yanpet report

1

YANBU Industrial College

Department of Mechanical Engineering

CO-OP Training Program

Final Technical Report

[Company: YANPET CO., Yanbu Al Sinaiyah]

MET 320

The Cooperative training report presented to the YANBU Industrial College

By

Anas Marwan Kaki (302038)

In partial fulfillment of the requirements for the award of Associate degree in

Mechanical Engineering (Manufacturing specialization)

COOP 20123

September 2013.

MET

DE

P A R T M E NT

MEC

HAN

IC

AL EN

GINEERING TECHNOLOGY

3

In the name of Allah the Beneficent, the Merciful. All praise is to him, who

taught by the pen, and taught man what he did not know. Peace be upon Mohammad, the unlettered prophet, whom he set as a teacher, guide

and mercy to all mankind.

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Acknowledgment

At the beginning I would like to thank almighty Allah for his guidance and protection

throughout my life and for helping me to complete my final report and for finishing all my

courses successfully.

Also, I would like to thank YANBU Industrial College and Mechanical Engineering

Department for giving me this opportunity to get an experience on working in the field and

dealing with others and for giving me all the supports. Thank you to the industrial affairs

department and to the COOP/summer training coordinator in the mechanical department. A

special thanks to Engr. CHANDRAKANT SHITOLE for all the supports and helps during my

coop training period.

Furthermore, I would like to thank YANPET COMPANY for giving me the chance to get

trained in it. Also I would like to thank all the members in the Vibration Department for all

their support during the training period. A special thanks to my superintendent Mr. MAJED

AL-HARBI.

Finally, I would like to thank all my friends for supporting me during my study period. A

thank you goes to my parents for all their support through my educational years.

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Introduction

On 4/9/2013, I was finished my co-op training period at Saudi YANBU Petrochemical

Company (YANPET) which was for 14 weeks.

However, I have to submit a report to YANBU Industrial College (YIC) that describes the

main activities and experiences that I have gained and learned from YANPET Company

during my training period.

So that, I wrote a report that contains four chapters. The first chapter talks about an

introduction to YANPET Company, such as an information about YANPET, production of

YANPET, YANPET vision & mission, and YANPET units.

The second chapter talks about safety, such as basic safety rules, work permits, and personal

protective equipment (PPE).

The third chapter talks about a theoretical background about my department (Vibration

Analysis), such as definition of vibration and vibration analysis, application of vibration

analysis, vibration characteristics, vibration analysis charts, and the causes of vibration.

Also this chapter talks about the different activities that I did during my co-op training period.

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Table of Contents

Chapter 1

1. INTRODUCTION

1.1. About YANPET ………………………………………………………….....13

1.2. YANPET Vision & Mission………………………………………………...13

1.3. Production of YANPET……………………………………………………..13

1.4. YANPET Plants……………………………………………………………..14

1.4.1. Utilities and Offsite…………………….........................................14

1.4.2. Olefins…………………………………………………………….14

1.4.3. Ethylene Glycol………………………………………..................14

1.4.4. Polymer………………………………….......................................14

Chapter 2

2. SAFETY

2.1. What is safety………………………………………………………………..16

2.2. Basic Safety Rules…………………………………………………………...17

2.2.1. Follow Safe Practices……………………………………………..17

2.2.2. Avoid Unsafe Activities…………………………………………..17

2.2.3. Protect Yourself…………………………………………………..18

2.3. Work Permits………………………………………………………………...18

2.3.1. Hot Work Permit………………………………………………….19

2.3.2. Cold Work Permit……………………………………...................20

2.3.3. Confined Space Entry Permit……………………………………..21

2.4. Personal Protective Equipment (PPE)………………………….....................22

2.4.1.1. Head Protection………………………………………………….23

2.4.1.2. Eye Protection…………………………………...........................23

2.4.1.3. Ear Protection……………………………………………………24

2.4.1.4. Body Protection………………………………………………….24

2.4.1.5. Hand Protection………………………………………………….25

2.4.1.6. Foot Protection…………………………………..........................25

2.4.1.7. Respiratory System………………………………………………26

2.4.1.8. Safety Harness………………………………………...................26

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Chapter 3

3. Theoretical Background

3.1. What is vibration…………………………………………………………….28

3.2. Machine Vibration………………………………………..............................28

3.3. Vibration Analysis…………………………………………………………..29

3.4. Application of vibration analysis…………………………………………....29

3.5. Vibration Characteristics………………………………………....................29

3.6. Vibration analysis charts……………………………….................................30

3.6.1. Trend chart………………………………………………………..30

3.6.2. Spectrum chart…………………………………………………....31

3.6.3. Time waveform chart………………………………………….….31

3.7. Causes of Vibration…………………………………………….....................31

3.8. Work Done No.1……………………………………………….....................32

3.8.1. Work Objective and Goal...............................................................32

3.8.2. Theoretical Background..................................................................32

3.8.3. Safety Requirement.........................................................................34

3.8.4. Work Details…………………………………………...................34

3.8.5. Man power and device used………………………………………35

3.8.6. Sequence of Work……………………………………...................36

3.8.7. Result…………………………………………………..................36

3.8.8. Conclusion……………………………………………..................36

3.9. Work Done No.2 ……………………………………………………………37

3.9.1. Work Objective and Goal...............................................................37

3.9.2. Theoretical Background..................................................................37

3.9.3. Safety Requirement……………………………………………….38

3.9.4. Work Details…………………………………………...................39


3.9.6. Sequence of Work……………………………………...................41

3.9.7. Result…………………………………………………..................41

3.9.8. Conclusion……………………………………………..................41

3.10. Work Done No.3…………………………………………………………….42

3.10.1. Work Objective and Goal………………………………………...42

3.10.2. Theoretical Background…………………………………………..42

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3.10.3. Safety Requirement…………………………………………….....43

3.10.4. Work Details……………………………………………………...43


3.10.6. Sequence of Work………………………………………………...45

3.10.7. Result……………………………………………………………..45

3.10.8. Conclusion………………………………………………………..45

3.11. Work Done No.4…………………………………………………………….46




3.11.4. Work Details……………………………………………………...47


3.11.6. Sequence of Work………………………………………………...49

3.11.7. Result & conclusion………………………………………………49

3.12. Work Done No.5…………………………………………………………….50




3.12.4. Work Details……………………………………………………...51


3.12.6. Sequence of Work………………………………………………...52

3.12.7. Result & conclusion………………………………………………53

Chapter 4

4. Conclusion & References

4.1. Conclusion…………………………………………………………………...55

4.2. References…………………………………………………………………...56

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List if Figures

Figure 1.1: Utilities & Offsite Plant………………………………………………………....14

Figure 1.2: Olefins Plant…………………………………………………………………….14

Figure 1.3: Ethylene Glycol Plant…………………………………………………………...14

Figure 1.4: Polymer Plant…………………………………………………………………...14

Figure 2.1: Safety first……………………………………………………………………….16

Figure 2.2: Hot work permit………………………………………………………………....19

Figure 2.3: Cold work permit………………………………………………………………..20

Figure 2.4: Confined space entry permit…………………………………………………….21

Figure 2.5: Personal Protective Equipment (PPE)…………………………………………..22

Figure 2.6: Head protection………………………………………………………………….23

Figure 2.7: Eye protection……………………………………………...................................23

Figure 2.8: Ear protection……………………………………………………………………24

Figure 2.9: Body protection………………………………………………………………….24

Figure 2.10: Hand protection………………………………………………………………...25

Figure 2.11: Foot protection…………………………………………………………………25

Figure 2.12: Respiratory system……………………………………………………………..26

Figure 2.13: Safety harness…………………………………………………………………..26

Figure 3.1: Movement of a pendulum………………………………………………………..28

Figure 3.2: Machine vibration………………………………………………………………..28

Figure 3.3: Vibration analysis………………………………………………………………..29

Figure 3.4: Vibration parameters…………………………………………………………….30

Figure 3.5: Trend chart………………………………………………………………………30

Figure 3.6: Spectrum chart…………………………………………………………………..31

Figure 3.7: Time waveform chart……………………………………………………………31

Figure 3.8: Centrifugal compressor………………………………………………………….33

Figure 3.9: Centrifugal compressor diagram………………………………………………...33

Figure 3.10: Journal bearing side wall wear out…………………………………………….35

Figure 3.11: Journal bearing side wall………………………………………………………35

Figure 3.12: Damage on impeller holder……………………………………………………35

Figure 3.13: (SKF device) for measuring compressor vibration…………………………….35

Figure 3.14: Steam turbine…………………………………………………………………..38

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Figure 3.15: Steam turbine diagram………………………………………………………....38

Figure 3.16: Steam turbine spectrum………………………………………………………..39

Figure 3.17: Seized ball bearing……………………………………………………………..40

Figure 3.18: Shaft rubbing marks…………………………………………………………...40

Figure 3.19: (SKF device) for measuring turbine vibration………………………………....40

Figure 3.20: Extruder………………………………………………………………………...42

Figurer 3.21: Extruder spectrum……………………………………………………………..43

Figure 3.22: Extruder locking gib………………………………………................................44

Figure 3.23: (SKF device) for measuring extruder vibration………………………………...44

Figure 3.24: Centrifugal pump……………………………………………………………….46

Figure 3.25: Centrifugal pump diagram……………………………………………………...47

Figure 3.26: Centrifugal pump spectrum…………………………………………………….48

Figure 3.27: (SKF device) for measuring the pump vibration……………………………….48

Figure 3.28: (Temperature gun) for measuring pump temperature….....................................48

Figure 3.29: Inline blender…………………………………………………………………..50

Figure 3.30: Inline blender's gearbox spectrum………………………..................................51

Figure 3.31: (SKF device) for measuring gearbox vibration……………….………………..52

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Nomenclatures

YANPET: SAUDI YANBU PETROCHEMICAL COMPANY

SKF: SVENSKA KULLAGERFABRIKEN

PE: Polyethylene

PP: Polypropylene

MEG: Mono Ethylene Glycol

DEG: Di Ethylene Glycol

TEG: Tri Ethylene Glycol

PEG: Polyethylene Glycol

HDPE: High Density of Polyethylene

PPE: Personal Protective Equipment

PDM: Predictive Maintenance

CPS: Cycle per Second

CPM: Cycle per Minute

RMS: Root Mean Square

In/sec: Inch per second

mm/sec: Millimeter per second

: Meter per Second Square

: Inch per Second Square

HZ: Hertz

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1.1. About YANPET

Saudi YANBU Petrochemical Company (YANPET) is one of the SABIC manufacturing

companies. It was created as a joint venture between SABIC and Exxon Mobil on 19 April

1980. It is located in the Kingdom of Saudi Arabia, in YANBU Industrial Citi. YANPET

Company was established to make the Kingdom as a major and more important producer of

petrochemicals and to diversify its economic base.

1.2. YANPET Vision and Mission

Vision

To be known as the best company producer of petrochemicals in the world.

Mission

Pursue excellence to accomplish a credible and gainful plant operation through total

commitment to safety and sustainability, while meeting the stakeholder's anticipations.

Also their mission is to attract and keep an eligible workforce through engagement, while

providing continuous training and career development opportunities.

1.3. Production of YANPET

YANPET Company produces many different products. These are:-

Ethylene.

Ethylene Glycol.

Polyethylene (PE).

Polypropylene (PP).

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1.4. YANPET Plants

1.4.1. Utilities and Offsite

The function of this plant is to supply and support YANPET's

Operating Units (Olefins, Ethylene Glycols, Polymers and

Packaging). The objective of this unit is to generate, distribute

and maintain sustainability of all required Utilities (Steam, Air,

Water and Others).

1.4.2. Olefins

This plant consists of two units (Ethylene I and Ethylene II). The

function of these two plants is to produce polymer grade

Ethylene by the thermal cracking of Ethane, Propane and A- 180

and plant recycle stream.

1.4.3. Ethylene Glycol

This plant consists of two units (Ethylene Glycol I and

Ethylene Glycol II). The objective of these units is to produce

different glycols. These are: Mono Ethylene Glycol (MEG), Di

Ethylene Glycol (DEG), Tri Ethylene Glycol (TEG) and

Polyethylene Glycol (PEG).

1.4.4. Polymer

This plant consists of four Units (Wet End 30, Dry End 30,

Wet End 230 and Dry End 230. The main function of these

Units is to produce High Density of Polyethylene (HDPE) and

Polypropylene (PP).

Figure 1.1

Figure 1.3

Figure 1.4

Figure 1.2

http://yanpetweb1.sabic.com/SiteDirectory/Operation/UO/default.aspx

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2.1. Safety

Safety is the most important thing in our lives. It is the first thing that we must think about

when we want to begin a new job. Some works specially plant works carry unreliable risks

while working, So that, the worker must be trained how to expect and express the risks which

may will happen during the work and getting ready for such kinds of risks. Safety preparing

was stated under standard rules and steps which must be explained carefully and clearly for

the employees and workers at the area in which the work is being done to reduce the chance

of accidents also minimize all kind of losses. All the workers in any company must wear

personal protective equipment (PPE) that protects them from dangers and hazards. Also they

have to be attention to all safety signs and follow them. In this chapter I will talk about

different safety topics that’s must be understood and followed by all the workers.

Figure 2.1

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2.2. Basic Safety Rules

This section contains safety rules applicable to all areas that shall be followed at all times.

2.2.1. Follow Safe Practices

All persons in vehicles shall wear seat belt and carrying YANPET driving

license at all times.

Use only proper tools and equipment maintained in a safe working condition.

Homemade tools are prohibited.

Maintain good housekeeping in your work area at all times.

Smoking is not permitted unless in designated areas only.

Matches and lighters are prohibited in restricted area.

Eating and resting is permitted in designated areas only.

Use proper manual lifting techniques, or obtain assistance or mechanical lifting

aids when lifting loads.

All operating machinery and electrical switchgear shall have all safety guards,

switches and alarms in place and functional.

All fire extinguishers and other emergency equipment shall be in good

condition, inspected regularly and kept clear of any obstruction.

All chemical or hazardous material containers shall be properly labeled and

stored.

2.2.2. Avoid Unsafe Activities

Climbing or standing on equipment, piping, valves or unstable surfaces (such

as chairs) to perform work is prohibited.

Finger rings, watches, jewelry, loose clothing, unsecured long hair, and other

loose accessories shall not be worn when you are working on any rotating

equipment.

Do not apply compressed air or other gases to yourself or others.

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No work shall be started in any area or on any equipment without consent of

the YANPET person-in-charge.

Electrical devices (such as mobile phones and pagers) are not allowed inside

YANPET Company.

Fighting on YANPET Company is prohibited.

2.2.3. Protect yourself

Approved hard hats without defects shall be worn in designated areas.

Approved safety footwear shall be worn in field operations, process areas and

other designated areas.

Approved safety eyewear with side protection shall be worn where designated.

Approved additional hazard-specific eye/face protection (e.g. grinding,

welding, drilling or scrapping) shall be worn where designated.

Proper personal protective equipment (PPE) shall be worn when handling

chemicals or hazardous material.

Approved hearing protection shall be worn in high noise areas.

Proper hand protection shall be worn when performing tasks that may present

a hand injury risks.

2.3. Work Permits

Any type of work must be performed by using a permit. There are three types of permits.

These are:-

1. Hot work permit.

2. Cold work permit.

3. Confined space entry permit.

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2.3.1. Hot Work Permit

Definition:

Works that involve ignition sources for flammable mixtures.

A Hot Work Permit is required for the following operations:

Examples:

1. Welding.

2. Grinding.

3. Electrical equipment or use of unapproved electrical devices.

4. Entry of heavy vehicles in electrically classified areas.

5. Sandblasting.

6. Drilling.

7. Chipping.

8. Soldering and brazing

Figure 2.2

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2.3.2. Cold Work Permit

Definition:

Work activity that does not involve any source of ignition for flammable mixtures.

A Cold Work Permit is required for the following activities:

Examples:

1. Use of hand tools ( such as vibration monitoring)

2. Maintenance work not involving arc welding or open flame in the plant.

3. Installing and removing scaffolding.

4. Air conditioning servicing.

5. Brushing & painting.

6. Housekeeping.

Figure 2.3

21

2.3.3. Confined Space Entry Permit

Definition:

Confined Space Entry is the entry of personnel into any space or structure that can be very

small and does not have enough ventilation.

A Confined Space Entry Permit is required for the following activities:

Examples:

Internal cleaning and inspection of:

- Tanks - Towers - Vessels - Boilers

- Furnaces - Duct - Excavation area

Figure 2.4

22

2.4. Personal Protective Equipment (PPE)

Personal Protective Equipment (PPE) is designed to protect employees from injuries that can

be result when you are dealing with chemical, electrical, mechanical, or any other workplace

hazards.

Personal Protective Equipment (PPE) include:-

Head protection.

Eye protection.

Ear protection.

Body protection.

Hand protection.

Foot protection.

Respiratory system

Safety harness.

Figure 2.5

23

2.4.1. Head Protection (Hard Hat)

Hard hats can protect you from head impact, penetration injuries, and electrical injuries such

as those caused by falling or flying objects, fixed objects, or contact with electrical conductors.

2.4.2. Eye Protection (Safety Glasses)

Besides safety glasses and goggles, PPE such as special helmets or shields can protect you

from the hazards of flying fragments, large chips, hot sparks, optical radiation, splashes from

molten metals, as well as objects, particles, sand, dirt, mists, dusts, and glare.

Figure 2.6

Figure. Figure.

Figure.

Figure 2.7

24

2.4.3. Ear Protection (Ear Plugs)

Wearing earplugs or earmuffs can help to protect your ears from any damage. Exposure to

high noise levels can cause irreversible hearing loss or impairment. Clean earplugs regularly,

and replace those you cannot clean.

2.4.4. Body Protection

Body protection such as coverall is used to protect the worker's body against hazards. So, it

must be worn by all the workers when they are working in any industrial area.

Figure 2.8

Figure 2.9

25

2.4.5. Hand Protection (Gloves)

Gloves can protect your hands from different hazard. So, they must be worn when you are

dealing with chemicals, hot metals, sharp tools, etc.

2.4.6. Foot Protection (Safety shoes /Boots)

Safety shoes and boots can help to prevent injuries by protecting employees from hazards

such as falling or rolling objects, sharp objects, wet and slippery surfaces, molten metals, hot

surfaces, and electrical hazards.

Figure 2.10

Figure.

Figure.

Figure 2.11

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2.4.7. Respiratory system (Air Filtration)

Respirators can help to prevent illness and injury to workers by protecting them against

adverse health effects caused by breathing air contaminated with harmful dusts, fogs, fumes,

mists, gases, smokes, sprays, or vapors.

2.4.8. Safety Harness

The harness is used as a falling protection. It must be worn when working at height. So, the

workers must wear it to protect them from getting injured.

Figure 2.13

Figure 2.12

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(50)

A

BC

A B A C A

Dis

pV

el

Accel

Figure 5. At B, acceleration is maximum to the left and displacement

maximum to the right, a 180 phase shift. Acceleration amplitude varies

as the square of frequency for a given value of displacement.

o

Avg RMS

Peak

Peak

to

PeakTimeA

mp

litu

de

Avg = 0.637 x Peak

RMS = 0.707 x Peak

Figure 6. The simple relationships which exist between average, RMS

and Peak amplitude values for sine waves are not valid for

combination or random waveforms.

Acceleration Acceleration

3.1. What is Vibration

Vibration is a mechanical oscillation around the equilibrium point. These oscillations can be

periodic like the movement of a pendulum, or can be random, like the vibration of a tire on a

bumpy road.

3.2. Machine Vibration

Machine vibration is simply defined as the back and-forth movement of machines or machine

components. Most of the time machine vibration can lead to machine damage.

Shown below are some examples of machine vibration.

Figure 3.1

Figure 3.2

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3.3. Vibration analysis

Vibration analysis is a Non-destructive technique that used to know the amount of

deterioration in a component of equipment without destroying or dismantling the equipment.

Vibration analysis is the most important technique

used for predictive maintenance (PDM). This

technique is used to detect and to find out the faults

early enough before breakdown or an expensive

failure occurs to the equipment.

3.4. Application of Vibration Analysis

Vibration analysis is a technique that can be used on all rotating machineries like:-

- Pumps

- Motors

- Compressors

- Gear Boxes

- Diesel/Gasoline Engines

- Turbines.

3.5. Vibration Characteristics

Frequency

Amplitude

Frequency:

It is the number of times oscillation that occur for a given time period. It is measured in CPS

(HZ) or CPM.

Amplitude:

It is the magnitude of vibration signal. It has three parameters, these are: - (Displacement,

Velocity, and Acceleration)

Figure 3.3

31

- Displacement: is the amount of movement that takes place. It is measured in peak-to-

peak or microns.

- Velocity: is the rate of change of displacement with respect to time (the speed of the

vibration). It is measured in mm/sec or in/sec.

- Acceleration: is the rate of change of velocity with respect to time. It is measured in

or

3.6. Vibration analysis charts

There are three types of charts that are used to show the condition of the haul equipment and

the condition of the components inside the equipment. These are: - (The trend, the spectrum,

and the time waveform)

3.6.1. The Trend:

The trend chart is used to show the overall level of the equipment. By using the trend

chart, the analyzer will be able to see and identify any dramatic increase or decrease

to the vibration of the equipment. See figure 3.5.

Axes: RMS vs. Date

Figure 3.4

Figure 3.5

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3.6.2. The Spectrum:

The Spectrum displays the frequencies at which a machine component is vibrating.

By using the spectrum, the analyzer will be able to know the exact fault that caused

the vibration. See figure 3.6.

Axes: Amplitude vs. Frequency

3.6.3. The Time Waveform:

The time waveform is used to help diagnose machine problems. A waveform does not

display the individual frequencies at which vibration occurs. It displays only the

overall effect. See figure 3.7.

Axes: Amplitude vs. Time

3.7. Causes of Vibration

There are a number of mechanical faults, as well as electrical faults, that can be detected and

cause vibration. Such as:-

Unbalance.

Misalignment.

Looseness.

Bent shaft.

Cavitation.

Resonance.

Rotor rubs.

Rolling element bearing faults.

Gear faults.

Some electrical motor problems.

Figure 3.6

Figure 3.7

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3.8. Work Done No.1

Equipment: Centrifugal Compressor (2K-7701G)

3.8.1. Work Objective and Goal:

To measure the vibration on the compressor and identifying the faults that

caused the vibration.

To make the compressor working normally.

3.8.2. Theoretical Background

Plant and its function

Utilities Unit 60, its function is to supply and support YANPET producing units

(Ethylene, Ethylene Glycols, Polyethylene and Packaging).

The Unit objective is to generates, distributes and maintain sustainability’s of all

required Utilities (Steam, Air, Water and Others) for process plants and non-process

unit in the complex.

Equipment and its description

Equipment: Centrifugal Compressor (2K-7701G)

Type: multi-stage

Compressors are the equipment used to pump and move different types of gases (e.g.

air & natural gas). They reduce the gas volume by forcing it into a smaller area,

therefore increasing its pressure.

33

Figure 3.9

Figure 3.8

34

3.8.3. Safety requirements

Wear all the personal protective equipment that is needed for this work order. These are:-

1. Coverall.

2. Safety shoes.

3. Safety helmet.

4. Safety glasses.

5. Ear plug.

6. Gloves.

3.8.4. Work details

Problem background

- Compressor had abnormal sound and tripped many times due to high vibration

in 1st stage.

Observation

- High abnormal noise coming from the compressor.

- We observed high vibration on the compressor from the 1st stage casing.

Recommendation

- Remove the compressor to the workshop for complete overhaul.

Finding after inspection (cause of problem)

- After they removed the cover of the 1st stage, they found comletely damge on

impeller holder, it was deattched completely.

- Also they found the journal bearing side wall wear out, and some rubbing

marks on the shaft.

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3.8.5. Manpower and device used

- Manpower: 2 persons

- Device used: Vibration collector (SKF)

Figure 3.13

Figure 3.11

Figure 3.10

Figure 3.12

36

3.8.6. Sequence of work

1) First, we received a call from the utility plant. They told us that the compressor (2K-

7701G) had abnormal sound and tripped.

2) After that, we plugged in the SKF device to the computer that has all the data about all

the equipment in the plant. So, we transferred all the data that belong to this

compressor to our SKF device.

3) Then, we went to that plant to measure the vibration level of the compressor by using

the SKF device. So, we found that the compressor has high vibration.

4) After that, we went to our department to see and identify what is the fault that caused

the vibration.

5) We plugged in the SKF device to the computer and transferred the new data that we

measured.

6) After that, we send a report to the utility plant telling them about the details of the

problem and some recommendation to solve the problem.

3.8.7. Result

- The journal bearing was replaced.

- The impeller and the impeller holder were replaced and fixed regularly.

- Compressor vibration readings were checked again after repair and all the readings

were within the range.

3.8.8. Conclusion The compressor was working normally and without abnormal sound. Also, the work was done

successfully and without any injuries.

37

3.9. Work Order No. 2

Equipment: Steam Turbine (GT1201B)

3.9.1. Work objective and goal

To do predictive maintenance on the steam turbine.

To perform vibration monitoring system on the turbine.

To avoid steam turbine from being damage.


Plant and its process

Ethylene Glycol (Unit I), its process consists of two phases:-

First: Ethylene is converted to ETHYLENE OXIDE by a catalytic oxidation reaction

(HALCON PROCESS).

Second: Ethylene Oxide is converted to GLYCOLS by a reaction with water.


Equipment: Steam Turbine (GT1201B)

Type: single stage

Steam Turbine is the equipment that used to transfer thermal energy (from steam) into

mechanical energy to generate rotary motion. It is used to drive other pieces of

equipment (e.g. pumps & compressors) by rotating a shaft.

38



1. Coverall.

2. Safety shoes.

3. Safety helmet.

4. Safety glasses.

5. Ear plug.

6. Gloves.

Figure 3.15

Figure 3.14

39

3.9.4. Work details

Problem background:

- The steam turbine was running with high abnormal noise.

Observation:

- High vibration at the turbine Non Drive End (NDE) bearing.

- The spectrum was showing indication of bearing failure.

Recommendation:

- Isolate the turbine for maintenance.

- Remove the top half cover of bearing housing.

- Inspect the bearing condition.

Finding after inspection (cause of problem):

- They found the ball bearing was completely damaged.

- Also they found some rubbing marks on the shaft.

- They said that the main cause of these damages is because the turbine was

running dry (without oil).

Figure 3.16

41



- Device used: vibration collector (SKF)

Figure 3.19

Figure 3.17

Figure 3.18

41


1) First of all we received a call from the Ethylene Glycol plant. They told us that the

steam turbine (GT1201B) is running with abnormal noise.

2) After that, we plugged in the SKF device to the computer that has all the data about

all the equipment in the plant. So, we transferred all the data that belong to this steam

turbine to the SKF device.

3) Then, we went to that plant to measure the vibration level of the steam turbine by

using the SKF device. So, we found that the steam turbine has high vibration.

4) After that, we went back to our department to see and identify what is the fault that

caused the vibration.


measured. Then we saw the spectrum and found that the vibration was due to bearing

failure.

6) After that, we send a report to the utility plant telling them about the details of the


3.9.7. Result

- The ball bearing was replaced and the shaft was repaired.

- The oil was filled.

- Steam turbine vibration readings were checked again after repair and all the readings

were within the range.

3.9.8. Conclusion

The steam turbine was running normally and without any abnormal noise. Also, the work was

performed successfully and without any accidents.

42

3.10. Work Done No.3

Equipment: Extruder (2Y-3123-V1)


To find out the faults that caused the vibration.

To avoid the extruder from being fail.

To do predictive maintenance.

3.10.2. Theoretical background


Polymer Dry End 230, the objective of this unit is to produce high density of

Polyethylene and Polypropylene pellets.


Equipment: Extruder (2Y-3123-V1)

The objective of the Extruder is to receive polymer resins and additives, then melt,

homogenize and extrude them as polyethylene pellets.

Figure 3.20

43



1. Coverall.

2. Safety shoes.

3. Safety helmet.

4. Safety glasses.

5. Ear plug.

6. Gloves.

3.10.4. Work details

Problem background

- Extruder (NDE) vibration alarm.

Observation

- High vibration reading, about 0.15 in/sec slightly increased.

- We observed that the locking gib of the extruder (NDE) base support was

slightly loose.

- The spectrum was showing indication of looseness.

Figure 3.21

44

Recommendation

- Tight the bolts of the locking gib.

- Shims are required between the base and the locking gib.

Finding after inspection (cause of the problem)

- The locking gib of the extruder (NDE) base support was loosed.



- Device used: vibration collector (SKF)

Figure 3.23

Figure 3.22

45


1) First, we received a call from the polymer unit. They told us that the extruder (2Y-

3123-V1) had a vibration alarm from the NDE side. They saw the alarm from the

computer in the control room.



equipment to the SKF device.

3) Then, we went to that plant to measure the vibration level of the extruder by using the

SKF device. So, we found that the extruder has high vibration.


the vibration.


measured. Then we saw the spectrum and found that the vibration was due to

looseness in the locking gib of the extruder (NDE) side.

6) After that, we send a report to the polymer plant telling them about the details of the


3.10.7. Result

- The shims were put between the base and the locking gib.

- The bolts were tightened on the locking gib by using a spanner.

- The vibration readings of the extruder were checked again after repair and all the

readings were within the range.

3.10.8. Conclusion

The extruder was running normally and without any alarm. Also, the work was performed

successfully and there were no injuries.

46

3.11. Work Done.4

Equipment: Centrifugal Pump (2Y-3123-V12A)


To determine the sources of high vibration.

To minimize unplanned shutdown.

3.11.2. Theoretical background





Equipment: Centrifugal pump (2Y-3123-V12A)

Centrifugal Pumps are the equipment which used to move and deliver different types

of liquids at high level, high pressure and high flow rate from one point to another.

Figure 3.24

47



1. Coverall.

2. Safety shoes.

3. Safety helmet.

4. Safety glasses.

5. Ear plug.

6. Gloves.


Problem background

- Centrifugal pump abnormal sound.

Observation

- High vibration reading about 0.33 in/sec.

- The spectrum was showing indication of misalignment.

- We measured the temperature of the equipment, and we found that the

temperature was fine, about 71 deg. C.

Figure 3.25

48

Recommendation

- Check the alignment of the coupling.

- Check the condition of the rubber coupling.


- They found the rubber coupling was damaged.


- Manpower: 3 people

- Devices used: 1. Vibration collector (SKF).Figure 3.27

2. Temperature gun. Figure3.28

Figure 3.28 Figure 3.27

Figure 3.26

49


1) First, we received a call from the polymer unit. They told us that the centrifugal pump

(2Y-3123-V12A) had high abnormal sound and over heat.



equipment to the SKF device, also we took the temperature gun with us to measure the

temperature of the pump.

3) Then, we went to that plant to measure the vibration level of the pump by using the

SKF device. So, we found that the pump has high vibration.

4) Also, we checked the temperature by using the temperature gun, and we found the

temperature was fine.


the vibration.


measured. Then we saw the spectrum and found that the vibration was due to

misalignment in the coupling area.



3.11.7. Result and Conclusion

- The rubber coupling was replaced.

- The coupling area of the centrifugal pump was aligned.

- The pump was running without any abnormal noise and all the vibration levels were

ok.

- The work was done successfully.

51

3.12. Work Done.5

Equipment: Gearbox of Inline Blender (2Y-4122B-V10)


To maintain vibration monitoring system on the equipment.

To diagnose the faults the caused the vibration.






Equipment: Gearbox of Inline Blender (2Y-4122B-V10)

The Inline Blender is used to mix various grades of polymer resin with some chemical

additives and transfer them to the extruder.

Figure 3.29

51



1. Coverall.

2. Safety shoes.

3. Safety helmet.

4. Safety glasses.

5. Ear plug.

6. Gloves.


Problem background

- Abnormal sound and knocking in the gearbox of the inline blender.

Observation

- We observed high vibration on the gearbox of the inline blender.

- The spectrum was showing indication of gear misalignment.

Figure 3.30

52

Recommendation

- Replace the defected gearbox with spare one.

- Check the alignment between the motor and the gearbox, also between the

gearbox and the inline blender.

- Fill the oil and check its level to the required level.


- After they opened the gearbox, they turned the shaft manually and found

misalignment between matching gear (excessive gear backlash) due to

overload running.

- They found some teeth of the gears were broken.



- Device used: vibration collector (SKF) device


1) First, we received a call from the polymer unit. They told us that the gearbox of the

Inline Blender (2Y-4122B-V10) has abnormal sound.



equipment to the SKF device.

3) Then, we went to that plant to measure the vibration level of the gearbox by using the

SKF device. So, we found that the gearbox has high vibration.


the vibration.

Figure 3.31

53


measured. Then we saw the spectrum and found that the vibration was due to gear

misalignment.



3.12.7. Result and conclusion

- The gearbox was replaced.

- The alignment between motor and gearbox, and between gearbox and inline blender

was checked.

- The oil was filled.

- The gearbox returned back to normal operation and without abnormal sound.

- The vibration was checked again after repair, and all the reading were normal.

55

4.1. Conclusion

In this report, I mentioned a brief introduction about YANPET Company. Also, I talked about

different safety topics that should be understood and applied in YANPET Company. After

that, I provided an overview about my department. At the end, I mentioned the work activities

that I have done during the 14 weeks of my training period.

Actually, the training period was very helpful for me and I have learned many things during

it. I have learned very useful information not only about my specialization but also about

different specializations. Of course meeting new people in job field and working with group

was very interesting experience for me.

Finally, I would like to thank almighty Allah for finishing my co-op training period and for

completing this report.

I hope that this report will gain your interests.

Thanks.

56

4.2. References

www.google.com

www.wikipedia.org

http://yanpetweb1.sabic.com

http://www.reliabilityweb.com/forms/beginners_guide_vibration.pdf

http://www.ask.com/question/what-is-vibration-analysis

http://www.indiana.edu/~emusic/acoustics/frequency.htm

http://www.dliengineering.com/vibman/thewaveformvsthespectrum.htm

http://www.forbesmarshall.com/fm_micro/downloads/shinkawa/FUNDAMENTALS

OF VIBRATION By FM - Shinkawa.pdf

MET 105.

SHE Handbook.

Training manual from the company.

My progress reports

My daily logbook.

http://www.google.com/

http://www.wikipedia.org/

http://yanpetweb1.sabic.com/

http://www.reliabilityweb.com/forms/beginners_guide_vibration.pdf

http://www.ask.com/question/what-is-vibration-analysis

http://www.indiana.edu/~emusic/acoustics/frequency.htm

http://www.dliengineering.com/vibman/thewaveformvsthespectrum.htm

yanpet report

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