Field Training Report

DEPARTMENT OF MECHANICAL ENGINEERING
JUBAIL INDUSTRIAL COLLEGE
FINAL REPORT ON COOPERATIVE TRAINING
Prepared by:
Ahmed Hassan Alnayem
401 900 982
Submitted to:
Dr. Jebaraj Azariah
SEMESTER 453 DATE 10 / 10 / 2024

ACKNOWLEDGEMENT
I am profoundly grateful to Allah, first and foremost, for his boundless blessings and guidance. I
also express my heartfelt gratitude to my parents for their support, and encouragement during my
academic journey. I sincerely thank Dr. Jebaraj Azariah, my COOP academic advisor, for his
invaluable guidance and support. Words cannot describe how thankful I am to Eng. Nasser
Almulhim, my work supervisor, the person who shared his great experience and guided me
throughout my coop period. I am also deeply thankful to all members of the Reliability Unit, Filed
Engineering Unit, Operation, and Line Maintenance Teams for their support in giving me the
opportunity in both high knowledge and hand working.
I deeply appreciate the opportunity given to me by the distinguished Mechanical Engineering
Department at JIC, and I am immensely thankful to Aramco Company for providing such a
beneficial platform to enhance my practical knowledge and experience.
ii
Table of Content
SUMMARY ..................................................................................................................................... i
ACKNOWLEDGEMENT .............................................................................................................. ii
1 INTRODUCTION ....................................................................................................................1
1.1 Introduction of the Report ................................................................................................ 1
1.2 Internship Plan.................................................................................................................. 1
2 COMPANY PROFILE .............................................................................................................2
3 DETAILS OF WORK EXPERINCE .......................................................................................3
3.1 Felid Engineering Unit (FEU) .......................................................................................... 3
3.1.1 Defect Notification of Pipelines................................................................................ 3
3.1.2 Package Solutions of the Defect ............................................................................... 7
3.1.3 Pipe Isolation ............................................................................................................ 8
3.1.4 Hydrostatic Pressure Testing of the Pipeline .......................................................... 12
3.2 Operation Team .............................................................................................................. 13
3.2.1 Gas & Oil Separation Plants (GOSPs) Components .............................................. 13
3.2.2 GOSPs Process........................................................................................................ 24
3.2.3 Safety Device .......................................................................................................... 31
3.3 Line Maintenance ........................................................................................................... 32
3.3.1 Valves ..................................................................................................................... 32
3.3.2 Relief / Safety Valves ............................................................................................. 35
3.3.3 Bearings .................................................................................................................. 37
3.3.4 Shaft Alignment ...................................................................................................... 41
3.4 Reliability Unit (RU)...................................................................................................... 46
3.4.1 Lubrication Condition Monitoring (LCM) ............................................................. 46
iii
3.4.2 Switchover of Rotating Equipment ......................................................................... 47
4 GENERAL SKILLS ACQUIRED .........................................................................................49
5 CONCLUSIONS ....................................................................................................................50
6 WEEKLY REPORTS .............................................................................................................51
iv
Table of Figures
Figure 1 Internal Corrosion ....................................................................................................................... 3
Figure 2 External Corrosion ...................................................................................................................... 4
Figure 3 Pin Hole......................................................................................................................................... 5
Figure 4 Scale in Pipes ................................................................................................................................ 6
Figure 5 Replacement of the defected selection........................................................................................ 7
Figure 6 Sleeve Installation ........................................................................................................................ 8
Figure 7 Coating of pipelines ..................................................................................................................... 8
Figure 8 Single Bloke Valve ........................................................................................................................ 9
Figure 9 Double Bloke and Bleed ............................................................................................................ 10
Figure 10 Install Blind .............................................................................................................................. 10
Figure 11 A Blind....................................................................................................................................... 10
Figure 12 Disconnect Spool/Isolation Valve ............................................................................................ 11
Figure 13 High Pressure Production Trap.1 ........................................................................................... 13
Figure 14 High Pressure Production Trap.2 ........................................................................................... 14
Figure 15 Low Pressure Production Trap.1 ............................................................................................ 14
Figure 16 Low Pressure Production Trap.2 ............................................................................................ 14
Figure 17 Dehydrator.1 ............................................................................................................................. 15
Figure 18 Dehydrator.2 ............................................................................................................................. 15
Figure 19 Desalter.1 .................................................................................................................................. 15
Figure 20 Desalter.2 .................................................................................................................................. 16
Figure 21 Water Oil Separation.1 ............................................................................................................ 16
Figure 22 Water Oil Separation.2 ............................................................................................................ 16
Figure 23 Degassing .................................................................................................................................. 17
Figure 24 Emergency Water Tank ........................................................................................................... 17
Figure 25 Vertical pump ........................................................................................................................... 18
Figure 26 Horizontal pump ...................................................................................................................... 19
Figure 27 Charge Pump ........................................................................................................................... 19
Figure 28 Recycle Pump ........................................................................................................................... 20
Figure 29 Booster Pump ........................................................................................................................... 20
Figure 30 Shipper Pump........................................................................................................................... 21
Figure 31 Injection Pump ......................................................................................................................... 21
Figure 32 Wash Water Pump ................................................................................................................... 22
Figure 33 Reprocessing Pump.................................................................................................................. 22
Figure 34 Low Pressure Compressor ...................................................................................................... 23
Figure 35 High Pressure Compressor ..................................................................................................... 24
Figure 36 Oil Trak.1.................................................................................................................................. 25
Figure 37 Oil Trak.2.................................................................................................................................. 26
Figure 38 Oil Trak.3.................................................................................................................................. 26
Figure 39 Nature Gas Track.1.................................................................................................................. 27
Figure 40 Nature Gas Track.2.................................................................................................................. 28
Figure 41 Water Track.1 ........................................................................................................................... 29
Figure 42 Water Track.2 ........................................................................................................................... 30
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Figure 43 Gas & Oil Separation Process................................................................................................ 30
Figure 44 Personal Sensor ........................................................................................................................ 31
Figure 45 Plant sensor .............................................................................................................................. 31
Figure 46 Ball Valve .................................................................................................................................. 32
Figure 47 Gate Valve ................................................................................................................................. 32
Figure 48 Gate Valves ............................................................................................................................... 32
Figure 49 Globe Valves ............................................................................................................................. 33
Figure 50 Ball Valves................................................................................................................................. 34
Figure 51 Check Valves............................................................................................................................ 35
Figure 52 Relief Valves ............................................................................................................................. 35
Figure 53 Bearings ................................................................................................................................... 37
Figure 54 Shaft Alignment ....................................................................................................................... 41
Figure 55 Radial Misalignment ............................................................................................................... 41
Figure 56 Angular Misalignment ............................................................................................................. 41
Figure 57 Gap or Axial Misalignment ..................................................................................................... 42
Figure 58 Checking the Radial Misalignment ........................................................................................ 42
Figure 59 Adjust the horizontally & Vertically ...................................................................................... 43
Figure 60 Checking the Angular Misalignment ..................................................................................... 43
Figure 61 Checking the End float ............................................................................................................ 44
Figure 62 Face-Peripheral Indicator Method......................................................................................... 44
Figure 63 Reverse Indicator Method....................................................................................................... 45
Figure 64 Validity Rule ............................................................................................................................. 45
Figure 65 shaft alignment for one of the injection pumps ..................................................................... 46
Figure 66 LCM Samples ........................................................................................................................... 46
Figure 67 ASTM LCM Colors ................................................................................................................. 47
Figure 68 An Example of Switchover ..................................................................................................... 48
Tables
Table 1 Internship Plan ............................................................................................................................. 1
Table 2 Vessels Comparison ..................................................................................................................... 18
Table 3 Pumps Specifications ................................................................................................................... 23
vi
1 INTRODUCTION
1.1 Introduction of the Report
Training at Saudi Aramco Company is one of the best opportunities, as it gives the students
a lot of information and helps them develop their professional personalities. This report
reflects the learnings and skills that I gained in my 16th weeks internship at Saudi Aramco.
My work and time with that organization will help to develop my future. It will help me to
apply the theoretical information to the real-world applications of the industries and other
departments.
That training program will help to prepare the students for their future careers. I have
completed my internship at Upstream Business line with Central Ghawar Producing
Department (CGPD), Central Ghawar Maintenance Division (CGMD), specifically in the
Reliability Unit (RU).
My training plan is focused on gaining hands-on experience and I can expect to have
advanced skills and knowledge that I can use in real-life workplace scenarios.
This will help me provide a strong foundation for my future career.
1.2 Internship Plan

During my training, there was a clear plan to know how your period will flow through the
weeks, the table below can give you the general idea of my Training Rotation:
Table 1 Internship Plan
Internship Plan
No. Work Activates/ Job Tasks Division/ Unit Duration
1 Safety Orientation, Division CGMD/RU 2 Weeks
Overview, Mandatory E-learning
2 Working with RU engineers & CGMD/RU 1 Week
technical advisor
3 Assignment with Field Engineering
Group/ Explore mechanism and CGPD/FEU 1 Week
procedure for replacement of
defective pipe
4 Working with UGOSP-7 Operation UPD/UGOSP-7 2 Weeks
5 Working with Line Maintenance CGMD/UGOSP-7&8 3 Weeks

(UGOSP-7&8) LM
6 Explore different reliability program
and systems & working with RU CGMD/RU 7 Weeks
engineers & technical advisors
Total 16 Weeks
1
2 COMPANY PROFILE
Aramco stands for Arabian American Oil Company. It is considered one of the largest
companies in the world that produces high-quality energy, chemicals, and refined
hydrocarbon products to help keep the world moving. It is a national oil company that is
owned by the Saudi state. As of 2022, Aramco was the world’s second-largest company in
terms of revenue. Aramco helps and benefits people and communities around the world to
solve the world's sustainability challenges and provides them with affordable and
sustainable energy sources.
Today, Aramco continues to deliver on its core mission of reliably supplying energy to the
Kingdom and the world and progress towards becoming the world’s leading integrated
energy and chemicals enterprise, a top refiner, and a creator of energy technologies.
Saudi Aramco Values: Saudi Aramco Products:

Citizenship Oil production
Safety Gas production
Accountability Chemical production
Excellence Lubricant production
Integrity Refined products
Base oils
Retail fuel
For the Central Ghawar Producing Department (CGPD), they manage 12 Gas and Oil
Separation Plants (GOSPs) through two divisions: Planning Engineering division and
Maintenance division. Each division has multi unites where every unit has its
Responsibilities.
The Maintenance Division is responsible for ensuring that all equipment, machinery, and
facilities within an organization are in an optimal working condition. This division handles
preventive, corrective, and routine maintenance tasks, addressing breakdowns, conducting
repairs, and performing regular inspections to prevent failures and extend the lifespan of
assets. The goal is to ensure continuous, efficient, and safe operations.
For the Reliability Unit (RU) Responsibilities include:

Monitoring equipment performance to identify potential issues.
Conducting failure analysis to determine root causes and prevent recurrence.
Developing maintenance strategies like preventive and predictive maintenance.
Optimizing asset life cycles through reliability improvement programs.
Collaborating with operations and maintenance teams to reduce downtime and
increase efficiency.
Implementing reliability best practices and standards to ensure safe, efficient
operations.
2
3 DETAILS OF WORK EXPERINCE
3.1 Felid Engineering Unit (FEU)
Felid Engineering Unit deals with pipelines that oil flow in it from the headwalls to
the Gas & Oil Separation Plants (GOSPs) and then after the separation process the water
injected back to the walls again. So, they are responsible about all that long pipe from any
problem to deliver the oil to the plants safely, and the water from the plants to the walls.
To summarize their work, they get information from the inspectors about the defect and
then they study the problem and solve through a plan called “Package” as they will be
shown below.
3.1.1 Defect Notification of Pipelines
Defect Notification: This refers to a detailed report outlining the specific problem
identified during the inspection process, which is then formally documented and
communicated by the inspector to the relevant party, known as the FEU (Field
Engineering Unit). The report typically includes a description of the defect, its
potential impact, and any recommended actions for resolution.
The common Problems in the pipeline as follow:
1- Internal / External Corrosion:

Internal Corrosion in Pipelines
Definition: Internal corrosion occurs when the inner surface of a pipeline is
degraded due to chemical or electrochemical reactions with the fluid being
transported.
Figure 1 Internal Corrosion

Causes:
 Chemical Composition: Certain substances, such as water, acids, and
sulfides, can react with the pipeline material.
 Microbial Activity: Bacteria can produce acids as metabolic
byproducts, leading to localized corrosion.
 Temperature and Pressure: High temperatures and pressures can
accelerate corrosion processes.
 Flow Velocity: Variations in flow rates can lead to erosion-corrosion,
especially at bends and fittings.
3
Effects:
 Reduced wall thickness, leading to potential leaks or ruptures.
 Contamination of the transported product.
 Increased maintenance and replacement costs.
External Corrosion in Pipelines
Definition: External corrosion occurs on the outer surface of a pipeline, primarily
due to environmental factors and exposure to soil, water, and atmospheric
conditions.
Figure 2 External Corrosion
Causes:
 Electrolytic Reactions: Contact with moisture or soil can create
electrochemical cells that promote corrosion.
 Soil Composition: Soil chemistry, including pH, conductivity, and the
presence of corrosive agents like chlorides, can significantly affect
corrosion rates.
 Temperature and Humidity: Variations in temperature and humidity
levels can accelerate corrosion processes.
 Protective Coating Failure: Damage or deterioration of protective
coatings can expose the metal to corrosive elements.
Effects:
 Pitting and localized corrosion, leading to structural weaknesses.
 Increased risk of leaks and environmental contamination.
 Higher operational costs due to repairs and preventive maintenance.
4
Prevention and Mitigation:
For Both Internal and External Corrosion:
Regular Inspections: Use of non-destructive testing methods to monitor pipeline
integrity.
Corrosion Inhibitors: Chemicals added to the transported fluid to reduce
corrosion rates.
Protective Coatings: Application of protective materials to the pipeline surface.
Cathodic Protection: Use of sacrificial anodes or impressed current systems to
protect against corrosion.
2- Pin Hole in Pipeline:

Definition: A pinhole in a pipeline refers to a small, localized hole that forms in the
pipe wall due to corrosion, erosion, or mechanical damage. These pinholes can lead
to leaks, which may not be immediately noticeable but can cause significant issues
over time.
Figure 3 Pin Hole
Causes:
 Corrosion: Often caused by internal or external factors, such as
chemical reactions with the transported fluid or environmental
conditions.
 Erosion: The physical wear of the pipe material due to the flow of
fluids, especially if they contain particulates or are at high velocities.
 Stress Concentration: Areas of weakness due to stress from bending,
thermal expansion, or manufacturing defects.
 Microbial Activity: Certain bacteria can cause localized corrosion,
leading to pinhole formation.
Effects:
 Leaks: Even small pinholes can result in fluid loss, affecting system
efficiency and safety.
 Environmental Impact: Leaks can lead to contamination of soil and
groundwater.
 Increased Maintenance Costs: Regular inspections and repairs are
necessary to manage leaks.
5
 Regular Inspections: Use techniques such as ultrasonic testing to

detect early signs of corrosion.
 Protective Coatings: Apply coatings to reduce exposure to corrosive
elements.
 Corrosion Inhibitors: Add inhibitors to the fluid being transported to
slow down corrosion processes.
3- Scale in pipes:
Definition: Scale in pipes refers to the buildup of mineral deposits on the inner
surfaces of pipelines. This accumulation can restrict flow, reduce efficiency, and
lead to potential damage over time.
Figure 4 Scale in Pipes

Causes:
 Mineral Precipitation: When water containing dissolved minerals (like
calcium, magnesium, and iron) evaporates or undergoes temperature
changes, these minerals can precipitate and form solid deposits.
 Water Chemistry: High hardness levels, pH, and temperature can
increase the likelihood of scale formation.
 Poor Flow Conditions: Low flow rates can lead to sediment settling
and subsequent scaling.
 Corrosion Products: Corrosion of the pipe material can also contribute
to scale formation as rust and other byproducts accumulate.
Effects:
 Reduced Flow Capacity: Scale can significantly restrict the diameter
of the pipe, impeding fluid movement and increasing pressure drop.
 Increased Energy Costs: Pumps may have to work harder to move
fluids through scaled pipes, leading to higher energy consumption.
 Equipment Damage: The presence of scale can lead to overheating and
increased wear on pumps and other equipment.
 Water Quality Issues: Scale can contaminate the fluid being
transported, affecting its quality.
6
 Water Treatment: Use chemical treatments to reduce hardness and
inhibit scale formation.
 Regular Cleaning: Implementing regular maintenance schedules to
mechanically clean pipes can help remove existing scale.
 Monitoring: Conduct regular inspections and monitor flow rates and
pressures to detect scale buildup early.
3.1.2 Package Solutions of the Defect
Package Solutions of the Defect: This involves developing a comprehensive plan,

referred to as a "Package," that encompasses all necessary actions and resources
required to address and resolve the identified defect. The package outlines the entire
scope of work, detailing the steps to be taken, the materials and tools needed, the
timeline for implementation, and the personnel involved in the process. By
consolidating all these elements into a single, organized plan, stakeholders can
ensure that the defect is effectively and efficiently rectified.
The common solutions for above defects are:
1- Replacement of the defected piping sections:

Replacement of defected piping sections refers to the process of removing and
replacing sections of a pipeline that have been identified as damaged, corroded, or
otherwise compromised. This ensures the integrity, safety, and functionality of the
entire piping system.
Figure 5 Replacement of the defected selection
7
2- Sleeve installation of pin hole sections:
Sleeve installation refers to the method of repairing pipelines that have developed
pinholes or small leaks by encasing the affected section with a protective sleeve.
This technique provides a quick and effective solution to prevent further damage
and maintain the integrity of the pipeline.
Figure 6 Sleeve Installation

3- Coating of the corrosion sections:
Coating of corrosion sections involves applying a protective layer to areas of a

pipeline that have experienced corrosion. This technique is used to prevent further
deterioration, enhance the lifespan of the pipeline, and maintain its structural
integrity.
Figure 7 Coating of pipelines
3.1.3 Pipe Isolation
In Hydrocarbon processing facilities, a major safety risk is posed by maintenance

especially those activities that require hot work.
Important part of providing safe maintenance is to ensure the part of the facility
being worked on, is completely isolated from all sources of energy that can pose
harm to the personal, the environment and the facility.
There are four methods of isolation as follow:
8
1- Single Bloke Valve:
How to do it:
 Close, Lock and Tag.
 Drain, Vent and Purge content.
 Ensure/ Check isolation integrity.
Figure 8 Single Bloke Valve

When to use it:
 Simple or routine maintenance activities.
 Primary isolation for blind installation.
 Not used for confined space or hot work.
Is it Positive Isolation? NO
2- Double Bloke & Bleed:

How to do it:
 Close, Lock and Tag block valves.
 Drain, Vent Valve:
o Make sure is not clogged or blocked.
o Attach a hose or hard piping to it.
o Open, lock and tag drain valve.
o Drain to a safe location.
 Ensure / Check isolation integrity.
9
Figure 9 Double Bloke and Bleed
When to use it:
 Simple or routine maintenance activities.
 Primary isolation for blind installation.
 Not used for confined space or hot work.
Is it Positive Isolation? NO
3- Install Blind:
How to do it:
 Ensure/ Check and Separate faces.
 Unbolt flange and separate faces.
 Insert the blind and tag.
Figure 10 Install Blind Figure 11 A Blind
10
When to use it:
 Hot work activities or confined spaces.
Is it Positive Isolation? Yes
4- Disconnect Spool/Isolation Valve:

How to do it:
 Ensure/ Check isolation integrity.
 Unbolt flanges and remove the section of the pipe.
 Insert the blind at the process side.
Figure 12 Disconnect Spool/Isolation Valve
When to use it:

 Long term maintenance.
 Hot work activities or confined spaces.
Is it Positive Isolation? Yes
11
3.1.4 Hydrostatic Pressure Testing of the Pipeline
Hydrostatic Pressure Testing of a Pipeline is a critical process used to validate the
integrity and strength of pipelines, ensuring they can safely operate under pressure
without leaking or failing. This test is typically performed after construction or
significant repairs of a pipeline.
After Pipe Isolation, we processed with 5 steps to ensure that the pipeline is safely
and ready to use:
1. Pressurization: The filled pipeline is pressurized to a level higher than its
normal operating pressure. This is usually 1.25 to 1.5 times the pipeline's
Maximum Operating Pressure. The goal is to simulate worst-case operating
conditions. Where St and S are equal, Test pressure = 1.5 x P. (ASME 831.3
1)
Where: St = allowable stress at test temperature, S = allowable stress at
design temperature.
2. Holding Period: The pipeline is held at the test pressure for a set duration.
This allows for any potential leaks, deformations, or weaknesses to
manifest.
3. Inspection:
 During the holding period, the pipeline is inspected for any signs of
leakage, deformation, or pressure loss. External sensors, visual
inspections, and other methods like pressure gauges are used to
monitor for failures.
 Pressure readings are taken regularly to check for a drop in pressure,
which would indicate a leak.
4. Evaluation:
 If the pressure remains stable and no visible issues are found, the
pipeline passes the test.
 If a leak or failure is detected, the pipeline is depressurized, and the
affected section is repaired. After repairs, the test is typically
repeated.
5. Depressurization and Draining: Once the test is completed and passed,

the pipeline is gradually depressurized. The water is drained, and in some
cases, treated or disposed of according to environmental regulations.
12
3.2 Operation Team
The Operation Team of Gas & Oil Separation Plants (GOSPs) plays a vital role in managing
and controlling the processes that separate crude oil from gas, water, and other impurities
before the oil is sent for further processing. GOSP facilities are essential in the upstream
oil and gas industry to ensure that extracted crude oil meets the required specifications for
transport and refining.
In this section, we will know more about the GOSPs Components and the separation
process as follow.
3.2.1 Gas & Oil Separation Plants (GOSPs) Components
In the GOSPs, there are 4 important systems: Fire water system; which is the most
important system in the plants for any emergency fire issue, Air system; which is
the system who responsible for controlling the valves in the plants, Chemical
injection system; which is the system feeding the process of specific chemicals, and
the Separation system which we are interested on it, and we will explain it letter.
Firstly, let us learn about the main components of the GOSPs. And I will differ them
into 2 categories:
1. Main Vessels:
1. HPPT: High Pressure Production Trap:

It is 3 phase separation and here is the first separation process for
oil, water and gas. In that vessel the pressure can reach to 120 psi
(825 KPa).
Figure 13 High Pressure Production Trap.1
13
Figure 14 High Pressure Production Trap.2
As we can see in the above images, since the water has the highest
density it will fall down first, the gas has the lowest density it will
fly up, and the oil will be between them where the wall will separate
the oil and the water.
2. LPPT: Low Pressure Production Trap:

It is 2 phase separation and here is the further separation process for
oil and gas. In that vessel the pressure reduced to 50 psi (345 KPa).
Figure 15 Low Pressure Production Trap.1
Figure 16 Low Pressure Production Trap.2
14
As we know, the oil has more density than the gas has so the oil will
be in the lower and the gas will fly up. After LPPT, the separation of
gas and oil is done, and the remaining steps are to dehydrate and
desalt the oil with salt and water.
3. Dehydrator:
Here is the further separation process for oil and water through
demulsification and electrostatic coalescence. It is 2 phase
separation process and its pressure arrives to 130 psi (900 KPa)
Figure 17 Dehydrator.1
Figure 18 Dehydrator.2
4. Desalter:
The purpose of the desalter is washing process to remove salts from
the oil. It is 2 phase separation process and its pressure arrives to
120 psi (825 KPa).
Figure 19 Desalter.1
15
Figure 20 Desalter.2
5. WOSEP: Water Oil Separation:

After all the previous separation processes, all the water comes to
the WOSEP to separate the water and oil in case there is an oil with
the water. It is 2 phase separation process and its pressure arrives to
70 psi (480 KPa).
Figure 21 Water Oil Separation.1
Figure 22 Water Oil Separation.2
16
6. Degassing:
Degassing is extracting wash water from a water well and supply it
to the desalter. It considers as a plant wash water supplier and its
inside pressure is about 50 psi (345 KPa).
Figure 23 Degassing
7. EWT: Emergency Water Tank:

It is a temporarily store water that comes from other vessels, it
should be empty in the normal situations, its inside pressure is about
0.9 psi (6.2 KPa).
Figure 24 Emergency Water Tank
17
Table 2 Vessels Comparison
Vessels Comparison
Vessel Name Process Type Inlet Outlet Pressure Pressure
(Psi) (KPa)
HPPT 3 Phase Separation: Gas, Oil & water Oil from Wet oil,
wells Oily water 120 825
& off Gas
LPPT 2 Phase Separation: Gas & Oil Wet oil Wet oil & 50 345
Off Gas
Dehydrator 2 Phase Separation: Oil & water. Wet oil Salty oil,
Demulsification &Electrostatic Oily water 130 900
Coalescence
Desalter 2 Phase Separation: Oil & water. Washing Salty oil Dry Oil
&Electrostatic Coalescence &Wash 120 825
water
WOSEP 2 Phase Separation: Oil & water. Oily Wet oil 70 480
water &Water
Degassing Gas Lifting Water Wash 50 345
from water &
wells Off Gas
EWT Storage - - 0.9 6.2
 Main Pumps and Compressors:

1. Main Pumps:
Pumps are categorized into two main types:
o Vertical pump:
General information:
 Takes smaller space than the horizontal pumps because of its
vertical design.
 Part aboveground and another part underground.
 Has one impeller.
 Does NOT shutdown when flow is low.
Figure 25 Vertical pump

18
o Horizontal pump:
General information:
 Increase pressure in stages.
 All part aboveground.
 Turns off when flow is law.
Figure 26 Horizontal pump

In the Gas & Oil Separation Plants have different pumps as follow where every pump has
its own function.
1. Charge Pump:
 It is vertical in shape.
 Located between LPPT and Dehydrator.
 Power: 500 hp.
 Voltage: 4160 volts.
 Capacity: 550 GPM.
 Inlet pressure: 50 psi (345 KPa).
 Outlet pressure: 130 psi (896 KPa).
Figure 27 Charge Pump
19
2. Recycle Pump:
 Located between Desalter and Dehydrator.
 Power: 75 hp.
 Inlet pressure: 120 psi (830KPa).
 Outlet pressure: 130 psi (896KPa).
Figure 28 Recycle Pump

3. Booster Pump:
 Located between Desalter and Stabilizing.
 Power: 600 hp.
Figure 29 Booster Pump
20
4. Shipper Pump:
 It is Horizonal in shape.
 Located between Desalter and Stabilizing.
 Power: 3700 hp.
 Capacity: 10,000 GPM.
 Inlet pressure: 120 psi (830KPa).
Figure 30 Shipper Pump

5. Injection Pump:
 It is Horizonal in shape.
 Located between WOSEP and Injection Wells.
 Power: 4000 hp.
Figure 31 Injection Pump

21
6. Wash Water Pump:
 Located between Degassing and Desalter.
 Power: 125 hp.
 Outlet pressure: 120 psi (830KPa).
Figure 32 Wash Water Pump

7. Reprocessing Pump:
 Located between Degassing and Desalter.
 Power: 30 hp.
 Inlet pressure: 0.9 psi (6.2KPa).
Figure 33 Reprocessing Pump
22
Table 3 Pumps Specifications
Pumps Specifications
Pump Name Location Shape Power Voltage Capacity Inlet Outlet
(Hp) (V) (GPM) Pressure Pressure
(Psi) (Psi)
Charge Pump Between LPPT and Dehydrator Vertical 500 4160 5500 50 130
Recycle Pump Between Desalter and Dehydrator Vertical 75 480 962 120 130
Booster Pump Between Desalter and Stabilizing Vertical 600 4160 5000 120 200
Shiper Pump Between Desalter and Stabilizing Horizontal 3700 4160 10000 120 400
Injection Between WOSEP and Injection Horizontal 4000 4160 1600 70 3700
Pump Wells
Wash Water Between Degassing and Desalter Vertical 125 480 600 50 120
Pump
Reprocessing Between EWT and WOSEP Vertical 30 480 260 0.9 70
Pump
2. Main Compressors:
There are two main compressors in the Gas and Oil Separation Plants where
their main purpose is to compress gases and increase the pressure, the
compressors type which used in the plants is center fugal.
1. Low Pressure Compressor (LP):

 Located between LP suction dram
and HP suction dram.
 Power: 1840 hp.
 Voltage: 4160 Volts.
 Capacity: 15 MMS.
 Inlet Pressure: 20 psi.
 Outlet Pressure: 130 psi.
23 Figure 34 Low Pressure Compressor

2. High Pressure Compressor (HP):
 Located between HP suction dram
and HP discharge dram.
 Power: 7350 hp.
 Voltage: 13800 Volts.
 Capacity: 96 MMS.
 Inlet Pressure: 100 psi.
 Outlet pressure: 225 psi.
Figure 35 High Pressure Compressor
3.2.2 GOSPs Process

After we learned all the plant equipment, vessels, pumps, and compressors, let
learned about the plant process and how the separation processes will be. The
process in general is the wet crude oil from the oil wells enters the GOSP in purpose
to separate it into 3 primary components: Dry crude oil, natural gas, and salty water.
(GOSP) Dry Crude Oil
Wet Crude Oil Gas & Oil

Separation Natural Gass
Plant
Salty Water
24
There are 3 main tracks in the GOSPs: Oil Track, Gas Track, and Water Track. Let
learn the tracks one by one:
1 – Oil Trak:
 Oil wells → Wet Crude oil → Trough wells Pipelines → Production Header
→ Chemical Injection → HPPT.
Figure 36 Oil Trak.1
Not that in there are 3 types of chemicals:
1. Scale Preventer, also called Scale Inhibiter Demulsifier

where can reduce the scale in the pipeline which we
presented in section 3.1.1.
2. Corrosion Preventer where can protect the pipeline, valves,

vessels and the other equipment from corrosion.
3. Separation Helper where that chemical can help us in the

separation process when can prepare the wet crude oil for the
separation before entering the vessels.
25
 HPPT → LPPT → Charge Pumps.

1. In HPPT with high pressure: 3 Phase, Gas to Natural Gass Track,
Water to Salty Water Track and the wet crude oil continue to LPPT.
2. In LPPT: with low pressure: mainly 2 Phase, Gas to Nature Gass
Track and the wet crude oil continue to the charge pumps.
Note that: There are some waters from LPPT goes to WOSEP.
3. In the Charge Pumps the pressure rises to the required pressure in
the Dehydrator.
 Charge Pumps → Dehydrator → Desalter (←Wash water pump

←Degassing) → Stabilizing Plants.
26
1. In Dehydrator: separation process for oil and water through
demulsification and electrostatic coalescence.
2. In Desalter: desalter is washing process to remove salts from the oil.
Note that: There are recycling process between the Desalter and the
Dehydrator because in the desalter there is washing proses so, we
need to re-dehydrate the oil again. This step for arriving the oil to
the required specification.
3. In Degassing: clean water from water wells where the gas relies to
the Nature Gass Track and the clean water to the Desalter.
2 – Nature Gas Track:

 Off Gass from HPPT → HP Suction Dram → HP Compressors.
 Off Gass from LPPT → LP Suction Dram → LP Compressors.
 LP Compressors → HP Suction Dram → HP Compressors.
Figure 39 Nature Gas Track.1
27
1. The Pressure of Gas released from HPPT is high since it is from high
pressure trap vessel.
2. The Pressure of Gas released from LPPT is high since it is from low
pressure trap vessel.
3. Now, the goal is to merge both gases. For the purpose of that, there
is the LP Dram to receive the LP Gas from LPPT.
4. Then, there is LP compressor before the HP Dram to raise the
pressure to the Gas pressure that received in HP Dram from HPPT.
5. After that, both gases go to the HP Compressors.
6. The function of the LP dram and HP dram are to deposit any liquid
produced during the previous process to ensure that the gas is free
of any liquids.
 HP Compressors → Chemical Injection → Reheater → After cooler → Off

Gas to Gas plants.
Figure 40 Nature Gas Track.2
1. After compressed the gas it will send to the Rehear to increase the
temperature.
The primary functions of the reheater are:

 Prevent Hydrate Formation: Hydrates (solid ice-like
compounds) can block pipelines and equipment,
especially at lower temperatures.
 Improve Gas Flow: reduces the viscosity and
improves the flow properties of the gas, making it
easier to transport through pipelines.
 Assist in Gas Processing: reheating is necessary to
bring the gas to the desired temperature for
downstream processing, compression, or treatment.
28
2. Then, it goes through the after cooler which it is from by tubes, fins
and fans to cool the gas. Note that, there are required specifications
we should arrive to it by heating and cooling prosses as there is a
loop between the reheater and the after cooler controlled by TVC
(Temperature Valve Control).
3. Last step is sending the gas to the HP discharge dram and then to the
gas plants.
3 – Water Track:
 Water from HPPT → WOSEP → Injection Pimps.
 Water from LPPT → WOSEP → Injection Pimps.
 Oil from WOSEP → LPPT.
Figure 41 Water Track.1
1. The water that separated from the HPPT went to the WOSEP with a
small amount of oil.
2. As well as the small amount of water that separated from the LPPT
went to the WOSEP with a small amount of oil.
3. Then, the oil back to the LPPT, and the water will send to the
injection pumps.
4. The injection pumps will do a huge increase in the pressure of the
water and inject it in the wells to get out the oil from the wells.
29
 WOSEP → EWT.
 EWT→ Reprocessing Pump → WOSEP.
Figure 42 Water Track.2

1. The Emergency Water Tanck only for emergency issues such as
shutdown the plant, sudden shutdown or failure in the injection
pumps, high level of water which is more than the capacity of the
WOSEP.
2. The water or sometimes oily water send to the EWT.
3. When the issue solved, the Reprocessing Pump will deliver the
water to the WOSEP to continue the process.
So, the whole process of the GOSP as follow:
Figure 43 Gas & Oil Separation Process
30
3.2.3 Safety Device
As we know in the Gas and Oil Plants there are dangerous gases such as H2S.
What is H2S?
Hydrogen sulfide (H₂S) is a colorless, toxic gas with a distinctive smell of rotten
eggs. It is commonly found in oil and gas operations, and exposure to high levels
can be hazardous, causing respiratory issues or even death.
So, to protect the employees in the plants and the environment we use a H2S
detector device. A H₂S gas detector is a device used in oil plants to detect the
presence of toxic hydrogen sulfide (H₂S) gas. It continuously monitors air quality
and alerts workers when H₂S levels exceed safe limits, ensuring safety in hazardous
environments.
There are many types of H2S detector devices, but the common two are the personal
one and the system in the plants which has several sensors placed in several
locations connected with the plant system to monitor any H2S gas leakage and give
alarms.
Note that: from 1 to 10 ppm (parts per million) is safe, above 10 ppm is toxic.
1 – The Personal Device:
Figure 44 Personal Sensor

2 – The Plant sensor:
Figure 45 Plant sensor
31
3.3 Line Maintenance
3.3.1 Valves
In oil and gas plants, valves play a critical role in controlling the flow of gases and
liquids throughout various stages of production, processing, and distribution. Each
type of valve has a specific function, depending on the nature of the fluid and the
process conditions.
Figure 47 Gate Valve Figure 46 Ball Valve
Below is a detailed overview of the most commonly used valves in oil and gas
plants:
1. Gate Valves
 Function: Designed to start or stop the flow of fluids, typically used in
on/off applications.
 Operation: Operates by raising or lowering a gate (disc) into the flow path.
Figure 48 Gate Valves
32
 Advantages:
o Minimal pressure drops when fully open.
o Suitable for high-temperature and high-pressure applications.
 Disadvantages:
o Not suitable for throttling (flow regulation).
o Slow to open and close.
2. Globe Valves
 Function: Primarily used to regulate flow in a pipeline.
 Operation: The disc moves perpendicularly to the seat, creating a tight seal.
Figure 49 Globe Valves
 Advantages:
o Good throttling capabilities.
o Better flow control than gate valves.
 Disadvantages:
o Higher pressure drop compared to gate valves.
o More complex design.
3. Ball Valves
 Function: Used for on/off control and sometimes for flow regulation.
 Operation: A rotating ball with a hole (bore) controls the flow. When the
bore aligns with the pipeline, flow occurs.
33
Figure 50 Ball Valves
 Advantages:
o Quick to operate (90° turn).
o Tight sealing (zero leakage).
o Suitable for high-pressure and high-temperature systems.
 Disadvantages:
o Not ideal for throttling, especially in applications requiring
precision.
4. Check Valves
 Function: Allows flow in one direction and prevents reverse flow,
protecting equipment like pumps and compressors.
 Types:
o Swing Check Valve: A disc swings on a hinge, allowing flow in one
direction.
o Lift Check Valve: The disc lifts to permit flow and closes to prevent
reverse flow.
34
Figure 51 Check Valves
 Advantages:
o Simple and automatic operation.
o Protects against backflow.
 Disadvantages:
o Possible wear from frequent cycling.
o Pressure drop can occur due to the design.
3.3.2 Relief / Safety Valves
Relief valves, commonly known as Pressure Relief Valves (PRVs) or Safety
Valves. This is critical to prevent equipment damage, fires, explosions, and other
safety hazards.
They are designed to automatically release pressure when it exceeds a set pressure,
to protect the system from over-pressurization. They are essential in maintaining
safe operating conditions for vessels, pipelines, compressors, and other critical
equipment.
Figure 52 Relief Valves

35
Types of Relief Valves
a) Pressure Relief Valve (PRV)
 Function: Opens gradually as the pressure increases above a set point,
relieving the excess pressure.
 Common Applications: Used in various parts of gas processing plants,
storage tanks, and pipelines to release pressure when necessary.
 Operation: Typically spring-loaded; the spring pushes the valve closed
until the pressure exceeds the preset value, causing the valve to open and
release the excess pressure.
b) Safety Valve
 Function: Designed to open rapidly (pop action) to prevent a catastrophic
failure when the pressure in a system rises above the designated safe limit.
 Common Applications: Used on boilers, pressure vessels, and reactors,
typically in systems where immediate pressure release is required to protect
personnel and equipment.
 Operation: As soon as the pressure reaches the threshold, the valve fully
opens, allowing the rapid discharge of fluid.
c) Vacuum Relief Valve
 Function: Designed to allow air or gas into a system to prevent a vacuum
from forming, which could damage equipment or cause collapse.
 Common Applications: Used in storage tanks, pipelines, and process
vessels where there’s a risk of vacuum formation.
 Operation: Opens when the internal pressure drops below atmospheric
pressure, preventing equipment from imploding.
Components of Relief Valves
The key components of a relief valve include:
 Valve Body: Houses the internal parts and provides connection to the
system.
 Disc or Poppet: The element that lifts when pressure exceeds the set point
to allow fluid to pass through.
 Spring: Provides the closing force, opposing the system pressure. The
tension in the spring determines the valve’s set pressure.
 Adjusting Screw: Used to adjust the set pressure.
36
 Inlet and Outlet Ports: Where the fluid enters and exits during pressure
relief.
 Seat: Provides a sealing surface between the disc and the valve body to
ensure tight closure under normal conditions.
3.3.3 Bearings
Bearings are critical components in rotating equipment found in oil and gas plants,
such as compressors, pumps, turbines, and motors. They support the rotating shafts,
reduce friction, and allow smooth, reliable operation under high loads, speeds, and
temperatures.
Figure 53 Bearings
Below is a detailed overview of three to four critical types of bearings commonly

used in such equipment:
1. Journal Bearings (Sleeve Bearings)
 Function: Supports the rotating shaft by allowing it to glide over a thin film
of lubricant, reducing friction and wear.
 Construction: Consists of a smooth cylindrical bushing (or sleeve) that
wraps around the shaft with a thin layer of oil or lubricant between them.
 Common Applications: Used in high-speed, high-load applications such as
gas turbines, compressors, and large centrifugal pumps.
 Advantages:
o Suitable for high-speed operations.
o Can handle heavy radial loads.
o Operates with low friction under proper lubrication.
o Long lifespan with minimal wear if properly maintained.
37
 Disadvantages:
o Requires continuous lubrication to prevent damage.
o Not ideal for handling axial (thrust) loads.
o Sensitive to contamination in the lubricant, which can cause wear or
failure.
2. Ball Bearings
 Function: Supports both radial and axial (thrust) loads by using balls that
roll between the inner and outer raceways.
 Construction: Comprises an inner and outer ring (raceways) with balls in
between, separated by a cage that evenly distributes the load.
 Common Applications: Widely used in pumps, motors, fans, and
blowers for both radial and moderate axial load applications.
 Advantages:
o Suitable for both radial and axial loads.
o Low friction, resulting in efficient operation.
o Operates well at high speeds.
o Simple and easy to replace or maintain.
 Disadvantages:
o Limited load-carrying capacity compared to other types of bearings.
o Susceptible to wear or damage in contaminated environments.
o Not suitable for extremely heavy loads.
3. Roller Bearings (Cylindrical, Tapered, and Spherical)
a) Cylindrical Roller Bearings
 Function: Designed to handle heavy radial loads while allowing some axial
displacement.
 Construction: Features cylindrical rollers arranged between an inner and
outer ring. The rollers are longer than their diameter, providing more contact
area.
 Common Applications: Used in gearboxes, turbines, compressors, and
high-load rotating equipment.
38
 Advantages:
o High radial load capacity.
o Suitable for high-speed applications.
o Allows some axial movement (in specific designs), making them
ideal for applications where shaft expansion is expected.
 Disadvantages:
o Limited ability to handle axial loads unless combined with other
designs.
b) Tapered Roller Bearings
 Function: Handles both high radial and high axial loads, particularly in one
direction.
 Construction: The rollers are conical in shape, making contact between the
races and the roller a combination of rolling and sliding.
 Common Applications: Found in pumps, compressors, and turbines,
particularly where both radial and axial loads are present.
 Advantages:
o High load-carrying capacity in both radial and axial directions.
o Durable and robust for heavy-duty applications.
 Disadvantages:
o Can handle only axial loads in one direction unless used in pairs.
o Requires precise alignment during installation to avoid uneven wear.
c) Spherical Roller Bearings
 Function: Designed to accommodate misalignment between the shaft and
housing, while handling both radial and axial loads.
 Construction: Has two rows of barrel-shaped rollers inside an outer ring,
allowing for self-alignment.
 Common Applications: Ideal for vibrating screens, crushers, turbines,
and applications where shaft deflection or misalignment is common.
39
 Advantages:
o Can handle heavy radial and moderate axial loads.
o Self-aligning, ideal for systems with shaft misalignment or
deflection.
o Suitable for high-load, low-speed applications.
 Disadvantages:
o Higher friction compared to ball or cylindrical roller bearings.
o Limited speed capability relative to other bearing types.
4. Thrust Bearings
 Function: Designed to specifically handle high axial (thrust) loads in
rotating equipment.
 Construction: Consists of a set of flat or tapered rolling elements (balls,
cylindrical rollers, or tapered rollers) positioned to manage the force parallel
to the shaft.
 Common Applications: Found in pumps, compressors, turbines, and
gearboxes, where significant axial loads need to be supported.
 Advantages:
o Excellent for handling high axial loads.
o Specific designs allow for high precision and low friction.
 Disadvantages:
o Not designed to handle radial loads (except in combined bearing
systems).
o Requires precise alignment to avoid premature wear.
40
3.3.4 Shaft Alignment
Shaft alignment is the procedure to bring the centerlines of driver and driven
shafts into one line. The geometry of both units should coincide with the actual
centerline of rotation. The task of shaft alignment is NOT so easy.
Figure 54 Shaft Alignment
Misalignment: Any error in lining the centerlines of the driver and driven.
Types of Misalignments:
a) Radial Misalignment: The centerline of the driver and driven are parallel
but NOT in a line. It can be in both Horizontal and Vertical planes.
Figure 55 Radial Misalignment
b) Angular Misalignment: The center line of both shafts is NOT parallel and
at a slight angle to each other.
Figure 56 Angular Misalignment
41
c) Gap or Axial Misalignment: Where there is too much or little axial
distance between the shifts.
Figure 57 Gap or Axial Misalignment
Causes and Effects of Misalignments:

 Causes: Any misalignment types can occur as a result of the following:
 Incorrect coupling installation.

 Loosening of the holding down bolts.
 Wear in the bearing OR bearing housings.
 Los of balancing of the rotating components.
 Mechanical damage of the shaft OR other components.
 Effects: There are many effects can be caused by the misalignment like:
 Excessive noise during operation.
 Excessive Vibration.
 High usage of lubrication.
 Overheating of Bearings, Coupling, and Gears.
 Heavy bearing wear.
 Heavy wear OR damage to coupling bolts, springs, disks, or rubber
bushes.
Rough Alignment Methods:
a) Checking the Radial Misalignment:
Place a straight edge or steel rule to check across the top and bottom of the
couplings. As well, measure any gap at both sides of coupling.
Figure 58 Checking the Radial Misalignment
42
 To adjust the gap vertically:
 Use feeler gauges to measure any gap at point (X).
 A shim (shims) its thickness equal to the gap Placed under the
lower unit to level it up.
 To adjust the gap horizontally:
 Use feeler gauges to measure any gap at both sides.
 Move the driver (usually) or the driven sideways to eliminated
the gap; this movement by using the jacking bolts.
Figure 59 Adjust the horizontally & Vertically
b) Checking the Angular Misalignment:

The Right condition is where the face gap of both coupling halves is equal at
each point; 4 points are taken at 90 degrees; top, bottom, left and right.
Figure 60 Checking the Angular Misalignment
 Measure the gap at the points by using a wedge gauge.

 When the readings are NOT equal, we have angular misalignment.
 When the top gap is bigger than the bottom, we need to insert shims
under the Back feet.
 When the bottom gap is bigger, we need to insert shims under the front
feet.
43
c) Checking the End float:
 Check the shafts have sufficient movement in horizontal plane to
provide the required end float.
 Check the shafts are pushed apart.
 Use a wedge gauge to check the coupling gap at the 4 points; 90 degrees
intervals.
 Move the driving unit (Motor) until the gap is corrected.
Figure 61 Checking the End float
Precise Alignment Methods:

a) Face-Peripheral Indicator Method:
 Connect the bracket solidly to the master coupling and position
indicators on the face and periphery of another coupling.
 Zero the indicators at the 12 o'clock position.
 Gradually rotate the shaft and bracket arrangement through 90° intervals
halting at 3,6 and 9 o'clock positions. Record each reading to see if it is
a plus or minus.
 Return to the 12 o'clock position to see if the indicator re-zero.
 Utilize 12 and 6 o'clock position readings and insert a shim at the front
and rear feet as required.
 Utilize 3 and 9 o'clock position readings and move the unit towards
left or right as required.
 Tighten the holding-down bolts, and recheck for accurate alignment.
Note: Only one shaft should be rotated.
Figure 62 Face-Peripheral Indicator Method
44
b) Reverse Indicator Method:
 Connect the bracket solidly to both couplings and position indicators on
the periphery.
 Zero the indicators at the 12 o'clock position.
 Gradually rotate the shaft and bracket arrangement through 90° intervals
halting at 3,6 and 9 o'clock positions. Record each reading to see if it is
a plus or minus for both indicators.
 Return to the 12 o'clock position to see if the indicator re-zero.
 Interpret the readings and insert shims at the front and rear feet as
required.
 Move the unit towards left or right as required.
 Tighten the holding-down bolts, and recheck for accurate alignment.
Figure 63 Reverse Indicator Method
Validity Rule:
Top reading + Bottom reading = Left reading + Right reading
Examples:
Figure 64 Validity Rule
45
Here some photos from the felid when we did the shaft alignment for one of the
injection pumps after installing the motor of the pump:
Figure 65 shaft alignment for one of the injection pumps
3.4 Reliability Unit (RU)

3.4.1 Lubrication Condition Monitoring (LCM)
Lubrication Condition Monitoring is the process of assessing the health,
effectiveness, and contamination levels of lubricants used in machinery and
equipment. This helps ensure optimal lubrication, detect potential issues, and
prevent equipment failures.
Figure 66 LCM Samples
46
There are lubrication oil tanks next to the critical rotating equipment like the
pumps and compressors to feed the bearing of the machine.
 LEM Samples of critical rotating equipment are an important oil test that
happens every 3 months to investigate any problem and prevent equipment
failure.
The problems that should be checked:
o Solids
o Water
o Emulsion
o Sand
o Iron wear is a very dark color.
After that, send the samples to the lab to examine them, where they
check:
o The color of lubrication according to ASTM Color.
Figure 67 ASTM LCM Colors
o Percentage of water.
o Viscosity at 40 ℃ and 100 ℃.
o Solids and Metal contents.
o Oxidation stability, etc.
3.4.2 Switchover of Rotating Equipment

The Switchover of Rotating Equipment is a maintenance strategy where the
operation alternates between a primary and standby (backup) rotating machine,
such as pumps, compressors, or fans. This practice ensures even wear on both
units, reducing the risk of overuse or prolonged inactivity, which can lead to
mechanical failure. By periodically switching the equipment, the switchover
process improves equipment reliability, minimizes unplanned downtime, and
extends the overall life of both machines. It also ensures that the standby unit is
always operational and ready for use if the primary equipment fails.
47
It is an essential part of a maintenance plan, especially in industries like oil and
gas, petrochemicals, and manufacturing where continuous operation is critical. It
ensures that equipment reliability is maintained by distributing operational loads
between primary and standby machines, helping prevent unexpected breakdowns.
There are some causes why we should do the Switchover of Rotating
Equipment:
 Balancing Wear and Tear.
 Preventing Standby Deterioration.
 Minimizing Unplanned Downtime.
 Proactive Maintenance.
 Automation in Switchover.
 Optimizing Energy Consumption.
 Testing and Verification.
 Switchover Scheduling.
Benefits of Rotating Equipment Switchover:

 Extended Equipment Life.
 Increased Reliability.
 Cost Savings.
 Improved Safety.
Example in Practice:
In the Gas-Oil Separation Plant (GOSP), a pump used to move oil through the
processing facility would typically have a standby unit. Both pumps (the primary
and the standby) are rotated on a regular schedule, such as switching every week
or every month. This ensures that both pumps stay operational and that the backup
is ready if the primary pump needs to be shut down for repairs.
Figure 68 An Example of Switchover

48
4 GENERAL SKILLS ACQUIRED
There are lots of skills that I gained through my CO-OP Training, some of them as follow:
 Business Communication.  Telephone Communication.
 Send Formal Emails.  Excel Skills:

1 Enter Data
2 Calculations.
 Reading & Reviewing.
49
5 CONCLUSIONS
My training at Saudi Aramco has enriched my expertise with valuable opportunities to gain
professional experience. During that period, I learned various professional and personal skills
to gain valuable hands-on knowledge that allowed me to apply the theoretical concepts I have
learned in real-world industrial setups.
I have learned about the Gas and oil separation process, and the critical rotation equipment in
the plants as pumps and compressors. As well as I have investigated and reviewed some of
their defects. All of that was in the felid.
On the other hand, the maintenance and reliability management I have learned a lot of things
as maintenance strategy assessment, vibration analysis, and how to follow up with tasks like
Lubrication Condition Monitoring (LCM), and reliability recommendations.
And I do not forget the skills that I acquired during that period, working in MS Excel increased
my ability to follow up the work in a short time and easy way as it made the calculations easy
for me. Skills in communicating with different people and environments was a great trip.
For all of this, I am very thankful to my all teams and members that I worked with at Saudi
Aramco, whose support was a motivation for me in this learning phase.
This training expanded my technical skills and enhanced my understanding of teamwork,
precision, and the importance of industrial operations. I am confident that the experience and
knowledge gained during this training will be valuable for pursuing my career as a mechanical
engineer.
50
6 WEEKLY REPORTS
In this section you can find my weekly reports as follow below:
51
WEEKLY RECORD OF TRAINING
WEEK NO: ONE FROM: 24/06/2024 TO: 27/06/2024
STUDENT NAME: Ahmed Hassan AL-Nayem I.D. No.: 401 900 982
NAME OF THE COMPANY: Saudi Aramco
Write below briefly:

a. The work you have done this week.
b. Any new tool/equipment you have used or something new you have learnt.
As a new intern, the first week is for introducing the general information about the
company:
1- To know the company’s structure in general.
2- To introduce its lines, departments, divisions, units, and groups.
3- Inform us about their policies and rules.
Also, they informed me where I will be in the training period and what they are doing
in that unit: Aramco – Upstream Business line – Central Ghawar Producing Dept. –
Central Ghawar Maintenance. Div. – Reliability Unit.
In Central Ghawar dept.: they manage 12 GOSPs (Gas Oil Separation Plants)
through two divisions (Plant Engineering and Maintenance).
In the Reliability unit, we are dealing with Rotating equipments.
Training Supervisor’s Assessment of the Student’s Performance this Week:
Excellent Very Good Good Satisfactory Not Satisfactory

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:
Nasser Almulhim 9/7/2024

Supervisor’s Name Signature Date
WEEK NO: TWO FROM: 30/06/2024 TO: 04/07/2024

As a new intern, before starting doing any work I have to take some courses that my
supervisor planned to me. According to the plan, I have taken:
1- Fire Safety Awareness – Office Safety
2- Industrial Fire Safety Awareness
3- H2S (Hydrogen Sulfide safety course)
4- Hazard Recognition and control
5- Privacy Data Protection
6- ICS for Emergency Responders

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: THREE FROM: 07/07/2024 TO: 11/07/2024

1- Attended SAOO Safety Orientation Course to get plant access.

2- Attended a meeting for a new Technology of a pump (Hydraulic Diaphragm
Metering Pump) with ProMinent Evolution Mikro Company.
3- Attended a meeting with the mangers, engineers and operators to show their plan
for shut down one of the GOSPs (Gas & oil separation plant) for plant
maintenance.
1- Centrifugal pump principle of operation.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: Four FROM: 14/07/2024 TO: 18/07/2024

In this week I start my rotation in different units, for week 4 I work with Filed
Engineering Unit (FEU). FEU deals with pipe lines that oil flow in it from the wells to
the Gas Oil Separation Plants (GOSPs) and the injection water from the GOSPs to the
wells. Their work boils down to 3 steps:
1- Defect Notification: Which is a report of the problem written by the inspector to the
FEU. The common problems are:
 Internal / External Corrosion
 Pin Hole
 Scale in pipes
2- Create a plan which they called it (a Package), where the package contains the
whole scope of work to solve the defect. Most of the solutions are:
 Replacement of the defected piping sections.
 Sleeve installation of pin hole sections.
 Coating of the corrosion sections.
3- Hydro Test for the defected piping sections which depends on ASME Standard.
1- Ultrasonic Thickness Measurement Sensor.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: Five FROM: 21/07/2024 TO: 25/07/2024

In week five, I start my second rotation with Operation Team (Site Visit) in one of
the Gas & Oil Separation Plants to have the overview idea of the process
1- Have an idea of the plant components (Vessels):
 HPPT: High Pressure Production Trap (Big vessel- 3 Phase).
 LPPT: Low Pressure Production Trap (Big vessel- 2 Phase).
 HPTT: High Pressure Test Trap (Small vessel- 3 Phase).
 WOSP: Water Oil Separation. (Big vessel- 2 Phase).
 EWT: Emergency Water Tank. (Tank).
 Dehydrator (Big vessel- 2 Phase- Electrical).
 Desalter (Big vessel- 2 Phase- Electrical).
 Degassing.
2- Understand the general idea of the plant Tracks:
 Oil Track - Gas Track - Water Track.
1- Renting Gas Monitor Device (Gas Detector) which is a personal sensor for
Harm released gases like H2S.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: Six FROM: 28/07/2024 TO: 01/08/2024

Another week with Operation Team.
1- Have an idea of the plant components (Pumps & compressors):
 Charge Pumps.
 Recycle Pumps.
 Booster Pumps.
 Wash Water Pumps.
 Injection Pumps.
 Reprocessing Pump.
 LP & HP Compressors.
2- Understanding the GOSP Process and draw a sketch of what I understood-
in the figure below.
1- Common Problems of Centrifugal pump: Cavitation, wear of impeller,
corrosion, overheating, leakage along rotary shaft and surge.
2- Types of Centrifugal pump impellers: Open, Semi-open and closed.
3- Types of Centrifugal pump impeller Vanes: Radial Vane, forward Vane and
backward Vane.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

Gas & Oil Separation Plant Process
REHEATER HP-1
Discharge Dram
HP-1 After
Compressor Cooler-2
HP FROM 100 psi
Suction Dram
TO 225 psi
Off Gas
Gas Gathering System
13.5 PSIA at 130 ْ F
After REHEATER HP-2
Cooler-1 LP Discharge Dram
Compressor LP HP-2 After
FROM 20 psi Suction Dram
TO 130 psi Compressor Cooler-3
Chemical Tanks
Corrosion Corrosion
Preventer Preventer
Test Header
HPTT
Dehydrator
Desalter
Auto-valve Motor Valve 100 - 120 psi
HPPT-1
Works By Compressed Air
690 - 825 Kpa Degassing
Chemical Injection Points OFF
Production Header 30 - 50 psi 120 - 150 psi
207 - 345 Kpa Charge 825 - 1030 Kpa 120 psi 50 psi
By Pass Valve
By Pass Valve
Pump-3 825 Kpa
120 psi
345 Kpa
Booster 825 Kpa

Manual Valve
Manual Valve Pump-1
Manual Valve Recycle 120 psi
Pumps 825 Kpa
Chemical Tanks
Scale Corrosion Separation
Wells Pipelines Preventer Preventer Helper
OFF
LPPT 30 - 50 psi 120 - 150 psi
207 - 345 Kpa Charge 825 - 1030 Kpa
Scale Inhibitor Demulsifier 30 - 50 psi
207 - 345 Kpa Pump-2 130 psi Booster Water From
900 Kpa Pump-2 a Well
Multi-Wells Pipeline HPPT-2

100 - 120 psi
690 - 825 Kpa 200 psi
1380 Kpa Wash Water
Pump-1
ON
50 psi
120 psi
30 - 50 psi 120 - 150 psi 825 Kpa 345 Kpa
207 - 345 Kpa Charge 825 - 1030 Kpa 400 psi

2760 Kpa
Pump-1 Shipper
Manual Valve Wash Water
Pump
Pump-2
Wells Pipelines
70 psi
480 Kpa EWT
WOSP-1 Injection
Pumps Stabilizing Plants
Group-1
Dry Crude Oil with:
3700 psi
- Water Less than 0.2 %
70 psi
480 Kpa 25500 Kpa - Salt Less than 10 PTB
WOSP-2`
0.9 psi
6.2 Kpa
- Hydrogen Sulfide Less than 70 ppm
Reprocessing
Injection Pump
Pumps 70 psi
480 Kpa
Group-2
3700 psi
25500 Kpa
Salty Water Bake to the Wells
Wet Crude Oil Header Injection Water Line HPPT: High Pressure Production Trap
Multi - Wells Wet Crude Oil Wash Water Line LPPT: Low Pressure Production Trap
Oil Trace Dry Crude Oil Line HPTT: High Pressure Test Trap
Water Trace Emergency Water Line WOSP: Water Oil Separation

Gas Trace Gas Return Line EWT: Emergency Water Tank
Intern Student: Ahmed Hassan AL.Nayem ID: ALNAYEAH
WEEK NO: Seven FROM: 04/08/2024 TO: 08/08/2024

In week Seven, I started my third rotation with Line Maintenance (with a Machinist
crew) which covers two plants to investigate the problems in the plants and
maintain, remove, or install the equipment.
1- Site visit to check the reason of pressure drop in the Jockey pump in the safety
system:
 Check the manual gage pressure. (No problem)
 Check the (check-valve) to see if there is any backwater that may cause a pressure
drop. (No problem)
 Then we found that there are two lines (discharged line, recycle line),
the recycle valve should be closed but it was open so, because of it the pressure in
the gage was dropped.
2- Install two Relief valves for different Vessels:
 WOSP Relief Valve: the WOSP Vessel is supposed to have 70 psi inside it. If the
pressure increases more the 70 psi the Relief Valve will open slowly and discharge
the gas to the flare to maintain the pressure at 70 psi.
 HPPT Relief Valve: the HPPT Vessel is supposed to have 100-120 psi inside it. If
the pressure increases more than that the Relief Valve will open fully and discharge
the gas to the flare.
1- Positive displacement pump for chemical injection.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: 8 FROM: 11/08/2024 TO: 15/08/2024

1- Alignment of a 19-ton motor with the injection multi-stage centrifugal pump:
a) Rough Alignment:
 Using a feeler gauge to adjust the motor vertically and horizontally
Roughly (with a big scale)
b) Soft Alignment:
 Using an inside micrometer to adjust the motor axially depends on the
size of the coupling.
 Using a dial indicator to adjust the motor vertically and horizontally
Softly (with a small scale).
 Using a micrometer precision carbide tip to measure of the thickness
of the steel shim sheets which can adjust the motor vertically by adding
or removing them.
How can we move the 19-ton motor?
 For Horizontal and axial direction: using jack Bolts.
 For vertical direction: using manual hydraulic pump.
2- Install a Relief valve and Remove another one:
 Install the Relief valve of the Dehydrator where the pressure of it is
120 psi to 150 psi and the Relief valve open when it arrives to 225 psi.
 Remove the Relief valve of the Emergency Water Tanke.
3- Injects the bearings of after-cooler fan motors with Grease.
1- Flexible diaphragm coupling.
2- Recycle valve with tiger teeth for broken the high pressure.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: 9 FROM: 18/08/2024 TO: 22/08/2024

1- Test of the rotation, vibration, temperature, etc. of the motor.
2- Install the coupling spool for the injection pump with the motor, and turn it ON.
3- Install a Relief valve and Remove another one in the Gas Trace:
 For safety purpose, there are relief valves in some points in the gas trace if the is a
sudden increase in the pressure.
 We face a problem while installing the relief valve, where the gate valve which place
under the relief was leaking of the gas, and that prevent us to install it.
4- Investigate the problem with instrument Crew:
 Operation Team report that there is a valve in the gas trace can NOT be controlled
in opening or closing.
 The instrument checked the actuator and they found there is no problem in the
actuator.
 Then, the machinist crew checked the valve and found the drive wheel of the valve
was stuck due to the corrosion.
1- Gravity Pump: A pump which return the oil from outside the plant to the separation
process.
 Vertical Centrifugal Pump with 3 stages.
 It has 1 Mechanical Seal.
 1 Bearing Housing.
 2 Coupling; 1 inside and 1 outside.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: 10 FROM: 25/08/2024 TO: 29/08/2024

1- Check LCM Samples; Lubrication Condition Monitoring:
 There are tanks of lubrication oil next the critical rotating equipment like the pumps
and compressors to feed the bearing of the machine.
 LEM Samples of critical rotating equipment is an important oil test that happen every
3 months to investigate any problem and prevent the equipment failure.
 The problems that should be checked:
o Solids
o Water
o Emulsion
o Sand
o Iron wear where it has a very dark color.
 After that, send the samples to the lab to examines it, where they check:
o The color of lubrication according to ASTM Color.
o Percentage of water
o Viscosity at 40 ℃ and 100 ℃.
o Solids and Metal contents.
o Oxidation stability, etc.
1- Regulator valve pressure: to reduce the pressure from high level to lower level.
2- Pilot OR Vacuum safety valve: to remove the prevent the Oxygen to pass through it.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: 11 FROM: 01/09/2024 TO: 05/09/2024

1- Collect and Send LCM (Lubrication Condition Monitoring) Samples:

 Collect 91 LCM Samples of Rotating Equipment.
 After checking the LCM samples that received from 6 GOSPs (Gas & Oil Separation
Plants), we send them to the lab for examination.
2- Review and update the Critical Motors Maintenance Strategy Assessment:

 All equipment in the plants have a strategy of maintenance.
 Here, we have 12 plants have 134 critical electrical motors for different rotating Equip. like
pumps and compressors.
 Reviewing the overhaul status of those motors.
1- Promix sensor: A sensor where it is placed on rotating Equip. such as shafts, bearings,
Gearbox, etc. to monitoring the range of vibration since it’s an important value to follow the
health of the equipment.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: 12 FROM: 08/09/2024 TO: 12/09/2024

1- Pipe Isolation:
Important part of providing safe maintenance is to ensure the part of the facility being
worked on, is completely isolated. There are 4 Methods of isolation:
 Single Bloke Valve.
 Double Bloke & Bleed.
 Install Blind.
 Disconnect Spool/Isolation Valve.
2- Hydrostatic Pressure Testing of the Pipeline:
Hydrostatic Pressure Testing of a Pipeline is a critical process used to validate the

integrity and strength of pipelines, ensuring they can safely operate under pressure
without leaking or failing.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: 13 FROM: 15/09/2024 TO: 19/09/2024

1- Review the Switchover Program for the Rotating Equipment:
It is a maintenance strategy designed to alternate between primary and standby machinery to
balance operational wear and extend equipment life. It ensures that both units like pumps and
compressors are regularly used, reducing the risk of failure from prolonged idleness or overuse,
while maintaining continuous operation in case of equipment failure.
2- Review vibration investigation reports:

 Vibration investigation report of a LP Gas Compressor:
- Analysis, Normal Behavior and Abnormal Behavior.
- Cause of high vibration.
- Recommendations of solution.
 Vibration investigation report of an injection pump.
- Findings.
- Analysis.
 Vibration investigation report of a Fire Water pump.
- Findings.
- Analysis.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:
30/9/2024
Nasser Almulhim
WEEK NO: 14 FROM: 24 /09/2024 TO: 26/09/2024

1- Forming and entering an Excel Sheet Data of Reliability Unit Recommendations:
- RU have regular recommendation letters.
- They have to follow up with those Recommendations.
- Since they are a lot, we form an Excel Sheet to follow them in easy way.
- It contains all Recommendations from 2021 to present.
This is an example of that sheet:

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: 15 FROM: 29 /09/2024 TO: 3/10/2024

1- Enter the data of the Reliability Unit Recommendations:

2- Follow up with some of them:

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:

WEEK NO: 16 FROM: 6 /10/2024 TO: 10/10/2024

1- Prepare a presentation using PPT that contain my experience during the COOP Training.
2- Present the benefit and gained experience to the Reliability Unit.
3- Clearance from the company.

[90-100%] [80-89%] [70-79%] [60-69%] [less than 60%]
Any other comment:


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DEPARTMENT OF MECHANICAL ENGINEERING

JUBAIL INDUSTRIAL COLLEGE

FINAL REPORT ON COOPERATIVE TRAINING

SEMESTER 453 DATE 10 / 10 / 2024

1.1 Introduction of the Report ................................................................................................ 1

1.2 Internship Plan.................................................................................................................. 1

2 COMPANY PROFILE .............................................................................................................2

3 DETAILS OF WORK EXPERINCE .......................................................................................3

3.1 Felid Engineering Unit (FEU) .......................................................................................... 3

3.1.1 Defect Notification of Pipelines................................................................................ 3

3.1.2 Package Solutions of the Defect ............................................................................... 7

3.1.3 Pipe Isolation ............................................................................................................ 8

3.1.4 Hydrostatic Pressure Testing of the Pipeline .......................................................... 12

3.2 Operation Team .............................................................................................................. 13

3.2.1 Gas & Oil Separation Plants (GOSPs) Components .............................................. 13

3.2.2 GOSPs Process........................................................................................................ 24

3.2.3 Safety Device .......................................................................................................... 31

3.3 Line Maintenance ........................................................................................................... 32

3.3.1 Valves ..................................................................................................................... 32

3.3.2 Relief / Safety Valves ............................................................................................. 35

3.3.3 Bearings .................................................................................................................. 37

3.3.4 Shaft Alignment ...................................................................................................... 41

3.4 Reliability Unit (RU)...................................................................................................... 46

3.4.1 Lubrication Condition Monitoring (LCM) ............................................................. 46

4 GENERAL SKILLS ACQUIRED .........................................................................................49

6 WEEKLY REPORTS .............................................................................................................51

1.2 Internship Plan

5 Working with Line Maintenance CGMD/UGOSP-7&8 3 Weeks

Saudi Aramco Values: Saudi Aramco Products:

For the Reliability Unit (RU) Responsibilities include:

The common Problems in the pipeline as follow:

1- Internal / External Corrosion:

Figure 1 Internal Corrosion

Figure 2 External Corrosion

2- Pin Hole in Pipeline:

Figure 3 Pin Hole

 Regular Inspections: Use techniques such as ultrasonic testing to

Figure 4 Scale in Pipes

3.1.2 Package Solutions of the Defect

Package Solutions of the Defect: This involves developing a comprehensive plan,

The common solutions for above defects are:

1- Replacement of the defected piping sections:

Figure 5 Replacement of the defected selection

Figure 6 Sleeve Installation

Coating of corrosion sections involves applying a protective layer to areas of a

Figure 7 Coating of pipelines

3.1.3 Pipe Isolation

In Hydrocarbon processing facilities, a major safety risk is posed by maintenance

Figure 8 Single Bloke Valve

2- Double Bloke & Bleed:

Figure 10 Install Blind Figure 11 A Blind

4- Disconnect Spool/Isolation Valve:

Figure 12 Disconnect Spool/Isolation Valve

When to use it:

Is it Positive Isolation? Yes

5. Depressurization and Draining: Once the test is completed and passed,

3.2.1 Gas & Oil Separation Plants (GOSPs) Components

1. HPPT: High Pressure Production Trap:

Figure 13 High Pressure Production Trap.1

2. LPPT: Low Pressure Production Trap: