Crude Oil Processing Optimization Initiative — from Concept to Successful Implementation and Sustainment

Abstract

Abstract The Khurais Central Processing Facility (KhCPF) has undergone various optimization initiatives since it was commissioned in June 2009. One of the major achievements in this effort is to maximize crude oil yield from its oil train facility. This paper shares its experience in implementing the optimization initiative from exploring such a simple concept of crude flashing to sustaining the optimum performance. It adopts a systematic approach from desktop assessment to performance test. The performance test demonstrates that additional stabilized crude oil production can be realized at the expense of lower gas and condensate yields from the facility. Even though the crude oil gain and gas loss is relatively insignificant — considering the production rate it is mandated to produce — the initiative has resulted in value creations to the Khurais production in general. First, the initiative is purely a low-hanging fruit type, and yet, at the prevailing crude oil price the initiative has contributed to positive net revenue. Second, it avoids spending unnecessary capital to build a new pipeline for injecting back the condensate into the stabilized crude oil. With the promising findings together with the anticipated benefits, the team decided to adopt the proposed initiative in actual operation. Today, the plant is on the operational mode with greater emphasis on sustaining optimum performance through an effective performance monitoring effort. This in-house monitoring tool has the capability to quantify the performance gap, prioritize the gap closure efforts and diagnose the potential root cause of the performance gap. Along this line, the crude yield key performance indicator (KPI) was introduced where the team monitors the crude specifications, mainly hydrogen sulfide (H2S) and Reid Vapor Pressure (RVP), to ensure the crude oil yield is maximized within the acceptable limits. Finally, the plant successfully commissioned the Advanced Process Control (APC) application to automate the sustaining effort online. The results so far have been very encouraging in sustaining crude oil yield value, minimum product giveaway and energy efficient operation.