(55b) Innovation- a Way to Optimize Investment, Utilization and Energy

Yanbu Refinery Department of Saudi Aramco had ambitious target of improving Cash Margins, Water and Energy Key Performance Indicators. However, uncertain economic environment reduced projects attractiveness. Realizing innovation potential along with deployment of promotion of critical behaviors helped in tapping Employees innovation skills. Innovation resolved several system constraints with minimal investments saving Millions of dollars apart from reducing emissions. Four case studies of successful implementation shows dramatic improvement in employee culture and establishment of “Made In YRD” Concept

As innovation is mother of all necessities, several innovations were generated to overcome the chronic concerns in the equipment reliability, performance to sustain production with minimal investments. Some innovations implemented include redesigning vendor proposals, mitigating summer concerns for compressors, providing supplement cooling water for new equipment, Utilizing spare equipment, promoting blending time Etc.

We had experienced closed loop Tempered Water (TW) system cooling limitations especially in summer especially after debottlenecking units. TWS is closed loop cooling water circulation system and is treated with chemicals like inhibitor and biocide. TW is mainly used to reduce crude column bottom RCO product rundown temperatures and also to supply cooling water to compressors including Instrument Air (IA) Compressor. In addition refinery installed additional air compressor which increased load on the system. Refinery by using innovation approach, recycled process water as boiler feed water. This saved 44m3/hr water with energy recovery.

We redesigned dryer vendor internals with innovative design to reduce pressure drop by 80% and save Compressor power. We have modified properties to utilize spare equipment and increase transfer rate, reduce give away and increase Utilization.