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Prince Mohammad Bin Fahd University C o l l e g e o f E n g i n e e r i n g

Department of Mechanical Engineering

Internship Final Report

At

Saudi Aramco Company

North Ghawar Producing Department

R e p o r t i n g P e r i o d

[16/06/2012 -08/08/2012]

S u b m i t t e d b y

[ A l i M o h a m m a d A l - M a r r i ]

[ 2 0 0 8 0 0 9 0 5 ]

s u b m i s s i o n d a t e ( 1 5 / 0 9 / 2 0 1 2 )

Mechanical Engineering Department

Summer 2012

2012

1

Abstract

I have worked with North Ghawar Producing Department with Operations Division,

Maintenance Division and Engineering Divisions. During the training period, I have worked in

the plant with as well as in the shops. I have spent around 15 days in each division; learning,

gaining new skills and participating in many activities which enrich my knowledge. It has

been new experience for especially when I participated in mothballing one of the facilities and

conducting preventive maintenance for equipment and instrumentations. The above training

activities were very helpful, essential and supportive to future engineering practices.

2

Acknowledgment

My thanks go to all operators, technicians and engineers who worked with me during my

training period. Thanks for their patient and support during this work. Also, my appreciation

goes to my supervisor who supported me to accomplish these works.

3

Table of contents

Page

Abstract 1

Acknowledgments 2

Table of contents 3

List of Figures 4

List of Tables 5

Introduction 6

The Company 7

Activities and responsibilities 11

Major tasks or projects 30

Conclusion 38

References 39

Student Log Sheet ( Appendix D) 40

Student Feedback Form 41

4

List of Figures

Page

Figure 1. All oil and gas fields 8

Figure 2. This figure shows all major vessels and

equipment of the GOSP.

13

Figure 3: Relief valve internal spring 14

Figure 4: Normally close (NC) (used to give alarm when

high level) 15

Figure 5: Normally open (NO) (used to give alarm when

low level) 17

Figure 6: Inboard and outboard locations of Mechanical

Seal 17

Figure 7: Control valves booster 18

Figure 8: Breaker and its Auxiliaries 18

Figure 9: Pipes 19

Figure 10: Valve 20

Figure 11: Excavation job 21

Figure 12: Compaction equipment 22

Figure 13: Transformer 23

Figure14: Motor control center.

24

Figure 15: Galvanic anodes in a Vessel

25

Figure 16: Impressed current system

25

Figure17: Types of scraper

27

5

List of Tables

Page

Table 1. Training schedule, assignments undertaken in

chronological sequence 11

Table 2: Advantages and disadvantages of Galvanic Protection

25

Table 3: Advantages and disadvantages of impressed current

system

26

6

Introduction

My first day with Operations, I met with the team which consists five persons; Foreman of the GOSP,

Shift Supervisor, Console Operator and two outside operators. The work time begins from 6:30 am

until 3:30 pm. However, I came 10 minutes earlier to take the turnover (what happen during last 8

hours) from night shift group. After that, I joined the outside operators to do the daily routine check

for the facility. As Safety is the top priority for Saudi Aramco, we checked first the Fire System which

contains of two fire water tanks and 4 pumps. 3 of those of those pumps are Electrical Pumps and one

is a Diesel Pump. Then, we went through a long checklist to write actual readings for all process

parameters such as vessels’ levels, pressures, and temperatures and communicate with the console

operator by radio to make sure that those readings are matching with the Digital Control Screen

(DCS) in the control room building. Moreover, shift supervisor introduced to me the production

header area with all piping connected to the GOSP inlet. After that, the second two weeks, from June

30 until July 11, 2012, I joined Maintenance Division after completing the first two weeks with

Abqaiq Producing Division ABGOSP-5 operation where I understand the GOSP processes very well.

This division is under NGPD (North Ghawar Producing Department). Every GOSP should have line

maintenance unit to maintain and keep the GOSP functioning safely. This unit consists of three groups

in order to meet the required preventive maintenance schedule for the existed equipment in the

facility, and those groups are Machinist, Instrumentation and Electrical.

As planned, the third two weeks, from July 14 until July 25, 2012, I joined North Ghawar Engineering

Division. This division is under NGPD (North Ghawar Producing Department) and has 4 engineering

units: Plant Engineering (PEU), Technical Support (TSU), Project Coordination (PCU) and Inspection

& Corrosion (ICU). I was assigned with Inspection since it is in charge of inspecting all NGPD

facilities applying Saudi Aramco standards. This unit has three groups (Mechanical, Support,

Corrosion). In the last two weeks from July 28 until August 08, 2012, I continued working with

Engineering Division but with another unit which is Plant Engineering Unit (PEU). I learned plant

engineers’ general requirements and responsibilities and I will share a mothballing procedure for one

facility that I have prepared along with Plant Engineer.

7

The Company

I got a chance to have my internship with Saudi Aramco Company which is the national oil company

of Saudi Arabia and the largest oil company in the world. Saudi Aramco has both the largest proven

crude oil reserves, at more than 260 billion barrels and largest daily oil production. Saudi Aramco

owns the Ghawar Field, the world's largest oil field, and the Shayba Field, one of the world's largest

oil fields. Ghawar is an oil field located in AL-Hasa ,Saudi Arabia. Measuring 280 by 30 km, it is by

far the largest conventional oil field in the world. Ghawar is entirely owned and operated by Saudi

Aramco, the nationalized Saudi oil company. Relatively little technical information is publicly

available, because the company and Saudi government closely guard field performance data and per-

field production details. Historically, Ghawar has been subdivided into five production areas, from

north to south: 'Ain Dar and Shedgum, 'Uthmaniyah, Hawiyah and Haradh. The major oasis of AL-

Hasa and villages are located on Ghawar's east flank, corresponding to the 'Uthmaniyah production

area. Ghawar was discovered in 1948 and put on stream in 1951. Some sources claim Ghawar peaked

in 2005, though this is strongly contested by the field operators. Approximately 60-65% of all Saudi

oil produced between 1948 and 2000 came from Ghawar. Cumulative production until April 2010 has

exceeded 65 billion barrels . Currently, Ghawar is estimated to produce over 5 million barrels of oil a

day (6.25% of global production). Ghawar also produces approximately 2 billion cubic feet of natural

gas per day.

8

Figure 1: This figure shows all oil and gas fields handled by Saudi Aramco. As notice the largest one is the

GHAWAR Field.

The principle company activities are to:

Maximize Profitability

The company is continuously striving to maximize profitability by focusing on achieving

maximum returns from Company assets. Maximizing profitability entails both revenue

enhancement and cost reduction. The Company can achieve revenue enhancement through the

capture of new business opportunities related to its core oil and gas business, enhancement of

efficiency and effectiveness in conducting business and optimization of the business portfolio.

The Company can lower the total cost of production by prudent management of resources,

capturing synergies and leveraging existing investments in people, processes and technology. The

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overall return on assets will be maximized by reducing cost, enhancing facilities utilization and

identifying equipment inefficiencies to increase capacity, availability and yield.

Remain a Reliable Supplier of Oil and Gas

This objective focuses on the Company’s ability to meet global and national commitments for

both Oil and Gas. This objective can be achieved through enhancements in reserves and

production capabilities, operational reliability of facilities, and improvements in logistics. The

Company will intensify its efforts to grow the Kingdom’s hydrocarbon reserves and continually

upgrade its operational and logistical capabilities. At the same time, the Company recognizes that

reliability and maintainability are increasingly important elements in its day-to-day business. In

order to remain a reliable supplier of Oil and Gas and achieve world class operational excellence,

efforts will be made to systematically measure, analyze and improve drivers of key operational

metrics.

Efficiently Meet the Kingdom’s Energy Demand

Continued economic prosperity and social welfare in the Kingdom will largely depend on the

availability of energy in the most economic and cost effective manner possible. This objective

covers a wide array of oil and gas exploration, reserves development, facility expansions,

improved domestic logistics and promotion of efficient use of energy.

Contribute to the Development of the Kingdom’s Economy

This objective focuses on the Company’s position as an enabler for local economic growth, both

in terms of employment and in terms of generating new businesses and ideas. The Company is

committed to further developing the oil and gas based local industries which in turn could help

spawn and grow a wide range of other industries leading to economic diversification. The

Company will also promote the establishment of new local businesses in the manufacturing and

service sectors.

Enhance Research and Technology

This objective is envisioned to deliver the innovations and breakthroughs that will drive growth

of Saudi Aramco’s core businesses, generate solutions that enhance efficiency and profitability of

the Company, contributes to cost reduction and provides technical leadership in select technology

10

areas. It should ultimately lead to maximum value realization and conservation of the Kingdom’s

valuable hydrocarbon resources.

Intensify the Focus on the Safety and Protection of the Environment

This objective focuses on the Company’s continued efforts to keep safety and environmental

concerns at the forefront of its employee’s minds.

Saudi Aramco’s environmental priorities include assuring its facilities compliance with

environmental regulations/standards and increasing environmental awareness in the Company

and the community.

Saudi Armco recognizes and embraces safety as a key goal of the organization and its employees

in order to be successful. An organizational culture that supports safety is essential for the

prevention of injuries, illness, loss of life and properties. The safety culture fits within the context

of Saudi Aramco’s organizational values, behaviors and practices. The Company recognizes that

programmatic approaches to safety issues need organizational and individual alignment.

Prepare the Work Force for the Future

One of the most important factors of Saudi Aramco’s success is its ability to attract and retain

highly skilled and motivated workforce to meet its current and future work requirements. The

Company needs to carefully rethink its future labor needs and what it is doing today to attract and

develop top talent and ensure leadership for the future in light of changing demographics, an

aging workforce, global sourcing for new workforce members, changing business models and

increasing complexity of operations.

I worked with North Ghawar Producing Department that is composed of:

3 Operations Divisions.

Maintenance Division.

Engineering Division.

11

Activities and responsibilities

My job was started with Abqaiq Operations Division where I worked as operator to learn about

GOSP Processes. Then, I joined Mainrenance division and assigned as a multi-purpose technician.

Finally, I worked with Engineering to be exposed to plant engineering general requirements and

responsibilities.

Table 1 below describes the training schedule for all workshops that were attended on a bi-weekly

basis. The details of these activities are described next.

Bi-Weekly

Session Work Performed

1st Abqaiq Producing Division

2nd

Maintenance Division

3rd

Engineering Division/ Inspection Unit (ICU)

4th

Engineering Division/ Plant Engineering Unit (PEU)

Table 1. Training schedule, assignments undertaken in chronological sequence

12

Operations Division

My first day with Operations, I met with the team which consists five persons; Foreman of the GOSP,

Shift Supervisor, Console Operator and two outside operators. The work time begins from 6:30 am

until 3:30 pm. However, I came 10 minutes earlier to take the turnover (what happen during last 8

hours) from night shift group. After that, I joined the outside operators to do the daily routine check

for the facility. As Safety is the top priority for Saudi Aramco, we checked first the Fire System which

contains of two fire water tanks and 4 pumps. 3 of those of those pumps are Electrical Pumps and one

is a Diesel Pump. Then, we went through a long checklist to write actual readings for all process

parameters such as vessels’ levels, pressures, and temperatures and communicate with the console

operator by radio to make sure that those readings are matching with the Digital Control Screen

(DCS) in the control room building. Moreover, shift supervisor introduced to me the production

header area with all piping connected to the GOSP inlet.

After completing two weeks with the GOSP operation, Alhamdulillah I managed to understand the

GOSP processes very well which is the main objective of this assignment. Below is a brief of the

process.

GOSP Purposes:

The GOSP main purposes are

To separate the associated Gas/water from the crude oil.

To remove the salt and wash the oil before it is shipped for further process in order to meet

shipped oil specifications (Salt to be 10 ppm and Base sediment & water to be 0.2%).

To dispose the salty water back to the filed in order to maintain the reservoir pressure

To test the production wells which help in monitoring and managing the reservoir.

13

Process Overview: (refer to figure 2)

Crude oil is introduced first to High Pressure Production Trap (HPPT), through the production header,

where light gases will be separated at 400 psig. Then, the oil will be diverted to Intermediate Pressure

Production Trap (IPPT) where gas is separated at 240 psig. After that the oil is transferred to low

Pressure Production Trap (LPPT) where heavier gases will be separated at 70 psig. After LPPT, the

oil will be pumped by 500 HP charge pumps (4.16 KV) to the Dehydrator, where the bulk of the water

is removed from oil. The dry oil is then sent to the Desalter where the oil is mixed with Wash water

(from Wasia Well) to remove the salt before it is shipped to Abqaiq Plants. The oily-water out from

HPPT, Dehydrator and Desalter are directed to water and oil Separation vessel (WOSEP) where the

oil is separated from the water. The water will be injected back to the field by 4000 HP injection

pumps (4.16 KV) to maintain the reservoir pressure while the oil will be sent back to LPPT through

recovery pump G-213. The HPPT gas will be directed to Shedgum Gas Plant and the gases from IPPT

and LPPT to Abqaiq plants.

Figure 2: This figure shows all major vessels and equipment of the GOSP.

14

Maintenance Division

Every GOSP should have line maintenance unit to maintain and keep the GOSP functioning safely.

This unit consists of three groups in order to meet the required preventive maintenance schedule for

the existed equipment in the facility, and those groups are Machinist, Instrumentation and Electrical.

Machinist group is responsible of the following;

Completing the monthly PM

Having work permit before starting his work

removing or installing valves

hanging bolts

changing gaskets( sheet, metal and steel)

greasing valves if needed

fixing or changing equipment parts changeover

I have learned too many useful things while I was working with this group. For example, removing

vessel’s relief valve which requires following Engineering procedure since it is a critical valve.

Figure 3: Relief valve internal spring

Also, I got in touch with Piping material selection, flange size and thickness which are depending on

the pressure and the fluid type. Also, mechanical seal is a device which helps join systems or

mechanisms (Pump and motor) together to prevent leakage. Bearing is used to hold the shaft and it

15

has two types which are ball bearing and cone bearing. Moreover, sleeve is used to protect the shaft

from getting scratched and it is easy to be replaced without replacing the shaft.

Figure 4: Inboard and outboard locations of Mechanical Seal

The Packing works instead of the mechanical seal and it is only used on simply thing like on the

water pump to reduce the leak and it permits only about 100 droplets/ min to cool up the pump. The

packing could be used in the valves to prevent gas leak. There are different types of packing and it

depends on the heat and liquid absorptions.

Instruments group is responsible of the following;

Completing the monthly PM


Every equipment uses air or send signal to the control room

Learned while with instrumentation Technician;

Every level switch has a vent

Level switch work mechanism; the float rise up when the level rise and it has a magnet at the

end of its rod. When the magnet touches the rod of the level switch, the circuit is closed. Then,

16

the alarm initiated in the control. If high high level is reached, signal is sent to ESD to shut

down.

TCV; temperature control valve can be controlled manually from box called pneumatic

control. By indicating the desired temperature, the valve will open and close to achieve that

temperature by cooling the oil or not.

JCV; power control valve is used to control the power of the compressor by controlling the

flow on the compressor using some calculation inside the control room to find the needed

power for the compressor

To do test on valves using air during shut down two types of air pump are used; Air pump and

Hydraulic pump.

Differences between flow element and flow transmitter; the flow element is very sensitive

and it could be RTD (3 wires; red and 2 whites). The flow transmitter is a group of sensors to

give readings.

The approximator is used to measure the vibration and it contains 3 ports called common, out

and voltage. The approximator needs specified length of wire. Some of them needs 5 and some

others need 9 to deliver accurate measurement. The vibration sensor needs to be very close to

the shaft and it is measured by tho ( 1/1000 in to measure the clearance between the shaft and

the bearing)

Switches There are two types of switches; Normally open (NO) (used to give alarm when low

level) and Normally close (NC) (used to give alarm when high level)

17

Figure 5: Normally open (NO) (used to give alarm when low level)

Figure 6: Normally close (NC) (used to give alarm when high level)

The difference between air failure to open and to close; Air failure to open used for safety

issue to release the pressure and Air failure to close used for safety to keep the levels in the

traps

The booster on control valves used to control the amount of pressure entering to control the

valve.

18

Figure 7: Control valves booster

Electrical group is responsible of the following;

Complete his monthly PM


To fix any electrical problem

Learned while with electrician;

Bugy grounding used to be put in the breaker place to measure the load (bus line, load line)

Meager is used to measure the insulation and continuity

MCC is Master Control Cabinet

Hot stick is used to find the load line (flash light)

Breaker consists of the following;

- Arc shot to catch the stroke of the vinger

- Air is used to remove sparks

- The connector is very wide to stretch the spark

- White cylinder for isolation

- Steal coil to provide magnetic field to help in catching the spark in the arc shoot.

Figure 8: Breaker and its Auxiliaries

Transformer mechanism: the current pass through the coil to provide magnetic field to help

in step up or down by the secondary coil depending on the number of coil.

19

Engineering Division

This division is under NGPD (North Ghawar Producing Department) and has 4 engineering units:

Plant Engineering (PEU), Technical Support (TSU), Project Coordination (PCU) and Inspection &

Corrosion (ICU).

Engineering Division/Inspection Unit

I was assigned with Inspection since it is in charge of inspecting all NGPD facilities applying Saudi

Aramco standards. This unit has three groups (Mechanical, Support, Corrosion).

In below, I will go over the three groups’ activities with the inspection procedure and how they are

implementing Aramco standards on their duties.

Mechanical Inspection:

This group is focusing on three fields; Plant equipment, welding and coating.

A) Plant equipment are the most important portion in the GOSP, so to get efficient operating

equipment you need to implement a high-quality inspection standard before using it. Following are

some of the equipment Valves, Pipes, and Drums.

In this report I will concentrate on those equipment that I have observed their inspection.

Pipes:

Figure 9: Pipes

20

1. Verify the piping layout as installed conforms to the drawings.

2. Verify the weld preparations conform to WPS.

3. Verify the qualifications of all welders (coaters, blasters, other as necessary) on the installation.

4. Verify pre-installation pressure testing of the equipment.

5. Verify the welding consumables ate of the proper type and properly stored.

6. Inspect the internal and external coating.

7. Check for damaged materials and equipment.

8. Verify the preheat treatment of the welds

9. Inspect piping support.

10. Inspect trenching of backfill of ditch, if applicable.

11. Verify post heat treatment of the welds.

Valves:

Figure 10: Valve

1. Locate the specific valve on the P&ID.

2. Identify the valve make and type.

3. Obtain a drawing of the valve.

4. Determine the pressure rating which will be on the valve body as part of the casting.

5. Measure the valve for nominal bore size and flange size.

6. Inspect the valve for corrosion/erosion.

7. Witness the body and seat hydro-test, if hydro-test is required.

21

Support Inspection

The support inspection can be classified into two groups: Civil and Electric inspection.

Civil inspection:

In this part I will go through the major civil inspection jobs:

A) Excavation:

Figure 11: Excavation job

1- Verify location of excavation is correct.

2- Locate vertical and horizontal control references points(if applicable)

3- Verify excavation work meets safety guidelines: slide sloping, shoring, method of (entry, exit,

safety boundary, markets)

4- Verify work in progress: soil type, soil conditions, elevation control, water table and horizontal

control.

B) Filling:

To inspect the filling you should first verify if the preparation of the site is meeting the requirements

then check if the fill meet the requirements e.g. type, gradation, maximum dry density or relative

density test results.

22

C) Compaction:

Figure 12: Compaction equipment

Verify the grading and proof rolling prior to laying first lift and also checking the lifts if it exceeds the

requirements, in addition make sure that the moisture content and uniform are mixed and distributed,

also the compactor should be checked if its meet the requirements, besides monitoring the compaction

efforts e.g. number and direction of passes and noticeable weak spots.

D) Concrete Placement

During the concrete placement the inspector should verify five things

1- Concrete mix

2- Cleanliness of job site concrete handling equipment

3- Temperature of concrete

4- Slump of concrete

5- Use the proper consolidation method

Also the inspector is supposed to inspect the conveying of concrete and methods to prevent

segregation.

23

Electrical inspection:

With the electrical inspection the inspector should stick with the inspection steps in sequence to get

the inspection done safely. In the report I will choose the procedure of the two major equipments

inspection:

A) Inspecting MV oil filled transformer

Figure 13: Transformer

1- Verify that the transformer feeder is tagged and locked out. (High voltage ; gloves and face shield

is needed)

2- Verify that spill and fire containment barriers (dikes, trenches, basins, firewalls, sprinkler system)

are installed where required.

3- Verify the nameplate data.

4- Visually inspect the integrity of the transformers enclosure.

5- Visually inspect the primary and secondary cubicles of transformer.

6- Inspect the primary and secondary cable terminations and verify the torque.

7- Inspect the primary and secondary bushings.

8- Verify the transformer turns ration test results.

9- Verify the megger test results.

10- Verify the dielectric oil test results

11- Verify that all grounds are correct and installed using approved methods.

24

12- Verify that all inspection reports are filled correctly.

B) Inspecting MV motor control center (MCC)

Figure14: Motor control center.

1- Verify that the MCC feeder is tagged and locked out. (High voltage; gloves and face shield is

needed).

2- Verify that all primary, secondary and control power is de-energized.

3- Verify that all component labels are present and correct.

4- Verify the integrity of the MCC housing.

5- Inspect all cable terminations and connections and verify the torque.

6- Inspect the primary and secondary connection points in all breaker compartments.

7- Inspect all compartments for loose parts and tools

8- Verify that the shutters are working correctly.

9- Verify that all racking devices are operating properly.

10- Inspect all bushes and insulators.

11- Inspect all bus connection points and verify the torque.

12- Verify doctor (low resistance test) of all bus joints.

13- Verify that the thermostat and heaters are working correctly.

25

14- Verify that all grounds are correct (size, type, color) and installed using approved methods.

15- Verify hi-pot test results.

Corrosion Inspection:

This group can be organized into two teams Cathadoic protection (cp) and corrosion team.

- Cathadoic protection

There are two types of Cathadoic protection:

A) Galvanic protection

Figure 15: Galvanic anodes in a Vessel

Galvanic anode system is applied when the current requirement is low and it uses sacrificial anodes to

generate the required current, the galvanic system usually used in vessels (Zink), water tanks

(Aluminum), and pipes under road and camel crossings (Magnesium).

Advantages Disadvantages

External power source is not required Driving voltage is limited

Installation costs are low Current output is limited

Maintenance cost are low Effective only in low soil resistivity

Table 2: Advantages and disadvantages of Galvanic Protection

B) Impressed current system

Figure 16: Impressed current system

26

This system is required when high current is needed, it uses rectifier to produce the essential current,

and it’s used on well casing and buried pipelines.

It can be installed horizontal or vertical depending on the conductivity of the soil.

Coke grease is added to the system to increase the flow of the current.

Advantages Disadvantages

High driving voltages High equipment and installation costs

High current outputs High maintenance costs

Adjustable current output low Possible interference problems with

foreign structures resistivity

Table 3: Advantages and disadvantages of impressed current system

- Corrosion group

The main objective of this group is to evaluate the failure cases which occurred, and give

recommendation based on their evaluation. They can evaluate by analyzing the data which they

obtained from the monitoring systems and coupons. Also this group is responsible of the type of

coatings and the material selection.

Through the assignment I have learned that most of the corrosion cases were due to old piping design.

The pipes were designed based on the previous flow rates, so this proves that the velocity of the flow

is an important factor in corrosion occurrences.

That is why the new technologies are required to reduce the corrosion, since the idea of changing the

design to the current flow will cost a lot.

Following is the group techniques to reduce the corrosion:

• Chemical inhibitor

Corrosion inhibitor is injected in three locations; production header, before entering the gas fin fan

and wash water. It’s injected to be mixed with water to form a layer on the pipe to protect it from

corrosion, the corrosion engineer is responsible to calculate and give the exact dosage rate to the

27

operation. In the oil side the inhibitor rate is depending on the water cut while in the gas side it’s

depending on the flow rate.

• Squeezing wells

Corrosion and scale inhibitor are injected to the oil well by a pump and the well should shut in for 48

hours to allow the inhibitor to precipitate on the formation.

• Scraping

The Scraper is used for scales in pipelines that cannot be removed by acid or other chemicals and it’s

applied one in a year. The following figure shows the types of scrapers:

Figure17: Types of scraper

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Engineering Division/Plant Engineering Unit (PEU)

I worked with Plant Engineering to be exposed to their general requirements and responsibilities.

Also, I have participated in preparing a mothballing procedure for one facility at NGPD which was my

major task during my training.

Requirements and responsibilities:

Following are the responsibilities of Plant Engineers:

A. PLANT OPERATION

1. Review the daily plant operation logbook, control room log sheet, field operator log

sheet, charts and the maintenance logbook.

2. Review current alarms, C-LOG, and SER (plant operation alarms/operation status)

report on daily basis and discuss any abnormal operating condition with the Ops.

Foreman and the Senior Engineer or the Supervisor.

3. Walk-down the plant area on daily basis to check for any abnormal condition.

4. Perform equipment/system testing as required.

5. Discuss the plant operation with the Ops. Foreman/Shift Supervisor.

6. Follow-up all maintenance and project activities related to the plant.

7. Explain details of all packages issued by UOED to the operators and the maintenance

group.

8. Discuss well testing and other wells related problems with the responsible production

engineer.

9. Issue the required recommendations to optimize GOSP operations.

10. Review major equipment failures and coordinate/plan long term solutions (as required

with other organizations).

11. Review/evaluate the needs for new material and find substitute in case of

unavailability.

12. Work with operations to maintain Zero (0) overdue relief valves.

B. DRAWINGS/LIBRARY

1. Mark-up and process as-built drawings.

2. Maintain plant library (e.g. filing, updating etc.)

C. PLANT TRIP/UPSET ANALYSIS

1. Collect the data and analyze/troubleshoot to determine the cause of every plant trip or

upset.

2. Prepare trip report.

D. INSPECTION

1. Interface with the area inspectors and discuss inspection activities in the plant.

2. Review and evaluate inspection worksheets.

3. Issue recommendations.

4. Maintain an updated status of all open inspection worksheets.

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E. PACKAGES

1. Familiarize with the application of industry codes and Saudi Aramco Standards.

2. Interface with other groups to resolve technical problems.

3. Familiarize with SAP system and know how to specify various materials.

4. Prepare packages to repair/modify and improve plant equipment/piping/devices.

Perform design calculations as required.

5. Review & comment on modification/design packages prepared by other groups.

6. Issue the flowlines revalidation hydrotest procedure.

7. Issue equipment/ system testing procedures as required.

8. Resolve comments on the packages from the Senior Engineer and the Unit Supervisor.

9. Follow up the implementation of packages in the field.

10. Mark-up the library drawing(s) and issue drawings to CADD Unit for as-built.

11. Follow SAPEMs to prepare all packages.

F. OPERATION INSTRUCTION MANUALS (O.I.Ms) & GENERAL INSTRUCTIONS

(G.Is)

1. Read and understand all O.I.Ms & G.Is as related to the plant

2. Review and update O.I.Ms.

3. The Instrument Set Point O.I.M should be kept updated. An official letter duly signed

by Supervisor, Operations Engineering Unit, is required to revise any set point. The

responsible plant engineer should write the reference letter# authorizing the change in

the set point, initial and date any changes in the plant library copy of the O.I.M.

4. Discuss the O.I.Ms/G.Is with the operators as needed.

G. MAINTENANCE HISTORY

1. Review the maintenance logbook (control room) on daily basis and write briefly the

work done on major equipment in the plant engineer's Maintenance History logbook.

See SAPEM-2 for a copy of the Maintenance History form.

2. Initiate investigations if repetitive failures occur.

3. Update and review the Preventive Maintenance Records with assistance from field

technicians.

4. Review the maintenance history for each work order in the SAP system.

H. JOBLOG/ SHUTDOWN LIST

1. Issue job request to get assistance from other groups as required.

2. Keep the joblog update.

3. Keep the shutdown list updated.

30

Major Tasks and Projects

Road Oil Plant Mothballing Procedure:

Management has decided to close Road Oil Plant (ROP) permanently. Consequently, mothballing

Road Oil Plant (ROP) is required to ensure that the required reliability and integrity of plant

machinery and stationary equipment will be maintained in good condition at a minimum cost.

Since NGED/PEU is responsible to issue the mothballing procedure, I had a great opportunity to work

with them in preparing the procedure. Below is what we have recommended in order to safely

mothball Abqaiq Road Oil Plant (ROP):

Conduct NORM survey at ROP before opening the vessels.

Use Nitrogen as mothballing media and maintain all pressure vessels at 50 psig.

Fire watch should be present during all cutting and welding jobs.

Expedite conducting the mothballing immediately following the ROP shutdown to avoid

corrosion activities due to prolong liquid stagnation.

Below is the required engineering package to mothball the Road Oil Plant (ROP):

BACKGROUND:

Mothballing Package consists of four main sections, which are

I. MOTHBALLING PREPARATION PROCESS FOR ABQAIQ ROAD OIL PLANT

(ROP).

II. ISOLATING, DRAINING, DEGASSING, STEAMING AND CLEANING.

III. PURGING AND MOTHBALLING

IV. MONITORING AND MAINTENANCE

I. MOTHBALLING PREPARATION PROCESS FOR ABQAIQ ROAD OIL PLANT (ROP).

1- Conduct NORM Survey:

A. A NORM survey shall be carried out pre mothballing job.

B. The survey shall include (where applicable):

Radiation dose-rates at the external surfaces of surveyed equipment

Alpha/beta contamination levels (Fixed and Loose)

C. Records of pre mothballing NORM survey shall be maintained by proponents.

D. Based upon the results of pre mothballing NORM surveys, control measures shall be

established to carry out work safely during the work as specified in SAEP-358 sections 7 and

8.

E. During the opening of the vessels, samples should be collected and sent to R&D for further

analysis

31

2- General:

A. Follow all safety precautions at all time.

B. Adequately mitigate hazards associated with the use of nitrogen for mothballing task. All

Saudi Aramco and contractor employess to be fully aware and triened in handulling nitorgen.

C. All Work Permit Should comply with work permit procedure and guidelines listed in GI

2.100.”Work Permit System.

D. Comply With SAEP-P-111 (Grounding)-Bonding (or grounding) of water or steam hose

nozzles will prevent a static electricity discharge.

E. Ensure all blind lists are accurate; tags are available and follow GI 6.012 isolation, lockout

and use of hold tags.

F. Ensure job safety analysis (JSA) for each high risk task is developed, approved and provided.

G. Develop site specific emergency response plan if not in existence for mothballing task, and

during this facility’s mothballing process.

H. Comply with the requirment of GI 2.709 (gas testing procedure).

I. The Operations Foreman will have the overall responsibility for coordinating the mothballing

and conducting safety review prior to the mothballing of ROP. However, the Field Service

Foreman will have the overall responsibility for coordinating the mothballing and conducting

safety review prior to the mothballing of the existing flowlins.

J. Any deviation from this procedure should be discussed with the respective Plant Engineer.

K. Inform area inspection 72 hours prior to the day of mothballing

L. Provide and use personnel protective equipment needed to deal with toxic chemicals.

M. Absolutely no work is allowed on the system while it is under pressure.

N. Schedule fire extinguishers, Scott Air Packs, First Aid Kits and other required safety

equipment and make them ready on site prior to the execution of this job.

O. Provide an adequate number of radios for key personnel to communicate.

P. Work permits must be obtained before any work is performed as per SAES-O-19.

Q. Field verifies all measurements and materials prior to job execution.

R. Ensure that all required material such as mothballing media, safety materials, blinds, gaskets,

filling nozzles, plugs, gauges, and safety equipment are available prior.

S. Empty the water draw-off pit.

T. Drain the water seal pot completely to the drain pit.

3- Shutdown Steps:

1. Close the wing valve of AW # 166.

2. Close inlet ZV-201A.

3. Gradually bring down the level in the Separator (D-103) by pressuring the crude into the

storage vessel (D-111) through the flash pot using the transfer pump (G-007).

4. Reduce the level in the storage vessel (D-111) to the minimum through the loading pump (G-

006) into tankers until low low level is observed by level switch.

5. After reducing the level in the storage vessel (D-111) to the minimum, close ZV-201F along

with the 8”X150# oil outlet isolation valve upstream the loading pump.

6. Depressurize all vessels to zero pressure.

7. Close the two 4”X150# isolation valves upstream and downstream the restricted orifice of

K.O.D. (D-104).

8. Drain and depressurize F/L 166 to zero pressure through the 3”X3000 API kill connection

valve to the well’s drain pit (Vacuum tanker should be on site to collect the drained liquid).

32

9. Swing the 6”X900 # spectacle plate upstream ZV-201A to the close position.

10. Lock closed the 4”X600# globe valve downstream ZV-201A.

ISOLATING, DRAINING, DEGASSING, STEAMING and CLEANING.

1- Vessels

A. Separator (D-103)

NO ACTIVITY RESP. INIT. DATE

1. Ensure that all vessels are at zero pressure ABPD

2. Open the two top vent valves on the separator (D-103). ABPD

3. Close the 6”X600# isolation valve on the separator recycle line

upstream the check valve. ABPD

4. Install two temporary supports below the separator recycle line, one

below recycle line upstream of the check valve. ABPD

5. Lock closed the 6”X150# isolation valve between the separator and

the transfer pump G-007. ABPD

6. Drains the 6” recycle line upstream of the check valve through the

1” drain valve. ABPD

7. Drop the 6”X600# check valve and install 6”X600# blind flange in

place at the upstream side. ABPD

8. Connect a vacuum tanker to the 6”X600# isolation valve. ABPD

9. Open this isolation valve and start draining the separator (D-103) to

the vacuum tanker. ABPD

10. Drain the liquid in the column of LS-21, LG-22 and LT-13. ABPD

11. After ensuring that the separator is completely drained, close the

6”X600# isolation valve. ABPD

12. Open the two 1”X800# vent valves located on KOD-104 upstream

the relief valves (PZV’s 201&202) for venting. ABPD

13. Drain the K.O.D. (D-104) through the 2” bottom drain line to the

drain pit. ABPD

14. Drain the columns of LS-21 and PS-154. ABPD

15. After draining of the K.O.D. (D-104) is complete, close the 2”

bottom drain line. ABPD

16. Remove the 6” dia. Spool(s) of D-103 gas line to KOD-104 and

install 8”X150# blind flange on D-103 side and 6”X150# blind

flange on KOD-104 side as per the sketch.

ABPD.

17. Drop out the 6” oil inlet spool to the separator and install a

4”X600# blind flange downstream the globe valve. ABPD

18. Open the top 6”X150# blinded nozzles. ABPD

19. Line up steam supply to the vessel at the 6”X150# inlet nozzle and

proceed at full steam for 6 to 8 hours. ABPD

20. Conduct gas test, to ensure that the vessel is completely gas free.

Re-steam if necessary. ABPD

21. On the satisfactory gas test, disconnect the steam source and

vacuum tanker. ABPD

33

22. All appropriate vents and drains shall be opened to the atmosphere

and the system steamed until proven to be gas free by taking the

required gas tests at all available vents.

ABPD

23. Allow the vessel to cool off by opening the 18” manhole which will

assist with free venting and the flow of air through the vessel. ABPD

24. Install air blower on the top 6”X150# nozzle to ventilate the

separator at least 24 hours. ABPD

25. The vessel should be inspected to determine the presence of sludge

or scale ABPD

26. If sludge or scale is present, it should be thoroughly wetted and

kept wet until clean-up is completed. Fire watch should be present

when opening the subject vessel.

ABPD

27. Removal of sludge and solid residue can normally be accomplished

by high- pressure water washing (hydro-jetting).

ABPD

28. The subject Vessel should be inspected and recorder any finding. ICU

B. Knock out drum (D-104) “should be done after completing (D-103)”

NO. ACTIVITY RESP. INIT. DATE

1. Provide a rigid support to the vertical section of the gas outlet line

from K.O.D. to flare

NGMS

D

2.

Drop the 6” dia. spool on the gas outlet line of K.O.D. and install

6”X150# blind flanges on the K.O.D gas outlet nozzle and on the

open end pipe.

NGMS

D

3. Remove either PZV-201 or PZV-202 for venting the drum and keep

the 3”X150# isolation valve open. ABPD

4. Drop the oil outlet spool upstream of the restricted orifice (RO-202)

and keep the 4”X150# valves closed. ABPD

5. Connect the steam source to the 4”X150# oil outlet nozzle and then

start steaming the K.O.D.

NGMS

D

6. After steaming is complete, stop steam source and drain it through

the 2” drain line. ABPD

7. Conduct gas test to ensure that the K.O.D. is completely gas free

Re-steam if it necessary. ABPD

8. On the satisfactory gas test, disconnect the steam source. ABPD

9.

All appropriate vents and drains shall be opened to the atmosphere



ABPD

10 Once steam-out has stopped, it is recommended to open the subject

vessels or pipelines as soon as possible in order to be inspected to

determine the presence of sludge or scale.

ABPD


or scale

ABPD


kept wet until clean up is completed. Fire watch should be present

ABPD

34


13. Removal of sludge and solid residue can normally be accomplished

by high- pressure water washing (hydro-jetting). It should be

remembered that inside opened vessels, an air-mover should be

installed to remove any vapors that may be released during the

cleanup. All sludge and scale removed from the subject vessel

should be kept wet until it can be safely disposed of.

Note: For Iron Sulfide or NORM sludge OIM 1.028 and SAEP-358

should be follows respectively.

ABPD


C. Flash pot “should be done after completing KOD-104”Drainage of the flash pot will be

performed during the drainage of the storage vessel (D-111) by gravity force.


1. Lock closes all the 3”X150# isolation valves downstream of the

heaters relief valves. ABPD

2. Make sure that the Flare is off ABPD

3.

Provide a temporary support to the 2” drain line from the flash pot

upstream the oil draw off weir and lock close the 2”X150# isolation

valves.

ABPD

4.

Disconnect the 2”X150# valve on the drain line from the flash pot

upstream of the oil draw off weir and install 2”X150# blind flange

to open end pipe.

ABPD

5. Disconnect the 8”X150# flanges of oil inlet and outlet lines of the

flash pot and blind the open end lines with 8”X150# blind flanges. ABPD

6.

Disconnect the 3”X150# flange on the relief line from the heaters to

the flash pot and install a 3”X150# blind flange to the open end

relief line.

ABPD

7. Disconnect the 6”X150# flange on the flare line from the flash pot

to the flare. Install 8”X150# blind flange to the open end flare line. ABPD

8. Disconnect the sight glass from the flash pot. ABPD

9. Connect the steam source to the gas outlet nozzle and then start

steaming the flash pot. NGMD

10. After steaming is complete, stop steam source and drain it through

the 2” drain line. ABPD

11. Conduct gas test to ensure that the Flash pot is completely gas free.

Re-steam if it necessary. ABPD

12. On the satisfactory gas test, disconnect the steam source. ABPD




ABPD

14. Once steam-out has stopped, it is recommended to open the subject



ABPD


or scale ABPD

35




ABPD

17.

Removal of sludge and solid residue can normally be accomplished






ABPD


D. Storage Tank (D-111) “should be done after completing Flash Pot”

NO ACTIVITY RESP. INIT. DATE

1. Close the 8”X150# inlet isolation valve to the storage vessel. ABPD

2. Lock close the 4”X150# isolation valve on the 4” inlet line from the

loading pump recycle line. ABPD

3. Lock close the 6”X150# isolation valve on the discharge of loading

pump. ABPD

4. Remove the 8”X150# isolation valve on the suction of loading

pump and connect to vacuum tanker. ABPD

5. Remove the 8”dia. Spool upstream the isolation valve of the inlet

line and blind the upstream open pipe by 8”X150# blind flange. ABPD

6. Open the isolation valve and start draining the storage vessel using


7. Drain the column of LS-121,122,123& 124 and level sight glasses. ABPD

8. After ensuring that the vessel is completely drained, close the

isolation valve connected to the vacuum tanker. ABPD

9. Remove the 8”X150# isolation valve on the inlet line and install

8”X150# blind flange with boiler maker. ABPD

10. Line up steam supply to the vessel at the 8”X150# inlet connection,

and proceed at full steam for 6 to 8 hours. ABPD

11. During steaming out process, check the vents to ensure steam is

flowing. ABPD

12. After steaming is completed, the storage vessel shall be drained to


13. Conduct gas test to ensure that the storage vessel is completely gas

free. Re-steam if necessary. ABPD

14. On the satisfactory gas test, disconnect the steam source and

vacuum tanker. ABPD




ABPD

16. Once steam-out has stopped, it is recommended to open the subject



ABPD

36


or scale ABPD




ABPD

19.

Removal of sludge and solid residue can normally be accomplished






ABPD


2- Well

The well will be kept as observation well.

3- Piping

A. Off plot

a. Flowline

The mothballing procedure of the flowline of well #166 shell be according to operation

instruction manual (OIM 1.029).

B. On Plot

a. Process piping

All process pipes should be removed, cleaned and stored in a safe location. This should be

done after ensuring that all pipes are depressurized, drained and can be removed safely.

b. Fire water

The firewater system should be ready for operation all the times. So no mothballing is

required for the firewater system.

c. Instrument Air

These systems can be shut-in without special measures.

4- Valves

All valves should be removed, cleaned and stored in a safe location.

5- Pumps & Motors

All pumps and motors should be removed, cleaned and stored in a safe location.

6- Flare System

Flare systems should be isolated from the flare tip and the in-plant portion mothballed as in-plant

piping. (Relief systems should remain in service where plant vessels/piping contain hydrocarbon

37

gas or liquid). Ground flare tips should be covered to prevent the accumulation of rainwater.

Bottom, low point drains should be left open for ground and elevated flares to drain firewater.

II. PURGING AND MOTHBALLING

After hydro jetting, cleaning and de-watering all vessels:

1- Close all isolation valves, nozzles & manholes except nitrogen connection points and vent

points to prepare for purging. Please refer to attachment-2

2- Introduce nitrogen through determined points and keep purging till you get oxygen reading

equal to 0 % at determined vent points.

3- Close vent points with blind/plug and continue introducing nitrogen till vessel pressure

reaches 50 psig.

4- Remove nitrogen source and install blind on nitrogen connections.

III. MONITORING AND MAINTENANCE

Vessels:


1.

Monitor the subject mothballed vessels after one month from the

date it was mothballed, for the first time, then quarterly for the first

year. After that the monitoring should be semiannually.

ABPD

2. Monitor the vessels regularly to assure positive pressure in the

system ABPD

3. Maintain updated records of the inspection activities. ICU

4. Make decision of re-mothballing when monitoring results fall

below requirements. ICU

38

Conclusion

I have worked with North Ghawar Producing Department with Operations Division, Maintenance

Division and Engineering Divisions (Inspection Unit & Plant Engineering Unit).

After working and participating in the above activities, I realized what it takes to follow procedures,

and perform tasks sharing duties with a team. I did learn a lot about the real world working

environment and gained so many communication as well as technical skills. Those skills that I will be

using later in the future to perform my professional tasks. I do recommend such activity and

participation for all students who are interested to have a head start toward their future professions.

39

References

1.Saudi Aramco Engineering Standards

2.Engineering Encyclopedia

3.http://www.sievert.in/ndt.html

4.Southern Area Plant Engineering Manual

5.Saudi Aramco Engineering Standards

40

Student Log Sheet

Please fill in the form carefully and ensure that it is attached at the back of your Final Technical Report

before uploading onto the Blackboard for your Advisor to grade.

Name of Company: Saudi Aramco

Have you been briefed on the company safety guidelines? Yes / No

Week Work Performed Supervisor's Signature and

Comment

1 Abqaiq Producing Division (Field)

2 Abqaiq Producing Division (GOSP)

3 Maintenance Division (Machinist Group)

4 Maintenance Division (Electrical &

Instrumentations Groups)

5 Engineering Division/ Inspection Unit (ICU)

(mechanical & Electrical)

6 Engineering Division/ Inspection Unit (ICU)

(Civil & Corrosion)

7

Engineering Division/ Plant Engineering

Unit (PEU)

Plant Engineering Responsibilities

8 Engineering Division/ Plant Engineering

Unit (PEU)

Mothballing Road Oil Plant

41

Student Feedback Form

Please fill in the form carefully and ensure that it is attached at the back of your Final Technical Report before uploading onto the Blackboard for your Advisor to grade.

Name of Student: Ali Mohammed Al-Marri.

Student ID: 200800905

Department: Mechanical

Period of internship: June/16/2012 - Aug/15/2012

Company Name: Saudi Aramco Company

Department student was attached to:

Saudi Aramco/North Ghawar Producing Department

Describe briefly your work experience:

I have worked with North Ghawar Producing Department with Operations Division, Maintenance Division and

Engineering Divisions (Inspection Unit & Plant Engineering Unit).

After working and participating in the above activities, I realized what it takes to follow procedures, and perform tasks

sharing duties with a team. I did learn a lot about the real world working environment and gained so many

communication as well as technical skills. Those skills that I will be using later in the future to perform my professional

tasks. I do recommend such activity and participation for all students who are interested to have a head start toward

their future professions.

Was nature of work assigned challenging? Yes/No

Was your work environment satisfactory? Yes/No

Was the work technical in nature? Yes/No

Were you treated as a member of a professional team? Yes/No

Were you able to learn from others? Yes/No

Were you able to talk to your supervisor when needed? Yes/No

Would you recommend that we continue to assign students to this company in future?

Yes/No

Would you work for this company after graduation? Yes/No

Overall, how do you rate the company in providing you

with this training? Excellent / Good / Satisfactory/Poor

42

What new knowledge or skill have you acquired as a result of this internship?

1- I understood the GOSP processes very well.

2- I learned what it takes to maintain the facility from different disciplines.

3- I was exposed to Saudi Aramco Engineering Standards and Engineering encyclopedia.

4- I learned how Saudi Aramco Engineers are preparing the engineering packages referring to their

standards and general instructions.

Which courses, if any, have helped you in learning the new knowledge, skills and technologies needed to do your work?

NONE

What would have better prepared you for this semester's work?

If I am not as a part time student, this will make me concentrate more on my work and reports.

Suggest ways in which you think the Internship Program, as a whole can be improved:

I suggest spending more time in the field as a trainee since I will gain more skills and knowledge.

Date:

Signature of Student:

prince mohammad bin fahd university416c6920416c2d4d... · prince mohammad bin fahd university ......

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