Engineering Procedure

SAEP-1664 12 October 2010

Design Guidelines for Crude Oil Stabilizer
Document Responsibility: Process & Control Systems Department

Saudi Aramco DeskTop Standards

Table of Contents

1 Purpose.............................................................. 2
2 Scope................................................................. 2
3 Conflicts and Deviations..................................... 2
4 References......................................................... 2
5 Background........................................................ 3
6 Definitions........................................................... 3
7 Process and Equipment
Design Considerations.................................. 3
8 Stabilizer Reboiler Temperature Control............ 7

Appendix-1: Thermosiphon Loop Design (paper)... 9

Appendix-2: Reboiler Temperature Control
(Sketch)................................................ 18

Previous Issue: New Next Planned Update: 12 October 2015

Page 1 of 1
Primary contact: Fernandez, Gabriel Thomas on 966-3-8735609

Copyright©Saudi Aramco 2010. All rights reserved.

Document Responsibility: Process & Control Systems Department SAEP-1664
Issue Date: 12 October 2010
Next Planned Update: 12 October 2015 Design Guidelines for Crude Oil Stabilizer

1 Purpose

This Procedure provides PROCESS engineering guidelines to design equipment for

crude oil stabilization. This however does not constitute as a minimum requirement,
but must be understood as “in addition to the minimum” that may be required per Saudi
Aramco Standards and Project Design Basis.

2 Scope

The scope of this Procedure for the design of Crude Oil Stabilization Process defines
the mandatory requirements governing the critical aspects of the design of the crude oil
stabilizer and its control, the reboilers, thermosiphon loop and the design of the pre-heat
train if provided.

3 Conflicts and Deviations

3.1 Any conflicts between this Procedure and other applicable Saudi Aramco
Engineering Standards (SAESs), Standard Drawings (SASDs), or industry
standards, codes, and forms shall be resolved in writing by the Manager, Process
& Control Systems Department (P&CSD) with Manager, Project Management
and Manager Proponent Department.

3.2 Direct all requests to deviate from this Procedure in writing to the primary
contact of this document, who shall study the request and respond as suggested
in 3.1 above.

4 References

The requirements contained in the following documents apply to the extent specified in
this procedure:

4.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-364 Process Simulation Model Development and
Support

Saudi Aramco Engineering Standards

SAES-E-004 Design Criteria of Shell and Tube Heat
Exchangers
SAES-L-310 Design of Plant Piping

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4.2 Industry Codes and Standards

American Society of Testing and Materials

ASTM-D-2889 Standard Test Method for Calculation of True
Vapor Pressures of Petroleum Distillate Fuels
ASTM-D-323-90 Standard Test Method for Vapor Pressure of
Petroleum Products (Reid Method)1
ASTM-D-6377-08 Standard Test Method for Determination of Vapor
Pressure of Crude Oil:
VPCRx (Expansion Method)1

5 Background

The need for this Procedure was based on the lack of industry experience, especially
within engineering design companies that were challenged to design crude oil
stabilization facilities. This was evidenced from the design reviews during the project
proposal stage; errors were also carried to detail engineering. These guidelines will
prevent rework; ensure that the facilities are designed with less complexity and save cost.

6 Definitions

TVP: True Vapor Pressure; it is the vapor pressure of the hydrocarbon mixture at its
operating temperature (test method ASTM-D-2889).

RVP: A measure of product volatility, measured in pounds per square inch (psi) at
100°F. The higher the RVP, the more volatile the product is and therefore, evaporates
more readily (test method ASTM-D-6377-08 or ASTM D-323-90).

Crude Oil Stabilizer: Distillation column with feed to the top and/or middle tray to strip
H2S (hydrogen sulfide) and light hydrocarbons to meet H2S and TVP specifications.

Reboilers: Heat exchangers used to provide heat to the bottom of a distillation column.

Thermosiphon: It is a method of circulating liquid in a vertical closed-loop circuit,

without requiring a conventional pump. The circulation is a result of the density
differences caused by heat transfer to the liquid from a heat source.

Trap out tray: Tray designed for total draw of liquid.

7 Process and Equipment Design Considerations

7.1 Stabilized Crude Specification: The crude oil shall be stabilized be meet a
TVP specification of 13.0 psia at a pipeline transport temperature of 140°F.
If process design basis dictates a different transport temperature then the

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Document Responsibility: Process & Control Systems Department SAEP-1664
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stabilization process must ensure that, at the pipeline transport temperature the
TVP must be below 13.0 psia.

The design H2S specification shall be 30 ppm (w/w). However, above TVP
specification shall also be simultaneously met. If the H2S specification results in
TVP greater than 13.0 psia at pipeline transport temperature, then it must be
reduced to lower than 30 ppm, such that the TVP specification is not exceeded
beyond 13.0 psia. The reboiler duty shall be based on the higher duty required
between the TVP and H2S specifications.

However, process facility design will vary depending on the RVP specified for
the crude. Additional cooling facilities may have to be added to ensure TVP of
13.0 psia is met while simultaneously meeting the RVP specifications.
Commentary:

It shall be understood that it is not always possible to meet both the H2S and the
TVP specification simultaneously. However, the TVP shall not exceed 13.0 psia
while trying to meet H2S specification. Similarly, the H2S specification shall not
be exceeded, it may be necessary to lower the TVP below 13.0 psia specification
to meet the H2S specification.

7.2 Stabilizer Feed Preheat Train: Crude oil Stabilization process design shall
incorporate energy conservation to recover the heat from the stabilized crude
bottoms.

If crude oil stabilization is done within the battery limits of the GOSP, then the
feed preheat train shall ensure heating the crude to a temperature not to exceed
140°F, to facilitate the breaking of emulsions, prior to dehydration/desalting.
This may be done with or without a preheater on the crude feed to the stabilizer.
(Note: Higher temperatures are not recommended to ensure enough margin is provided
to avoid vaporization in Dehydrator/Desalter at typical operating pressures).

Where the GOSP and stabilization process are far removed from each other (i.e.,
Stabilizer is not a part of the GOSP) then the crude bottoms shall preheat the
feed to the column (Stabilizer). Where this scheme is used, the feed shall be
split to provide optimum heat transfer and column design. There may be other
means of recovering the energy from the column bottoms.

The preheat train shall be designed to minimize heat transfer equipment cost.
However, if necessary process design shall build in flexibility to cool the
stabilized crude to the pipeline by fin fan coolers, if summer crude inlet
temperatures are not low enough to allow pipeline transport at < 140°F. The
other option is deep (higher bottoms temperature) stabilization to meet TVP of
13.0 psia at the higher pipeline temperature, but this may affect the RVP spec.

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Document Responsibility: Process & Control Systems Department SAEP-1664
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The optimum combination shall be determined during the project proposal phase
based on flexibility and available economics.

The process simulations shall be based on the latest version of the approved
simulation software. The process simulation software that will be used in a
project shall be concurred by P&CSD. Simulation development shall conform
to the guidelines given in SAEP-364.

7.3 Stabilizer Column Design: The crude oil stabilizer shall be designed to operate
at not more than 3.0 psig at the top of the column. For operating pressures
higher than 3.0 psig, concurrence shall be obtained from the Primary Contact of
this Procedure. The low pressure operation of the stabilizer column ensures low
reboilers duty, low bottoms temperature, thereby reduced rate of fouling.

Multiple feeds to the column will be based on feed preheater design (not more
than two).

The column trap out tray (feed tray to the reboilers) shall be designed as a single
tray within the column, despite the number of tray passes or reboilers connected
to the column. The different reboilers shall be fed from the common trap out
tray. (Separate trap out trays for individual reboiler feeds shall not be designed,
even if balanced outside the column). The column tray design, including the
trap out tray, shall be performed by tray vendor.

The column shall be designed with trays, primarily due to the fouling nature of
crude (packings shall not be used).

The re-boiled fluid (vapor/liquid mixture) returned from the reboilers shall be
designed to enter below the trap out tray.

The reboilers hydrocarbon feed and return lines shall be equipped with through
conduit valves to facilitate isolation.

7.4 Reboiler Design: The Reboiler/s shall be designed as once through

thermosiphon Reboiler/s and not as circulating thermosiphon reboilers. Such a
design reduces the vapor loading to the bottom tray; the benefits are reduced
column diameter and less likelihood of flooding.

Reboilers shall be designed to operate horizontally with crude on the shell side
and heating medium on the tube side of the heat exchanger and in accordance
with SAES-E-004.

Multiple Reboilers shall not be designed to operate in series. This is required to

eliminate high pressure drop in the thermosiphon loop.

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7.4.1 2 x 50% Reboilers: Normal design shall provide 2 x 50% reboiler

installed capacity, with one ready spare tube bundle in warehouse.
Reboiler design could be optimized based on existing reboiler designs to
provide common spare bundle/s. Such a design shall provide dedicated
nozzle on the column and independent piping to each reboiler. The trap
out tray shall be common (to any nozzle) and piping to the reboilers shall
not be externally connected to makeup 100% reboiler design flow.
Reboiler outlet piping shall also be segregated. All such piping shall be
geometrically symmetrical.

7.4.2 2 x 100% Reboilers: Design philosophy where 2 x 100 % reboilers are

provided must consider that only one reboiler shall operate during
normal operation. Operating two in parallel for such design will lead to
excessive fouling and thermosiphon loop instability. Such a design shall
provide dedicated nozzle and independent piping to each reboiler. The
trap out tray shall be common (to any nozzle) and piping to the reboilers
shall not be externally connected to makeup 100% flow to each reboiler.
Reboiler outlet piping shall also be segregated. All such piping shall be
geometrically symmetrical.

7.4.3 4 x 25% Reboilers: Such a design shall provide one ready spare tube
bundle in warehouse. The reboilers shall be arranged two (50%
capacity) on either side of the column. The trap out tray shall be
common (to any nozzle) and feed to the reboilers on each side through a
common line from the column externally split to feed each of the 25%
reboilers on one side. If this is done, then the outlet or return to the
column from each side shall be connected to provide a single line to the
column. All such piping shall be geometrically symmetrical.

7.5 Thermosiphon Loop Design: Design shall ensure vapor equalizing line
(Appendix-1, Figure-4) is provided from the vertical section of each
thermosiphon loop, to equalize with the vapor pressure in the column above the
trap out tray. The connection on the thermosiphon loop shall be made at the top
of the line above the vertical section as shown in Figure-1. This is to ensure that
the equalizing line connection is not made in the liquid section of the
thermosiphon loop.

Design shall ensure that there is no slug flow in the thermosiphon loop.
Changing line diameter is one way to eliminate the slug flow.

Design contractor shall ensure detailed hydraulic calculations are provided as

per the guideline provided in Appendix-1. Hydraulic information for Available
Head for Thermosiphon Flow (AHTF) and Required Head for Thermosiphon
Flow (RHTF) shall be included in this check.

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Document Responsibility: Process & Control Systems Department SAEP-1664
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7.5.1 Reboiler Piping: The piping design shall be independent to each

reboiler and symmetrical as mentioned in paragraphs 7.4.1 through 7.4.3
above.

7.5.2 Reboiler piping and Thermosiphon Loop Design shall be designed as

described in Appendix-1.

7.5.3 The piping shall be designed in accordance to SAES-L-310.

7.6 Steam Injection: Where steam is available, steam shall be injected into the
crude upstream of the reboiler to facilitate higher vaporization within the
reboiler at lower processing temperature, due to the partial pressure effect of
steam. Process simulation shall determine the optimum steam injection rate to
meet the TVP and H2S specifications; however, as a guideline 12.0 lbs/hr of
steam is required per 1000 barrels/day of crude processed.

8 Stabilizer Reboiler Temperature Control

The heating medium for the shell and tube heat exchanger reboiler shall be preferably
60 psig steam or hot oil where steam is not available. Hot water system is not
recommended.

8.1 Steam Heating: Where steam is used for heating, the design shall use 60 psig
saturated steam with less than five degrees Fahrenheit (<5°F) superheat. Higher
pressure steam results in high tube skin temperatures and increased fouling.

The reboiler shall be designed with condensate subcooling to a temperature

<180°F to prevent condensate from flashing in the condensate collection header.
It is common knowledge that continuous flashing and condensing of steam in
the return header after the temperature control valve (TCV) (Appendix-2) causes
continuous hammering of the return condensate lines, and can result in
mechanical failure of the header. Higher subcooled temperatures are acceptable
in so far as the return header back pressure is maintained to attain condensate
temperature 10°F below the flashing temperature in the entire length of the
header, prior to discharging into the condensate drum. The condensate header
must enter the drum horizontally. If a back pressure control valve is used it shall
be located close to the condensate drum.

The temperature control scheme shall be designed according toAppendix-2.

The reboiler crude oil outlet temperature is controlled by steam heating and
flooding the tubes with condensate. The TCV on the condensate line is
normally controlled by the fluid temperature from the reboiler to the column.
However, the TCV will not let uncondensed steam out as the controller has a
temperature override from the condensate temperature out of the reboiler.

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For multiple systems connected to a common condensate header, a condensate

backpressure controller may be provided and shall be located close to the
condensate return drum. The pressure setting shall ensure there is a minimum of
+10°F gap between the equilibrium condensate temperatures for the pressure
setting on the header and the condensate from the reboilers (return condensate
temperatures being lower); this will prevent hammering in the line from flashing
condensate.

8.2 Hot Oil Heating: Where steam is not available hot oil heating shall be
provided. However, the reboiler inlet temperature for hot oil shall not exceed
390°F.

Revision Summary
12 October 2010 New Saudi Aramco Engineering Procedure.

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Document Responsibility: Process & Control Systems Department SAEP-1664
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Appendix-1
Thermosiphon Loop Design

What went wrong in the Design of the Total Drawoff

Tray and the Thermosiphon Loop on a Crude Oil
Stabilizer Column?

By

Gabriel T. Fernandez
Saudi Aramco

Presented at the Distillation Topical Conference, AIChE Spring Meeting,

Tampa, Florida, April 2009
April 27, 2009
Tampa Convention Center
#26 - Improved Design and Operation in Refinery Distillation (T8001)
Paper # 26c

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Document Responsibility: Process & Control Systems Department SAEP-1664
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Introduction

The subject of discussion deals with the crude expansion program for which new crude oil
stabilizers were being designed. Typically, the capacity of each stabilizer could range from
300,000 barrels per day (bpd) to as high as 750,000 and sometimes 950,000 bpd.

Prior to getting into the subject matter of this paper, information on the facility will help to
understand the design aspects better, refer to Figure -1 for the ensuing discussion. Crude oil
stabilizers are similar in design; their function is to strip H2S (hydrogen sulfide) and light
hydrocarbons from crude to meet H2S and True Vapor pressure (TVP) specification for crude
transportation and storage. It is a distillation column with feed to the top (stripping section
only); sometimes for very light crudes a rectification section is included to contain desirable
fractions in the crude.

Energy for heating to strip the H2S and light ends is provided by reboilers. This particular
design uses once through thermosiphon reboilers. The crude oil from the bottom tray of the
column is collected in a trapout tray (drawoff tray) with total drawoff. From here it is directed to
the thermosiphon horizontal reboilers that are heated by 60 psig (~ 300oF) steam, the vapor
liquid mixture from the reboilers is returned to the column at an elevation below the drawoff
tray. The stabilizers operate at a pressure of ~6 psig at the top of the column; this ensures low
reboiler duty, low bottom temperature and thereby reduced rates of fouling.

Equipment Design

The following discussion is an example of an area for potential error that can be made in the
design of the entire thermosiphon loop. It will also help in trouble shooting existing
thermosiphon operations of similar design.

The once through thermosiphon loop consists of (Figure -2) the section associated with the
tower (Part A) that is the total drawoff tray with its appurtenances and the outlet nozzles that
are normally designed by the tray vendor. The part outside the tower (Part B), starting from
the column flange consisting of the reboiler inlet piping, the reboiler and the return piping are
designed by the engineering contractor.

Typically the contractor designs the inlet piping to the reboilers. The piping takes off from the
column to match the nozzle diameter, the line size is reduced after it splits and then enters the
reboiler. After the reboiler, the return line size is increased and is much larger as it now has to
accommodate the two phase flow, it then enters the column. The liquid and vapor separate
inside the column, the vapor travels upward and the stabilized crude oil collects in the bottom
of the column, and is pumped out to storage. After the crude is cooled in heat exchangers it is
shipped.

The tray vendor was requested to provide the drawoff tray hydraulics (for the part A, Figure-2);
the results indicated the liquid head that would build up, above the drawoff nozzle, for normal
flow to provide the required drawoff rate.

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Similarly, the design contractor was also requested to provide the hydraulics of the
thermosiphon loop corresponding to Part B (Figure-2). The hydraulics indicated that for the
required thermosiphon flow it was sufficient to have the liquid head in the reboiler inlet piping.

This indicated that there was a disconnect between the hydraulics presented by the tray
vendor and the design contractor. The tray vendor indicated that the level in the loop would be
in the drawoff tray, whereas the design contractor indicated that the level would be in the
vertical section of the loop feeding the reboiler. Looking at the hydraulics in isolation both
were right, but in reality the drawoff tray is an integral part of the thermosiphon loop. This
discrepancy meant that the system performance would be unstable and was caused by the
segregated handling of the design.

The design contractor and the tray vendor were informed that the system as designed would
not operate in a stable manner due to flashing. The thermosiphon flow would not be
continuous and would be unstable and pulsating.

To rectify the design, the design contractor was requested to provide a vapor equalizing line
from the elbow of the vertical section of each thermosiphon loop feeding the reboilers, to the
vapor space above the drawoff tray in the column (Figures -2 & 4). This also ensured that the
equalizing line connection was not made in the liquid section of the thermosiphon loop. The
nature of the hydraulics results in the drawoff to flash in the vertical section of the inlet to the
reboilers and the suggested new line would equalize the pressure with the tray above, thereby
ensuring a continuous and stable flow in the thermosiphon loop.

Design Example

The following example will illustrate the above discussion on hydraulics.

Refer to Figure-3. The design crude feed to the column is approximately 735,000 barrels per
day (bpd) at standard conditions (60oF).

The oil from the bottom tray is collected in the trapout tray. There are two 36 inch outlet
nozzles each diverts 50% of the flow to the reboilers (approximately 379,000 bpd at actual
conditions including internal reflux) on each side of the column.

In each loop, the crude flows to the shell side of two sets of horizontal thermosiphon reboilers
and then returns, via a 48 inch header, to the column. In the return header to the column the
flow is two phase. (The same is true of the other loop).

The thermosiphon loop hydraulics is described in Table-1.

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Table-1
Head
Description
psi in
Oil head in Trapout tray: The flow through the 36 inches (in) outlet nozzle is 50% 4.94(1)
of the total flow to the thermosiphon reboilers; the other 50% goes to the second
loop with its own thermosiphon reboilers.
This part shows that the level of oil is at least approximately 4.9 in over the nozzle
diameter in the trap out tray.

Pressure drop in the loop Delta P

Section feeding the reboilers psi ft
The loop section S to A1: (S-S1-Ao-A-A1)…Trial 1 0.170
36 in nominal size and is approximately 86 ft long as shown in Figure-3.
The flow is single phase (Based on Available Head 48.7 ft)
(Available head=top of level in drawoff tray to bottom of reboiler)

Actual delta P…final trial (Based on required head 16.44 ft from trial and 0.142
error calculations).
Section A1 to B: 24 in identical header to one of the two reboilers and is 12 ft 0.0448
long (single phase)
Section B to E: 16 in identical header to each of the two nozzles on the reboiler 0.1014
section; almost 5 ft long (single phase).
Section E to E1: Flow through the exchanger (being heated and phase change) 2.0

Section returning from the reboilers psi

Section E1 to E2: 36 in identical header from each of the two nozzles on the .021
reboiler; almost 5ft long (two phase).
Section E2 to F: 36 in identical header from each of the reboilers; almost 9 ft long .0517
(two phase).
Section F to G2: 48 in common section return to the column about 71 ft long .4054

Static Head
Static head: From reboiler inlet nozzle through the reboiler and the return line to 3.1584(2)
the column (section E through G2)
Delta P in the entire loop Trial 1 2.7943
Delta P in the entire loop Final Trial 2.7666
Total static head + delta P in the entire loop Trial 1 5.9527 16.52 (ft)
static head + delta P in the entire loop final Trial (Figure-2) 5.9250 16.44 (ft)

1- J. A. Kaferle, Jr; Chemical Engineers Calculation and Shortcut Deskbook

2- D.Q. Kern, Process Heat Transfer

NOTE: The intent of the hydraulic values in Table-1 is for illustrative purpose only.

From the above Table-1 we see that the minimum head required for the thermosiphon flow on
the inlet side of the reboiler is 16.44 ft (Figure-2), and this head will give us the required flow
through the thermosiphon loop, we can call it Required Head for Thermosiphon Flow (RHTF).
The Available Head for Thermosiphon Flow (AHTF) is from the top of the liquid head in the
trapout tray (Figure-2) to the inlet of the reboiler, therefore, the total AHTF is 48.7 ft (46.8+
18/12+4.94/12).

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The inlet line to the reboilers is capable of a lot more flow than the 379,000 bpd if the line is full
from the inlet of the reboilers to the top of the level in the drawoff pan on the column.
The feed available is around 379,000 bpd and cannot meet the hydraulic demand of the loop.
As a result, the liquid flashes in the loop to balance the hydraulics (Figure - 4), thereby the flow
reduces to a rate lower than that available from the trapout tray. The liquid head then builds
up in the loop; once enough head builds up, the liquid starts flowing again. The nature of the
flow in the loop is unstable and pulsating.

Providing a balance or equalizing line from the vapor space on the thermosiphon loop to the
column space above the trapout tray splits the thermosiphon loop into two systems. The first
system is the trapout tray and the nozzle up to the balance line connection. The second
system is the rest of the loop. With the provision of the balance line, each section works
independently of the other. The liquid finds its own head in the trapout tray and flows
uninterrupted. Similarly, the liquid finds its own level in the thermosiphon loop, balanced by
pressure in the column, and thus flows in a stable manner.

Conclusion

For a once-through thermosiphon loop, feeding from a total or partial drawoff tray (trap out
pan) — if the required head for thermosiphon flow (RHTF) is lower than the available head for
thermosiphon flow (AHTF) — an equalizing line must be provided on the vertical section of
each thermosiphon loop (Figure-2). This design equalizes the pressure in the line with the
pressure in the column, above the trap out pan. In any case, it may be a good idea to provide
such an equalizing line, as it relaxes the stringency in the hydraulic design of the loop and
assures continuous and stable flow in the thermosiphon loop. The equalizing line connection
on the drawoff line could also be made at the top of the line, in the vapor space close to the
vertical section, within the mechanical design constraints.

Definitions

AHTF- Available Head for Thermosiphon Flow equals top of level in drawoff tray to the bottom
of the inlet to the reboiler.

RHTF- Required Head for Thermosiphon Flow is calculated by trial and error, and is the head
on the inlet side of the reboiler to overcome the loop pressure drop and the static head
on the return loop including the reboiler.

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Figure-1

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Figure-2

Part A Equalizing line

Drawoff Tray Part B – piping outside the

column
Vapor
Two phase – liquid + vapor

Liquid

Stabilizer
Column 46.8 ft 42.9 ft

AHTF 48.7 ft RHTF 16.44 ft

Reboiler

Liquid phase

AHTF - Available Head for Thermosiphon Flow

RHTF- Required Head for Thermosiphon Flow

For AHTF > RHTF, provide Equalizing Line

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Figure-3

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Figure-4

Graphical View of the Fluid Behavior

Equalizing
line

Head required
in tray

Liquid Flashes if
no equalizing line

Head required in pipe

for thermosiphon flow
Vapor

Return from
reboiler

Liquid

To reboiler

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Appendix-2: Reboiler Temperature Control (Sketch)

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