Best Practice
SABP-A-034 1st July 2018
Plant Performance and Capacity Testing
Procedure for Upstream Crude Oil Processing
Document Responsibility: Oil and Gas Process Engineering Committee.
Saudi Aramco DeskTop Standards
Table of Contents
1 Scope............................................................ 2
2 Conflicts........................................................ 2
3 References................................................... 2
4 Abbreviations................................................. 3
5 General.......................................................... 4
6 GOSP Process Description........................... 5
7 Test Preparation............................................ 6
8 Test Procedure.............................................. 7
9 Test Results.................................................. 12
10 Acknowledgment.......................................... 13
Previous Issue: 11 September 2011 Next Planned Update: 1st July 2023
Page 1 of 13
Primary contacts: Salman Alrasheed (RASHSA0W) on 013880-8897 and Simone Mulas (MULASSX) on 013
880-9485.
Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
1 Scope
This Best Practice provides guidelines for conducting periodic Plant Performance and
Capacity Testing of a Gas Oil Separation Plant (GOSP) & Stabilization facilities. The
results obtained from such tests shall facilitate analyzing the plant performance at the
design conditions and to identify bottlenecks, if any. This shall be considered as First
Level of plant limitation. Such bottlenecks may arise in the produced water handling
system due to increase in water cut change of injection specs or in the gas handling
systems due to change in GOR or in oil-water separation efficiency due to change in
emulsion type (loose/tight) of wild crude feed mix or in equipment performance due to
aging of equipment, even though oil production rate might be within design rate. In case
there is significant change in GOR, need for flare and relief systems audit should be
confirmed and conducted, if required, even though oil rate may be within design.
In case of conducting a capacity test to check if the GOSP can handle higher than
design capacity, which is the Second Level of plant limitation, a flare and relief
systems audit must be performed and concurred by P&CSD/DPED/Flare & Relief
System Unit in order to verify the adequacy of the flare and relief system. Furthermore,
there may be plant limitations due to equipment size, tie-line pressure control, valve
sizes, pipe sizes, and other design parameters which need to be identified.
2 Conflicts
In case of conflict between this Best Practice and any Saudi Aramco standard or
specification, P&CSD should be consulted for clarification.
3 References
This Best Practice is based on the below referenced standards:
Saudi Aramco References:
Saudi Aramco Engineering Standards
SAES-F-007 System Design Criteria of Flares
SAES-J-003 Instrumentation - Basic Design Criteria
SAES-L-132 Material Selection for Piping Systems
SAES-L-150 Pressure Testing of Plant Piping and Pipelines
SAES-G-005 Centrifugal Pumps
Saudi Aramco Best Practice
SABP-K-401 Site Performance Testing of Centrifugal Compressors
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
4 Abbreviations
API American Petroleum Institute
BAT Best Available Technology
BOD Bio-chemical Oxygen Demand
BPD Barrels Per Day
BS&W Basic (Bottom) Sediments and Water
BTEX Benzene, Toluene, Ethyl Benzene, Xylene
CDS Closed Drain System
CFD Computational Fluid Dynamics
CFU Compact Floatation Unit or Cyclonic Floatation Unit
CM Ceramic Membrane module
CML Computer Model Library
ESD Emergency ShutDown
RVP Reid Vapor Pressure
TVP True Vapor Pressure
GOSP Gas Oil Separation Plant
H2S Hydrogen Sulfide
HPPT High Pressure Production Trap (2 or 3-phase separator)
HTRO High Temperature Reverse osmosis
H2 S Hydrogen Sulfide
WOSEP Water Oil Separator
LPPT Low Pressure Production Trap
LPDT Low Pressure Degassing Tank
PTB Pounds per Thousand Barrels
MAOP Maximum Allowable Operating Pressure
MOC Management of Change
CSD Consulting Services Department
P&CSD Process and Control Systems Department
PFD Process Flow Diagram
P&FDD Production and Facilities Development Department
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
P&ID Piping and Instrumentation Diagram
PPM Part Per Million
PPP Production Priority Plan
PPS Parallel Plate Separator
R&DC Research and Development Department
RMD Reservoir Management Department
RO Reverse Osmosis
SDI Silt Density Index
TDS Total Dissolved Solids
TMP Trans-Membrane Pressure
TOC Total Organic Carbon
TPS Tilted Plate Separator
TSS Total Suspended Solids
TT Temperature Transmitter
UV Ultraviolet
5 General
In Saudi Aramco there are numerous gas oil separation plants (GOSPs) processing wet
crude through flash separators, desalting and gas compression in addition to
stabilization facilities. The GOSPs are designed to handle oil rates ranging from 100 to
over 1300 MBCD with watercuts up to 70%. Over the years watercuts have increased,
and in some GOSPs watercuts will exceed design capacity in the coming years. This
increased quantity of water has created, and will continue to create, a number of
challenges at the GOSPs.
These challenges are generally related to 3-phase production traps, dehydration and
desalting and WOSEP/Injection Pumps and include increased chemical consumption,
increased water (and salt) carryover into the oil, off-spec effluent water, wide emulsion
pads (rag layers) formation, and electric grid shorting among others. These problems
cause operational upsets and lead to the crude/water quality, pipeline corrosion issues
and thereby higher operating costs.
This document will provide the Performance and Capacity Testing Best Practice. It will
establish the First Level of plant limitation (operations at design capacity) such as
vessels, pumps, compressors, control valves, piping, etc., and the Second Level of plant
limitation (operation above design capacity) such as Flare & Relief (to be addressed after
the first level limitation is overcome).
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
6 GOSP Process Description
Figure 1 – Typical Process Scheme of Crude Processing Facilities with Stabilization
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
7 Test Preparation
The test should be conducted ahead of master plan and capital project initiation in order
to determine the actual plant capacity.
Prior to the test, ensure that the below preparations requirements are met:
7.1 For First Level of plant limitation, i.e., at the design capacity:
7.1.1 Measuring instruments used in the test must be calibrated and ensure no
ESD signal is on bypass.
7.1.1.1 Ensure that operating pressures of key process equipment are as
per the design.
7.1.1.2 Ensure that standby equipment is available.
7.1.1.3 Ensure that Relief Valves are set correctly.
7.1.1.4 Ensure that availability of all chemicals and chemical supply as
required
7.1.1.5 Ensure that sufficient number of wells are lined up and trunklines
with relevant MOVs open for the oil train feeding during the
test.
7.1.1.5 Ensure the adequate amount of utilities (wash water, steam, etc...)
during the test.
7.1.1.6 Ensure that Lab to collect and analyze all the pre-agreed and
prioritized number of samples.
7.1.2 The test will be carried out with all control loops set on Auto and
Cascade Mode per design with set points for PICs, LICs, PDICs, TICs
and FICs as per the P&ID/OIM.
7.1.3 The period of the capacity test shall be determined by the area Plant and
Process Engineering and shall be adequate enough to reach steady state
operations (minimum 24 hrs).
7.1.3.1 Confirm if the test is to be performed with and without scraping
of trunk lines.
7.2 For Second Level of plant limitation i.e. at higher than design capacity:
7.2.1 Flare and relief systems audit must be done and concurred by
P&CSD/DPED/Flare & Relief System Unit specified by SAES-F-007
paragraph 8.2.1.
7.2.2 Consult with P&CSD/OPU to identify plant/equipment limitations due to
equipment size, tie-line pressure control, valve sizes, pipe sizes, and
other design parameters.
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
7.2.3 Confirm MAOPs of flowlines, trunklines and pipelines from ILI and
inspection records. If any pipeline is derated, evaluation should be done
on the pipeline flowrate and operating pressure prior to conducting the
test. It should also be ensured that the plant operational high/high-high
settings in the DCS/ESD system are in line with the derated condition.
7.2.4 Initiate MOC to cover design evaluation of plant piping and equipment.
7.2.5 Identify any potential or past integrity/failure issues from
Operations/Maintenance that need to be either monitored closely during
the test or addressed prior to the test, such as equipment/structural
vibrations, temporary repairs etc.
7.2.6 Run minimum of 5 days for both summer and winter conditions.
8 Test Procedure
8.1 General
Prior to starting the data collection for a test point, ensure that below preparation
requirements are met:
8.1.1 The test should be started after all instruments are calibrated and gauges
are in acceptable working condition. Communication should be
established with OSPAS and with downstream receiving facilities, which
may be stabilization facilities, gas plant or oil tank farms/terminal, to
confirm their adequacy and preparedness for receiving expected change
in their feed or higher rate of feed. For conducting the test in a smooth
manner, communication and coordination links with defined
responsibilities should be established across all interfacing plants at
upstream and downstream, such as offshore satellite GOSPs, Field
Services, Production Engineering and the downstream recipient facilities
mentioned above.
8.1.2 Area plant and process engineering shall develop the capacity test matrix
sheet which includes all process conditions and equipment as specified in
section 8.2 such as flowrates, pressure, temperature, levels, equipment
status, specifications, control valves positions, main discharge streams
pressures, gas flaring, liquid carry over to KO drums, etc.
8.1.3 Production priority plan (PPP) should be clearly established. Production
Engineering/Reservoir Management Department shall identify the wells
that will be: opened, closed, relaxed (by increasing choke opening), new
wells (activated for increasing production). This PPP should be part of
the Capacity Test procedure. The plan should state the forecasted oil,
water and gas rates from each well. In oil fields, the wells have range of
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
GOR varying from High to Low. The wells should be listed with its
GOR level (High, Normal, Low). The wells having low & normal GOR
should be opened/relaxed first and the ones with high GOR wells later.
This approach will result in smooth and stable production ramp-up,
while ensuring that the total expected gas rate is always within the design
limits of the producing facilities.
8.1.4 GOSP capacity test shall be repeated in summer/winter to establish Atm,
LP and HP gas compressors (if any) limitations.
8.1.5 In a Capacity Test, during any increments of plant flowrate, a period of
1-2 hours must take place before any sampling is made to allow for the
process to stabilize hence more representative results will be obtained.
8.1.6 In a Capacity Test, the following must be ensured:
8.1.6.1 All centrifugal compressors shall be tested in according to
SABP-K-401.
8.1.6.2 All centrifugal pumps shall be tested in according to SABP-G-
005.
8.1.6.3 Piping fluid velocities does not exceed limits specified by
SAES-L-132, Section 5.
8.1.6.4 Control valves are not operated beyond its design operating
range as per its ISS (e.g, 10% to 90%).
8.1.6.5 Crude quality specifications as per SAES-A-010 section 5 are
maintained.
8.1.6.6 If a major process upset or surging (fluctuating) feed is
observed at a particular production rate, then the rates increase
should be altered accordingly.
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
8.2 Collected Data
The following data shall be collected during the test (after the target oil rate has
been achieved, maintain the rate for at least 24 hours and continue to record
process data every hour):
Location Process Parameter
Production Header Pressure
Production Header Multiphase Flow meters cumulative readings (if present)
Demulsifier injection rate
Temperature
Pressure
Interface level
HPPTs/LPDT Oil level
Gas flowrate
Water flowrate
Valve positions (Water, Oil & Gas)
Temperature
Pressure
IPPTs/LPPTs/Spheroids Oil level
Gas flowrate
Valve Positions (Oil & Gas)
Flowrate
Charge Pumps, Water
Transfer pumps, Injection Number of Pumps Running
pumps
Suction & discharge pressure
Hot Stream Flowrate
Cold Stream Flowrate
Cold Stream Temperature (in/out)
Crude Heaters
Hot Stream Temperature (in/out)
Cold Stream differential pressure
Hot Stream differential pressure
Demulsifier rate
Mixing Valve differential pressure (if present)
Dehydrator
Temperature
Interface level
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
Location Process Parameter
All Grids voltages
Water flowrate
Interface LCV Position
Crude outlet BS&W
Wash water rate
Mixing valve differential pressure
Interface LCV Position
All Grids voltages
Desalter
Interface level
Temperature
Crude outlet BS&W
Crude outlet Salt
Pressure
Tie Line
Control valve position
WOSEP pressure
WOSEP water level
Oil in water analysis
Produced Water Ensure less than 100 ppm at all times
Treatment & Disposal
System Water disposal rate
D/S WOSEP LCV position
Injection pump and Disposal line pressures
Dumping valve position
suction drum level
Compressor flow, % recycle
Compressor discharge flow (i.e., without recycle)
compressor suction & discharge pressure
compressor suction & discharge temperature
Gas Gathering
compressor cooler in/out temperature
compressor recycle valve position
Total product gas flowrate
product gas temperature
product gas pressure
Crude Stabilizer Hydrocarbon and water dew point temperature
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
Location Process Parameter
Inlet crude flowrate
Reboiler steam/condensate rate
Gas out flowrate
Stabilizer pressure
Stabilizer reboiler crude in/out temperature
Steam inlet temperature
Condensate outlet temperature
TCV position
Steam drum level (if present)
Steam drum pressure (if present)
Steam drum LCV position
Bottom crude rate
Column dif. pressure
Steam injection rate
H2S content in bottom crude
RVP of crude
Crude cooler inlet/outlet temperature *
Crude cooler differential pressure *
Chemicals (demulsifier,
Chemical consumption rate
corrosion inhibitor, etc...)
* Crude coolers in some cases are the same as crude heaters, i.e., crude/crude exchangers.
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
9 Test Results
9.1 The responsible Plant Engineer as well as the Process Engineer should
participate in the performance and/or capacity test and collect the test data from
plant operations.
9.2 Crude Product Specifications must be kept below the following limits as per
SAES-A-010:
BS&W: 0.2 % vol
Salt: 10 PTB
H2S: 60, 30, 10 or 1 ppmw
TVP: 13 PSIA @ 130F or crude storage temperature
9.3 Report the average results achieved during the test:
1. Oil Production Rate
2. Disposal Water Rate
3. Wash Water Rate
4. Gas Rate
5. Oil Tie/Line Press
6. Gas Tie/Line Press
7. Oil analysis (BS&W and Salt-in-crude) to pipeline
8. Stabilization rate and analysis
9. Bottlenecks that were identified during the test
10. Production Separator Separation efficiency for all three phase separators
(HPPT,LPPT,LPDT)
11. Dehydrator Separation Efficiency
12. Conduct salt balance result using produced water and wash water sample
analysis
13. Reliability of the online BS&W analyzer.
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Document Responsibility: Oil and Gas Process Engineering Committee. SABP-A-034
Issue Date: 1st July 2018 Plant Performance and Capacity Testing
Next Planned Update: 1st July 2023 Procedure for Upstream Crude Oil Processing
9.4 When the plant throughput beyond the design point is established with no visible
plant limitations:
9.4.1 The new capacity of the plant should not be considered to be a
sustainable capacity i.e. can be maintained for prolonged periods of time.
9.4.2 Should the new throughput is to be considered as the new plant
sustainable capacity; MOC must be initiated in consultation with
P&CSD and CSD to ensure that plant process and equipment integrity is
not jeopardized.
10 Acknowledgment
This best practice initiative has been reviewed by NAOO & SAOO proponents and
P&CSD would like to acknowledge and appreciate their representatives who shared
their experience and input.
Revision Summary
1st July 2018 Revised Saudi Aramco Best Practice.
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