A Smart-In-Situ-Proactive Approach for HSE-Integrity of Facility Monitoring-Assuring and Shutdowns Optimization, Main Oil Stabilization Column Re-boiler Case Study
Authors: Al-Hammadi Ibrahim Thani , Al Bishr Ibrahim M. , Yahiaoui Ahmed , Aly Samir Handak , El-Farmaoui Mohamad Ahmad 
Published: December 2014

Gaining customers satisfactions is the utmost supplier's ultimate goal for their end products domestically and internationally. Therefore; Abu Dhabi Company For Onshore Oil Operations (ADCO) has been always keen to applying state-of-art technology of intelligent and integrated field (i-field) along with Collaborative Work Environment (CWE) and Field Data Integration System (FDIS) capabilities in order to manage fields HSE-Integrity and deliver mandated production at the required industry specifications. This strategy enabled monitoring hydrocarbon processing facility via generating continuous Triggers and Trends (T&Ts) to monitor rotating and static equipment performances and intervene proactively via analyzing reported data such as temperature profiles across Stabilization Column, Compressors vibrations, Glycol consumptions at the dehydrations system, Deslaters etc…

Stabilization column is considered the heart of the operation where most essential separations of light components of hydrocarbon goes through for liberation of gases and delivering stable crude for export.

Throughout years of operation modes, it was numerously observed that stabilization column main re-boiler revealed history of multiple-malfunctioning and substantial thermal efficiency decay which resulted temporarily in having negative impacts on meeting the design specifications of oil in terms of Raid Vapor Pressure (RVP), salt and water contents.

Therefore; to restore re-boiler efficiency, it conventionally dictates total facility shutdown for off stream inspections and maintenance where complicated mechanical cleaning and repairs by specialized contractors carried out. It eventually ends up with substantial production losses and huge unbearable cost and time. This as well involves use of heavy duty tools/equipment such as cranes/machines where risks of working at height and/or under suspended loads which are ones of ADCO Nine Life Protection Rules (LPRs).

To overcome normal worldwide industrial practices and avoid intolerable fatal risks that may happen, an alternative applicable SMART and creative approach is fashioned. This cleaver tactic is introduced where re-boiler is cleaned in-situ by being pickled into inhibited fresh water for several times till Total Solids and Salts (TSS) is fully recovered. Once salts contents are measured at very low percentage, the system is boxed up and operations are resumed consequently.

The truth is that "Thinking outside the Box Safe Approach" had derived this initiative. It targeted avoiding unexpected and/or prolonged shutdown periods, sustain productions, satisfy integrity desires, restore Stabilization column temperature efficiency, enhance HSE culture in ADCO operating sites, maximize usage of resources, improve contributed young United Arab Emirates (UAE) nationals competency and optimize contracted activities costs.

This paper aspires to share the valuable experience gained by applying this brave methodology in one of ADCO fields for maximizing similar process equipment efficiency, and to establish the best practices adoption guidelines for other field operators.