figures of excess oxygen (2%) volume (dry) in flue gas would increase boilers efficiency. Introducing high efficiency oil burners would increase boilers efficiency Maintaining high efficiency of gas burners throughout the burner turndown range would increase boilers efficiency. Higher effectiveness of common windbox would help increase boilers efficiency. Efficiency could be increased by reducing excess air (combustion air), and less power consumption is achieved, too. More precise calculation of stack metal and acid dew point corrosion temperatures would help determine exact lining thickness to reduce risk of loosing energy. More compliance with Saudi Aramco Engineering Standards SAES-N -001 & 100 through 140 (for refractory and insulation) would help reduce risk of loosing energy from the furnace.

SAES/SAMSS #

32-SAMSS-021

Paragraph 7.7.3

32-SAMSS-021

Manufacture of Industrial Boilers Manufacture of Industrial Boilers Manufacture of Industrial Boilers

Paragraph 11.1.2 Paragraph 11.2.1 Paragraph 11.3.1

32-SAMSS-021

32-SAMSS-021

32-SAMSS-021

Manufacture of Industrial Boilers

Paragraph 11.6.3

32-SAMSS-021

Manufacture of Industrial Boilers

Paragraph 12.2.1, 1) & 3)

32-SAMSS-021

Manufacture of Industrial Boilers

Paragraph 14.5

32-SAMSS-021

Manufacture of Industrial Boilers

Paragraph 14.7

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS Life Cycle Cost Evaluation:

32-SAMSS-021

Manufacture of Industrial Boilers

Paragraph 27

Calculating the efficiency penalty on the Boiler Manufacturer for not meeting the guaranteed efficiency during performance test. Performance Guarantees:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 1.10

Optimizing the heater efficiency by lowering the excess air. Proposal:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 1.8.2-l

Energy conservation recommendations include: using of air-preheats, highefficiency burners, etc. Design Considerations:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 2.2.2

Optimizing the heater efficiency by lowering the excess air. Design Considerations:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 2.3.8

Optimizing the heater efficiency by using corbels to minimize bypassing in convection section. Structures and Appurtenances: Optimizing the heater efficiency by air or flue gas leakage prevention. Structures and Appurtenances:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 8.2.13

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 8.3.1.4

Optimizing the heater efficiency by providing horizontal partitions to minimize bypassing in convection section. Stacks, Ducts, and Breechings: Optimizing the heater efficiency by maintaining an adequate draft. Stacks, Ducts, and Breechings:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 9.1.13

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 9.1.15

Optimizing the heater efficiency by maintaining the flue gas stack exit velocity no less than 4.5m/sec in order to avoid inversion and downwash.

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS Stacks, Ducts, and Breechings:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 9.1.20

Optimizing the efficiency by insulating the burners with plenum or wind box to provide proper distribution of air to burners. Burners and Auxiliary Equipment:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 10.1.13

Optimizing the heater efficiency by lowering the excess air (10% excess air for fuel gas and 15% excess air for fuel oils). Burners and Auxiliary Equipment:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 10.1.27

Optimizing the heater efficiency by making burner fuel and air control accessible to the necessary operating adjustment. Burners and Auxiliary Equipment

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 10.3.5

Optimizing the efficiency by including pneumatically operated damper to control combustion air and flue gas flows. Life Cycle Cost Evaluation:

32-SAMSS-029

Manufacture of Fired Heaters

Paragraph 15

Energy cost appears in calculating the efficiency penalty on the Heater Manufacturer for not meeting the guaranteed efficiency during performance test. Scope:

32-SAMSS-029

Manufacture of Fired Heaters

Appendix F, Paragraph F.1.1

Energy cost appears in Heater Manufacturers evaluation required to decide the need for air-preheating systems based on energy conservation. Mechanical:

API 560

Fired Heaters for General Refinery Service

Paragraph 2.3.4

Optimizing the heater efficiency by preventing air or flue gas leakage in the convection section.

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS Life Cycle Cost Evaluation:

SAES-F-001

Design Criteria of Fired Heaters

Paragraph 12

Energy cost appears in calculating the efficiency penalty on the Heater Manufacturer for not meeting the guaranteed efficiency during performance test. Addressing the fouling service fouling factor in heat exchangers. Selection of a fouling factor value has a significant effect on a heat exchanger performance that might result in a significant waste of energy. Addressing the service fouling factor in heat exchangers. Addressing the service fouling factor in heat exchangers. Addressing the use of variable pitch fans to control amount of airflow as well as variable speed drivers and their role in saving energy. Addressing the service fouling factor and thermal capacity limits in heat exchangers. Addressing the use of variable pitch fans.

SAES-E-004

Design Criteria of Shell and Tube Heat Exchangers

Paragraph 6.2.10

SAES-E-006

Design Criteria of Double Pipe Heat Exchangers Design Criteria of Air-Cooled Heat Exchangers Design Criteria of Air-Cooled Heat Exchangers Design Criteria of Plate and Frame Heat Exchangers Manufacture of AirCooled Heat Exchangers

Paragraph 6.2.3

SAES-E-007

Paragraphs 6.1.6 & 6.1.7

SAES-E-007

Paragraph 6.5

SAES-E-014

Paragraph 6.2.1

32-SAMSS-011

Paragraph 7.2.3.18

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

2.1.2
SAES/SAMSS #

HVAC/Utilities
SAES/SAMSS TITLE PARAGRAPH COMMENTS Control thermal conductivity by using building insulation that minimizes net heating and cooling loads on a timeintegrated (annual) basis. Roofs, walls, floors and portions of all air conditioned or mechanically-ventilated buildings shall be insulated. (U-factor) of insulated roofs, walls, partitions or floors shall not exceed 0.568 W/(m K) or (0.10 btu/h ft F). Selecting the 2.5 % exceedance temperature values given in SAES-A112 to be used as the minimum ambient design criteria for HVAC system design, equipment selection and equipment specification purposes for the geographic areas listed for all Saudi Aramco facilities. Indoor Design Conditions to be used for HVAC systems for different facilities. In all HVAC systems the return air and fresh air shall be ducted to the air handling unit within the A/C equipment room. The selection of a cooling source requires an analysis of the various alternatives. If chilled water from an existing central plant is available in sufficient quantities and in close proximity, it shall be considered the first choice for a cooling source. Minimize flow quantity by designing for the maximum practical temperature range. Design parameters for existing central chilled water supply temperature 9C (48F).

SAES-N-004

Design and Installation of Building Thermal Insulation

Section 4

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.2.1.1

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.2.2

SAES-K-001

Paragraph 4.4.2.5

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.4.3.1

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.4.3.2.1

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC)

PARAGRAPH

COMMENTS Design for the lowest practical pressure rise. Design parameters for existing central chilled water supply with Maximum pressure drop through system 140 kPa (20 psi) Designing Chilled water demand for 0.05 L/S per kW (3 GPM/Ton). Use of water cooled condensers requires an evaluation of the condenser water fouling characteristics and it's availability. Location of air conditioning equipment components shall be selected to minimize piping and equipment pressure drop. All enclosed portions of buildings, customarily used by occupants, shall be provided with fresh ventilation air with the minimum amount of outside air shall equal the greater of the following: 5% of supply air plus all exhaust air. The ventilation air requirements listed in Table 2 of ASHRAE STD 62

SAES-K-001

Paragraph 4.4.3.2.2

SAES-K-001

Paragraph 4.4.3.2.3 Paragraph 4.4.3.3.2

SAES-K-001

SAES-K-001

Paragraph 4.4.5.1

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.4.10.2.a

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.4.10.2.b

No outside/make-up air is required for residences. However, infiltration load shall be accounted for at a minimum rate of 0.5 air change per hour in heating/cooling load calculations. Water pressure drop through coils, water chillers or condensers shall not exceed 100 kPa (35 ft w.c., 15 psi). This value applies to chillers, condensers, and cooling coils at their rated fouling factor, unless a lower pressure drop is specified in the design documents.

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.8.4.2

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC)

PARAGRAPH Paragraph 4.8.4.3 Paragraph 4.8.4.4 Paragraph 4.8.4.5 Paragraph 4.8.4.6 Paragraph 4.8.4.7 Paragraph 4.8.4.8

COMMENTS Insert type turbulence promoters, not integral to the coil tubing, (turbulators) shall not be used. The air velocity through coils shall not exceed 3 m/s(600 fpm). Wet coil pressure drop shall not exceed 38 Pa (0.15 in. w.c.) per row of coil. Dry coil pressure drop shall not exceed 25 Pa (0.10 in. w.c) per row of coil. Number of rows per coil shall not exceed 10 rows. Fin spacing of evaporator and condenser coils shall not be closer than 15 fins per inch. Water cooled condensers shall have wall thicknesses and fouling factors as required by27-SAMSS-001 and 27SAMSS-002. Casing filter mounts or filters shall have seals to prevent air bypass. AHU panels shall have insulation with a minimum of 2" glass fiber insulation having a density not less than 48 kg/m (3.0 lb/ft). Fans shall be air-foil, backwardinclined, backward curved, or forwardcurved and shall conform to AMCA 99 and AMCA 210 requirements. In variable air volume (VAV) systems a variable speed fan shall be provided. Propeller fans may be used for exhaust services. Use of orifice, duct splitters or extractors to provide pressure drop in duct systems is not allowed.

SAES-K-001

SAES-K-001

SAES-K-001

SAES-K-001

SAES-K-001

SAES-K-001

SAES-K-001

Paragraph 4.8.6

SAES-K-001

Paragraph 4.8.8.6 Paragraph 4.8.8.7.d

SAES-K-001

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.8.9.1

SAES-K-001

Heating, Ventilating and Air Conditioning (HVAC)

Paragraph 4.8.12.4

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC) Heating, Ventilating and Air Conditioning (HVAC)

PARAGRAPH

COMMENTS Turning vanes, as per SMACNA HVAC Duct Construction Standards, shall be provided in all rectangular elbows of low velocity systems. Ducts shall be insulated in accordance with Table 10-D of the Uniform Mechanical Code (SAES-K-100). PVC nitrile rubber insulation (such as Armaflex) shall not be used exposed to sunlight. Chilled water lines shall be insulated in accordance with Standard Drawing AA-036913. Chilled water lines shall be insulated in accordance with Standard Drawing AA-036913. The air velocity through filters shall not exceed 3 m/s. Dirty pre-filter pressure drop shall not be greater than 125 Pa (0.50 in WC) or final filter pressure drop greater than 250 Pa (1.00 in WC). Pump capacity at peak efficiency, with impeller furnished, shall be equal to or greater than the design capacity. Vendor shall advise in his quotation the minimum stable cooling capacity of the package without the use of hot gas bypass under conditions where the entering condenser cooling medium temperature varies linearly from the maximum specified on the Data Sheet at 100% cooling load to the minimum at 0% load, as per ARI 550/590. If this minimum capacity is less than 15% of full cooling capacity vendor shall supply a suitable automatic hot gas bypass system.

SAES-K-001

Paragraph 4.8.12.8

SAES-K-001

Paragraph 4.8.13.1

SAES-K-001

Paragraph 4.8.13.4

SAES-K-001

Paragraph 4.8.13.4 Paragraph 4.8.15.3 Paragraph 4.8.15.4

SAES-K-001

SAES-K-001

SAES-K-001

Paragraph 4.8.16.2

27-SAMSS-001

Packaged Water Cooled Centrifugal Chillers for Utility Services

Paragraph 5.1.5

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS Compressor capacity control shall be by means of suction (pre-rotation) guide vanes. Capacity reduction shall be automatically controlled by temperature actuated controls. External parts of guide vane mechanism linkage shall be of corrosion resistant materials. Guide vanes shall have mechanisms to prevent vane closure to an extent which would allow the compressor to enter into surge. All waterboxes, nozzles, divider plates, and coverplates shall be internally epoxy coated per SAES-H-100 (or Buyer-approved Vendor's equivalent), and internally catholically protected using sacrificial anodes. Requirements for installation of sacrificial anodes, including selection of the anode type and material shall be by mutual agreement between Buyer and Vendor before issuance of the Purchase Order. To ensure the protection of the waterbox internal coating an approved corrosion resistant sleeve shall be used to mount the sacrificial anode within the waterbox. Condensers and coolers shall be designed for water flow velocity of at least 3 fps, but not greater than 9 fps. Waterside pressure drop shall not exceed 30 feet water gauge (13 psi) for coolers or condensers. Condenser tubes shall be seamless, 90-10 copper-nickel (UNS C70600), -inch O.D., 22 BWG (0.028 inches measured at root of fin enhancement), integrally internally and externally enhanced, conforming to ASTM B359.

27-SAMSS-001

Packaged Water Cooled Centrifugal Chillers for Utility Services

Paragraph 6.1.3

27-SAMSS-001

Packaged Water Cooled Centrifugal Chillers for Utility Services

Paragraph 6.5.1.1.3

27-SAMSS-001

27-SAMSS-001

Packaged Water Cooled Centrifugal Chillers for Utility Services Packaged Water Cooled Centrifugal Chillers for Utility Services Packaged Water Cooled Centrifugal Chillers for Utility Services

Paragraph 6.5.1.1.9

Paragraph 6.5.1.1.10

27-SAMSS-001

Paragraph 6.5.1.2.1

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE Packaged Water Cooled Centrifugal Chillers for Utility Services Packaged Water Cooled Centrifugal Chillers for Utility Services Packaged Water Cooled Centrifugal Chillers for Utility Services

PARAGRAPH

COMMENTS Design condenser waterside fouling factor shall be equal to or greater than 0.00053 m.C/W (0.00025 hr - ftF/BTU). Cooler tubes shall be seamless copper, integrally internally and externally enhanced, -inch O.D., 22 BWG (0.028 inches measured at fin root enhancement), conforming to ASTM B359. Design cooler waterside fouling factor shall be equal to or greater than 0.00018 m.C/W (0.0001 Hr-ftF/BTU).

27-SAMSS-001

Paragraph 6.5.1.2.2

27-SAMSS-001

Paragraph 6.5.1.3.1

27-SAMSS-001

Paragraph 6.5.1.3.2

2.1.3
SAES/SAMSS #

Compressors, Gears and Steam Turbines

SAES/SAMSS TITLE Centrifugal Compressors Centrifugal Compressors PARAGRAPH COMMENTS The minimum allowable compressor polytropic efficiency at the normal operating point shall be 81.0%. The power at the normal operating point shall be guaranteed within 1% positive tolerance. Integrally Geared Compressors are acceptable for process air or gas services upon approval by the Compressors, Gears & Steam Turbines Standards Committee Chairman and shall comply with the requirements of API 617, 7th edition. The guaranteed leakage rate for each seal shall be stated in the Compressor Vendor's proposal and shall be no greater than 5 scfm (141 liters/min) for any service.

31-SAMSS-001

Paragraph 2.1.3

31-SAMSS-001

Paragraph 2.1.3

31-SAMSS-001

Centrifugal Compressors

General

31-SAMSS-001

Centrifugal Compressors

Paragraph 2.2.17

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE Centrifugal Compressors

PARAGRAPH Paragraph 2.9.5.2

COMMENTS High speed balancing on the rotor is an acceptable alternative to the low-speed sequential and final trim balancing. The motor nameplate rating (exclusive of service factor) shall be a minimum of 110% of the greatest horsepower (including gear and coupling losses) required for any of the specified operating conditions. Assembled compressor Gas Leakage Test:

31-SAMSS-001

31-SAMSS-001

Centrifugal Compressors

Paragraph 3.1.5

31-SAMSS-001

Centrifugal Compressors

Paragraph 4.3.5.3

The assembled compressor (with or without the end seals) shall be pressurized to the maximum surge rated discharge pressure shown on the compressor curves. The horsepower based on the measured head at the normal operating point shall be guaranteed within 1% positive tolerance. The Vendor shall supply an operating map and nozzle-to-nozzle performance curves for the compressor based on test results. For variable speed drive, the Vendor shall supply curves showing change of head, power and efficiency versus speed covering the complete range of operation. Certified copies of test data are required. Magnetic Bearings: The use of an active magnetic bearing system for the compressor and driver shall be considered, based on an economic evaluation, when the lube oil system can be totally eliminated, resulting in a "dry" train. Where compressors are operated in parallel arrangements, a load sharing controller shall function to distribute the load by keeping each machine equidistant from its surge curve or surge control margin.
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31-SAMSS-001

Centrifugal Compressors

Paragraph 4.3.6.1.4

31-SAMSS-001

Centrifugal Compressors

Paragraph 5.3.3.1.1

SAES-K-402

Centrifugal Compressors

Paragraph 4.4

SAES-K-402

Centrifugal Compressors

Paragraph 4.10.3

Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE Centrifugal Compressors

PARAGRAPH

COMMENTS The anti-surge controller shall act to maintain the recycle valve in a closed position during normal operation and normal loads. A temporary stainless steel conical strainer of adequate strength shall be installed, during commissioning, in the compressor suction line upstream of performance pressure sensor. This strainer has to be mounted into a dropout pipe spool. Shop Performance Test:

SAES-K-402

Paragraph 4.10.5.4

SAES-K-402

Centrifugal Compressors

Paragraph 5.3

SAES-K-402

Centrifugal Compressors

Paragraph 6.3

A performance test shall be specified and witnessed for each compressor duty. Field Performance Test: As soon as possible after the installation is completed, a field performance test shall be conducted on the compressor. Life Cycle Cost Evaluation: Quotations for compressors of 1000 HP and larger shall be evaluated on the basis of a Life Cycle Cost (LCC). This cost is composed of initial cost of the compressor plus the present worth of the consumed power cost over an operating period of 20 years. The Life Cycle Cost of the compressor shall be determined using the life cycle cost spreadsheet LCC-005 or LCC-006.

SAES-K-402

Centrifugal Compressors

Paragraph 7.1

SAES-K-402

Centrifugal Compressors

Paragraph 8

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS The steam turbine type (back pressure, condensing, extraction/ condensing or induction/condensing) shall be determined by the process steam balance requirements. Extraction/condensing steam turbines shall be considered whenever the plant design uses steam let-down valves to produce process steam at lower pressure than that produced by the boiler design. Consideration shall be given to induction/condensing steam turbines in place of pressure blow-off or let-down valves to maintain the plant intermediate pressure steam headers at their design operating pressure. Field Testing: As soon as possible following installation of the equipment train, special-purpose steam turbines shall be load tested to verify performance, efficiency and steam consumption. The test procedure shall be agreed with the vendor at the time of purchase and shall be generally in compliance with ASME PTC 6/ ASME PTC 6S. The results of these tests shall form the basis for performance acceptance.

SAES-K-501

Steam Turbines

Paragraph 4.1.5

SAES-K-501

Steam Turbines

Paragraph 5.4

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

2.1.4
SAES/SAMSS #

Gas Turbines and Diesel Engines

SAES/SAMSS TITLE PARAGRAPH Scope: Procedure provides instructions for economically evaluating major equipment purchases with regards to their estimated total ownership cost (Life Cycle Cost) to Saudi Aramco over a fifteen (15) years period. These costs include procurement and operation cost (energy cost and quantifiable periodic maintenance) of the equipment. For All the rotating equipment, energy conservation is achieved through the application of Equipment Life Cycle Cost (LCC) Procedure. COMMENTS

SAEP-341

Equipment Life Cycle Cost Procedure

2.1.5
SAES/SAMSS #

Electrical System Design & Automation

SAES/SAMSS TITLE PARAGRAPH COMMENTS Lighting systems shall be designed for energy efficient operation. Commentary 4.1.3: Lighting systems should be designed to automatically turn off or minimize lighting when it is not required. In buildings, lighting in areas that are not continuously occupied should have accessible manual switches and/or occupancy sensors to insure that lighting turned off when the area is not occupied. Outdoor non-plant area and street lighting fixtures shall be individually controlled by a photocell mounted on the fixture.

SAES-P-123

Lighting

Paragraph 4.1.3

SAES-P-123

Lighting

Paragraph 4.1.11

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS Energy-efficient fluorescent lamps type T5 or T8 and compatible energy efficient electronic ballasts having less than 10% THD (total harmonic distortion) shall be used in lighting fixtures for offices, control buildings, and in industrial areas where fluorescent lighting is required. The use of energy-efficient fixtures like High Pressure Sodium, Metal Halide shall be maximized. Mercury vapor fixtures shall not be used. The standard prescribes the design and required functions to measure plant electrical parameters including energy consumptions. Energy indices are generated from the power consumption data prescribed in this standard. For plants with DCS, real-time and historical data (data logs) from PMS shall be made available for direct interface with the DCS. The intention of this paragraph is to make electrical energy data available to monitor plant efficiency, generate efficiency indices, etc. Per-process Area Data Logs PMS shall be customized to calculate and log energy and power for each operating area (process area in the plant). Log intervals for the power and power factor shall be every six (6) hours. This paragraph describes energy data aggregation to generate effective energy consumption measurements of each process area.

SAES-P-123

Lighting

Paragraph 4.2.2

SAES-P-123

Lighting

Paragraph 4.2.5

SAES-P-126

Power Monitoring System

General

SAES-P-126

Power Monitoring System

6.4

SAES-P-126

Power Monitoring System

7.8.3

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

2.1.6
SAES/SAMSS #

UPS, DC Systems and Power Design & Automation

SAES/SAMSS TITLE PARAGRAPH COMMENTS The charger/rectifier shall be sized to provide a battery recharge time of 8 hours to at least 80% of battery capacity, as specified on the Data Schedule. This is specified to limit the UPS input current consumption, thus improves the UPS overall efficiency. Temperature Compensated Charging: Negative temperature compensated charging feature shall be provided on all chargers. This is to make sure that battery recharge current is optimum. Required Recharge time of the system battery; UPS batteries: 8 hours to at least 80% capacity. This is specified to limit the UPS input current consumption, thus improves the UPS overall efficiency. The UPS battery charger/rectifier shall be equipped with temperature compensated charging probe and facility. This process shall adjust the charging voltage to compensate for the electrolyte temperature using the negative coefficient of 3 mV per cell per degree Celsius deviation from the ambient 25C. This is to make sure that battery recharge current is optimum.

17-SAMSS-514

Battery Chargers / Rectifiers

Paragraph 6.1.2

17-SAMSS-514

Battery Chargers / Rectifiers

Paragraph 6.5.14

17-SAMSS-516

UPS Systems

Paragraph 6.7.3.1

17-SAMSS-516

UPS Systems

Paragraph 6.7.3.13

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS The minimum battery backup time shall be in accordance with Table 1, and shall be based on the actual load calculation. This is to avoid over sizing battery capacity which results in optimum battery recharge current and efficient system. Battery recharge time (for photovoltaic applications: within 30 days to 90% Ah capacity; and for all other applications: within 8 hours to 80% Ah capacity) This is specified to limit the UPS input current consumption, thus improves the UPS overall efficiency.

SAES-P-103

UPS and DC Systems

Paragraph 5.3.6

SAES-P-103

UPS and DC Systems

Paragraph 7.2.1

2.1.7
SAES/SAMSS #

Motors and Generators

SAES/SAMSS TITLE PARAGRAPH COMMENTS The minimum efficiency of the CDM shall be 95% at rated load and frequency. This value is to determine the overall efficiency for the Complete Drive Module. If specified within Data Schedule 1, the drive system shall be regenerative. Paragraph 8.6 Normally during ramping down, motors with high inertia have access energy might be resent to the network if the AFD is regenerative.

16-SAMSS-517

Adjustable Frequency Drive System -1 kV and Above

Paragraph 8.3

16-SAMSS-517

Adjustable Frequency Drive System -1 kV and Above

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS Power conversion bridges within a BDM rated 10,000 kW and larger shall be liquid cooled.

16-SAMSS-517

Adjustable Frequency Drive System -1 kV and Above

Paragraph 17.1

The liquid cooling is to allow the heat associated with the high power switching to be dissipated outdoors properly which helps the drive to work at the rated efficiency. The following system tests shall be performed on the CDM: Efficiency tests (type test).

16-SAMSS-517

Adjustable Frequency Drive System -1 kV and Above

Paragraph 25.4.1

This test is to certify that the Complete Drive Module was designed and manufactured to comply with 95% efficiency at the rated load and frequency. If auxiliary cooling fans are used for TEAAC Auxiliary cooling fans use 60% less energy than shaft mounted fans. The stator core test shall be performed for all motors rated 6.6 kV and above and all motors rated above 3700 kW (5000 HP). The Stator core test ensures core losses are kept low to improve efficiency. The complete test shall be performed for all motors rated 6.6 kV and above and all motors rated above 3700 kW (5000 HP). Efficiency testing ensures motor meets or exceeds efficiency requirements. Minimum guaranteed efficiency shall be 94% for motors with rated synchronous speed of 1800 RPM or higher (i.e., 2 or 4 pole motors) This value is to determine the motor efficiency that related the input power to output power.

17-SAMSS-502

Form-Wound Induction Motors 250 HP and Above

2.4.1.2.3f

17-SAMSS-502

Form-Wound Induction Motors 250 HP and Above

4.3.4.1

17-SAMSS-502

Form-Wound Induction Motors 250 HP and Above

4.3.5.1.1

17-SAMSS-502

Form-Wound Induction Motors 250 HP and Above

Paragraph 5.2

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE Severe-Duty, Totally Enclosed, Squirrel Cage Induction Motors to 500 HP (370 kW)

PARAGRAPH

COMMENTS Motor electrical performance and characteristics shall be in accordance with NEMA MG 1 or IEC-60034

17-SAMSS-503

Paragraph 5.1

NEMA standards and IEC standards both determine the accepted efficiency levels as well as the values of the different losses. Industry Codes and Standards NEMA MG1 30.2.1.18 Regenerative Braking: A form of dynamic braking in which the kinetic energy of the motor and driven machinery is returned to the power supply system. This requirement will help to resend the excess energy of high inertia loads to the network during ramping down. Minimum guaranteed efficiency at rated output shall be 94% for generators with rated synchronous speed of 1800 RPM or higher. This value is to determine the generator efficiency that related the input power to output power. This material spec is for synchronous motors, which are typically 1.5-2% higher efficiency than induction motors. If auxiliary cooling fans are used for TEAAC Auxiliary cooling fans use 60% less energy than shaft mounted fans. The stator core test shall be performed for all motors rated 6.6 kV and above and all motors rated above 3700 kW (5000 HP). Stator core test ensures core losses are kept low to improve efficiency.

17-SAMSS-503

Severe-Duty, Totally Enclosed, Squirrel Cage Induction Motors to 500 HP (370 kW)

Paragraph 5.1

17-SAMSS-510

Brushless Synchronous Generators

Paragraph 5.2

17-SAMSS-520

Synchronous Motors

General

17-SAMSS-520

Synchronous Motors

2.4.1.2.3h

17-SAMSS-520

Synchronous Motors

4.3.4.1

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

SAES/SAMSS #

SAES/SAMSS TITLE

PARAGRAPH

COMMENTS The complete test shall be performed for all motors rated 6.6 kV and above and all motors rated above 3700 kW (5000 HP). Efficiency testing ensures motor meets or exceeds efficiency requirements. Minimum guaranteed efficiency shall be 94% for motors with rated synchronous speed of 1800 RPM or higher (i.e., 2 or 4 pole motors) This value is to determine the motor efficiency that related the input power to output power. New or replacement 1000 HP and larger motor driven pump and compressor applications in pipeline service, GOSP crude oil shipping pump service, GOSP HP gas compressor service, and pump or compressor applications with significant variations in operating conditions shall be evaluated for variable speed operation utilizing Adjustable Frequency Drive(s) (AFD). This is specified to utilize the process variation to save energy. Motors 15000 hp and above should be synchronous motors.

17-SAMSS-520

Synchronous Motors

4.3.5.1.1

17-SAMSS-520

Synchronous Motors

Paragraph 5.2

SAES-P-113

Motors and Generators

5.13

SAES-P-113

Motors and Generators

6.2

Table 1 mandates the use of synchronous motors 15,000 Hp and larger, which are typically 1.5-2% higher efficiency than induction motors. The motor losses shall be derived from the motor vendor's guaranteed efficiency at the operating load of the driven equipment. Life cycle cost evaluation takes into account the cost of energy when evaluating motor quotations based on efficiency.
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SAES-P-113

Motors and Generators

Sec 8

Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

2.1.8
SAES/SAMSS #

Onshore Structures
SAES/SAMSS TITLE PARAGRAPH COMMENTS Floors shall be thermally insulated when the air-conditioned space is above a non-conditioned space or ambient air (as in a building elevated above grade). Partitions shall be thermally insulated if the air-conditioned space is adjacent to a non-conditioned space or to an area of high heat output. The overall heat transmission coefficient (U-factor) of insulated roofs, walls, partitions or floors shall not exceed 0.568 W/(m K) or (0.10 btu/h ft F).

SAES-N-004

Design and Installation of Building Thermal Insulation Design and Installation of Building Thermal Insulation Design and Installation of Building Thermal Insulation

Paragraph 4.2

SAES-N-004

Paragraph 4.3

SAES-N-004

Paragraph 4.4

2.1.9
SAES/SAMSS #

Flare Systems Design

SAES/SAMSS TITLE System Design Criteria of Flares PARAGRAPH COMMENTS The use of a flare gas recovery as the first stage in the flare system will recover the routine daily flare gas consisting of purge gas and leakages. The smokeless capacity of the flare should be designed according to the environmental requirements. Over design will increase the consumption of steam/air. Use of steam control system will minimize steam usage. Use of a variable speed blower for an air assist flare application can save energy. The use of the correct amount of purge gas requirement in the flare system can result in purge gas conservation.

SAES-F-007

Paragraph 6.1

SAES-F-007

System Design Criteria of Flares

Paragraph 6.10

SAES-F-007

System Design Criteria of Flares

Paragraph 6.21

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

2.1.10
SAES/SAMSS #

Instrumentation
SAES/SAMSS TITLE PARAGRAPH COMMENTS All boilers shall be provided with a flue gas oxygen analyzer and oxygen trim controller to monitor and control the amount of oxygen in the flue gas. The analyzer shall comply with 34-SAMSS512, "Oxygen Analyzers." Combustibles Analyzer: Combustibles analyzers are recommended for use on large fuel gas or oil fired boilers as an aid to safe economical operation. The output of combustibles analyzers shall be used for indication and alarm only.

SAES-J-602

Burner Management, Combustion and Waterside Control Systems for Water tube Boilers System Design Criteria of Flares Burner Management, Combustion and Waterside Control Systems for Water tube Boilers System Design Criteria of Flares

7.2.1.1

SAES-J-602

7.2.3

2.2

List of Energy Requirements in Engineering Procedures (SAEPs)

SAEP TITLE PARAGRAPH COMMENTS During DBSP development, energy optimization opportunities should be identified and evaluated on case by case bases. Study reports, minutes of meetings, letters, and other supporting documentation shall be clearly referenced and, if practical, included in an Appendix (e.g., Proposed Facilities). It is particularly important to document instances in which the DBSP scope differs from the scope recommended by studies or other scope evaluations, due to Proponent preferences or other considerations. The need for detailed evaluation of specific energy optimization opportunities should be identified in the draft DBSP issued for formal review.

SAEP #

SAEP-1350

Design Basis Scoping Paper (DBSP) Preparation and Revision Procedure

Paragraph 5.4.8.2

SAEP-1350

Design Basis Scoping Paper (DBSP) Preparation and Revision Procedure

Paragraph 5.4.9

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Document Responsibility: CSD/ESD/Energy Systems Unit SABP-A-011 Issue Date: 10 June 2006 Energy Conservation Requirements in Saudi Aramco Next Update: 10 June 2011 Engineering Standards and Materials System Specifications

12 June 2006

Revision Summary New Saudi Aramco Best Practice.

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