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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
9
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
Having work permit before starting his work
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
Having work permit before starting his work
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
28
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.
29
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
and the system steamed until proven to be gas free by taking the
required gas tests at all available vents.
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
11. The vessel should be inspected to determine the presence of sludge
or scale
ABPD
12. If sludge or scale is present, it should be thoroughly wetted and
kept wet until clean up is completed. Fire watch should be present
ABPD
34
when opening the subject vessel.
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
14. The subject Vessel should be inspected and recorder any finding. ICU
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.
NO. ACTIVITY RESP. INIT. DATE
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
13. 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
14. 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
15. The vessel should be inspected to determine the presence of sludge
or scale ABPD
35
16. 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
17.
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.
ABPD
18. The subject Vessel should be inspected and recorder any finding. ICU
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
the vacuum tanker. ABPD
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
the vacuum tanker. ABPD
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
15. 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
16. 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
36
17. The vessel should be inspected to determine the presence of sludge
or scale ABPD
18. 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
19.
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.
ABPD
20. The subject Vessel should be inspected and recorder any finding. ICU
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:
NO. ACTIVITY RESP. INIT. DATE
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:
1