Progress Report #1: CO-OP Training in YASREF

Yanbu Industrial College
Mechanical Engineering Technology Department

CO-OP TRINING REPORT
Progress Report #1
CO-OP Training in YASREF
(Yanbu Aramco Sinopec Refining Company Ltd.)
Project Quality Management Division (PQM)
Omar Ahmad Abdullah Al Aseeri

Student #: 312179
Date: 29/8/2014
Phone #: 0598057237
Reviewer name: Engr. MOHAMMAD AGMAL

Email: ajmalm@rcyci.edu.sa
1.0 Intoduction in safety :
Saudi Aramco has a long-standing commitment in promoting the safety of our employees, their
families and our broader community. A culture of safety is supported inside the company and
promoted in our communities through a variety of initiatives that tackle our societys most
critical safety challenges.
As we continued our efforts to make our operations as safe as possible, our lost-time injury (LTI)
rate in 2013 dropped by 18.2 percent from 2012 and 25 percent from 2011 to 0.09 per
200,000 work hours.
The second phase of Petro Rabigh has achieved 6 million accident-free work hours, and six other
refineries reached between 1 million and 5 million accident-free work hours. This improvement
was largely the result of rigorous in-the-field training and adherence to policies.
For example, roughly every 50 workers at the Manifa Project had a safety man during
construction, and detailed evacuation plans have been put in place and well-rehearsed.
Management at YASREF conducted 16 emergency drills and approximately 1,500 safety

workshops for 32,000 individuals. In fact, such intensive safety procedures are standard across
Saudi Aramcos numerous facilities.
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1.1 Personal Protective Equipment (PPE):
The personal protective equipment is a very important aspect in a work site. To prevent stop of
the work and keep workers safe from injury, We as an inspectors need to wear:
Hard hats
Safety glasses
Safety shoes
Gloves
2.0 Intriduction about the company :

2.1 YASREF Vision
Our commitment to remain the world leader in the production of petroleum-based energy is
complemented by our commitment to help solve a host of pressing issues. We believe we can
make a difference wherever we do business by investing in innovation and entrepreneurship,
creating educational opportunities, powering economic progress, increasing environmental
awareness, and working in partnership for energy sustainability.
2.2 BACKGROUND
In May, 2006 Saudi Aramco and ConocoPhillips executed a Memorandum of

Understanding to participate in a joint effort with respect to the development of a
400 MBD capacity refining facility to be built in Yanbu, Saudi Arabia.
Kellogg Brown & Root (KBR) was selected as the FEED phase contractor and
work was initiated in their Houston offices in July, 2006. This effort has recently
been completed and the project is now moving into the execution phase.
2.3 LOCATION
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The Yanbu Export Refinery (YER) is located in Yanbu Industrial City on the Red
Sea, West Coast of the Kingdom of Saudi Arabia as shown in Figure 1, YERP
Location.
FIGURE 1 YERP Location

The refinery site and surrounding synergy and infrastructure facilities are shown
in Figure 2, YERP Overall Site Plan. Refinery crude oil feedstock comes from
the Yanbu Crude Oil Terminal (YCOT) located near the YER; liquid products are
exported at the Yanbu Natural Gas Liquids (YNGL) facility adjacent to YER and
solid byproducts are exported at the King Fahad Industrial Port (KFIP).
The main YER site plot plan is shown in Figure 3, Overall Plot Plan.
3.0 PROJECT DESCRIPTION
3
The Yanbu Export Refinery Project (YERP) is a grassroots 400,000 barrel per
stream day (BPSD) integrated petroleum refinery in the Yanbu Industrial City
located on the west coast of Saudi Arabia along the Red Sea. The refinery will
process 100 percent Arabian Heavy Crude and will produce gasoline, high
quality diesel, and liquefied petroleum gases (LPG) as well as byproduct sulfur
and petroleum coke for export. The refinery will include process units for the
separation and conversion of the feed crude into finished products, utility and
offsite systems to support the refinery operation, and associated feed,
intermediate and product storage facilities. Refinery electrical power, potable and
process water, and seawater cooling water will be supplied from existing
infrastructure facilities, and refinery generated process and sanitary wastewaters
and hazardous and non-hazardous wastes will be transferred to existing off-site
facilities for treatment and/or disposal.
Arabian Heavy crude oil from the Yanbu Crude Oil Terminal (YCOT) adjacent to
the proposed refinery is processed via a hydrocracker based scheme as shown
in Figure 4, Refinery Process Block Flow Diagram. Gaseous components from
the crude distillation are further processed in a combination of open art and UOP
technologies to produce propane and butane for use as refinery fuel gas and/or
LPG products. Sulfur is removed from the light components and exported as a
byproduct through the King Fahad Industrial Port (KFIP). Middle distillate
components from the crude distillation are further processed in several UOP
based technologies to produce gasoline and diesel as the primary refinery
products. Heavy components from the crude distillation are further separated in a
Vacuum unit. The overhead components are cracked via a Chevron
Hydrocracker with light cracked components combined for further processing
with middle distillate streams and the heavy cracked components combined with
vacuum distillation heavy components for final processing in a ConocoPhillips
Delayed Coking Unit. Coke is transported to the KFIP for export.
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FIGURE 2 Overall Plot Plan showing Contract Packages
The Contract Packages developed for the Yanbu Export Refinery Project are shown
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in Table 1, Contract Packages.
TABLE 1 Contract Packages
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4.0 Job Description:
We as inspectors, inspect the work of contractors before their start the working , During the
work, we also inspect what they do. Also after they complete their tasks, we inspect the finished
work. For example, we inspect welding , installation of pipes , installation of struts , ensure the
safety of the equipments and the safety of their work and test it . Also, we run some tests for the
equipments and materials such as NDT and hydro test.
5.0 Area and its Process:

SP-1 Tank Farm Packages includes installation of 33 storage tanks with different diameters up to
110mt, capacity up to 1.2 million barrels, 13 spheres 60,000 barrels each and spheroids.
The tank farm package is one of Yanbu export refinery packages which treat and process
400,000 Barrel/Day of Arabian Heavy Oil.
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6.0 Assignments & Activities :
Note * The company is still in the construction stage.
From week 1 to week 5:
# Doing assignment from the manager about the project : what is the types of
project , what is the life cycle of the project , list people whose related with your
work and what is your activity .. .
#take lesson in welding inspection with the Chief engineer for Me about :
How to inspect the welding and what is the type of the welding (SMAW, GTAW
GMAW and FCAW ).
#make inspection to some pipes at SP-1 area :
*inspect the welding , joints and flanges of the pipe .
* inspect the direction of the of pipe according to the Site Map.
*inspect level of the pipe .. it must be in same level .
The Result : all Approved .

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What safety measures are emphasized at the refinery?

What safety measures are emphasized at the refinery?

What are the contractor's responsibilities as inspectors?

What are the contractor's responsibilities as inspectors?

Yanbu Industrial College

Mechanical Engineering Technology Department

Omar Ahmad Abdullah Al Aseeri

Reviewer name: Engr. MOHAMMAD AGMAL

Management at YASREF conducted 16 emergency drills and approximately 1,500 safety

2.0 Intriduction about the company :

In May, 2006 Saudi Aramco and ConocoPhillips executed a Memorandum of

FIGURE 1 YERP Location

3.0 PROJECT DESCRIPTION

TABLE 1 Contract Packages

5.0 Area and its Process:

Note * The company is still in the construction stage.

From week 1 to week 5:

#make inspection to some pipes at SP-1 area :

*inspect the welding , joints and flanges of the pipe .

* inspect the direction of the of pipe according to the Site Map.

*inspect level of the pipe .. it must be in same level .

The Result : all Approved .

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