Title : Enhancing LPG capacity at Rabigh bulk plant: A case study on flow optimization and operational efficiency
Abstract:
Rabigh Bulk Plant (RBP) is a critical node in Saudi Arabia’s liquefied petroleum gas (LPG) distribution network, linking upstream production at Petro Rabigh Company (PRC) to downstream domestic demand. Historically, the plant faced throughput constraints that limited sustainable loading capacity, despite PRC’s daily production. This capacity gap translated into operational inefficiencies and significant economic impacts.
To address these challenges, a comprehensive capacity assessment was conducted focusing on hydraulic performance, control valve optimization, and truck loading operations. As part of the implemented modifications, a Pressure Control Valve (PCV) was installed at the pumps’ discharge header to regulate loading pressure, in addition to the adjustment of flow control valve (FCV) set points and system reconfiguration. These improvements successfully enhanced the LPG loading system, enabling the plant to achieve its target capacity while maintaining safe operating pressures and stable flow behavior.
Operational outcomes indicated that 31% reduction in truck loading times, with average durations improving from 41 minutes to 28 minutes. Balanced flow rates across loading system confirmed system reliability, operational stability, and scalability under the new configuration. Importantly, the improvements also translated into significant annual cost savings of $31 MM by minimizing delays, improving truck turnaround, and maximizing product lifting.
This study underscores the significance of system-level optimization in energy infrastructure. By integrating hydraulic simulations with real-time operational monitoring and pressure control, the project not only unlocked latent plant capacity but also delivered measurable improvements in efficiency, safety, and economic value. The findings provide a replicable framework for other distribution terminals seeking to expand throughput without major capital investments.
