YANBU INDUSTRIAL COLLEGE

DEPARTMENT OF MECHANICAL ENGINEERING TECHNOLOGY

‫قسم تقنية الهندسة الميكانيكية‬

COOP training
MCET 310

Name of the Industry/Company/Establishment

(Replace above with Industry/Company Logo or Delete the text box)

Prepared By

Name: Hasan Mohammed Samkari

ID number: 3713127

Reviewed By

Name of Reviewer

Semester 3, 2020
 Table of contents:
Acknowledgement_____________________5

Abstract_______________________________6

Chapter one _________________________________7 to 8

Chapter two_________________________________9 to 11

Chapter three _______________________________12 to 22

Chapter four________________________________23 to 29

Conclusion______________________________________30

References______________________________________31

Table of figures
Figure 3.1 Types of pumps _____________________________________________11
Figure 3.2 reciprocating pumps__________________________________________12

Figure 3.3 Rotary pumps _________________________________________________13

Figure 3.4 Dynamic pumps______________________________________________13

Figure 3.5 Centrifugal pumps _____________________________________________14

Figure 3.6 Types of turbines _____________________________________14

Figure 3.7 Turbine _____________________________________________14

Figure 3.8 Water Turbine _____________________________________________15

Figure 3.9 Wind Turbine __________________________________16

Figure 3.10 Types of compressors_____________________________________16

Figure 3.11 heat Exchangers _________________________________17

Figure 3.12 Types of seals __________________________________________18

Figure 3.13 Bearings ___________________________________19

Figure 3.14 Ball Bearing_______________________________________________19

Figure 3.15 Roller Bearings ____________________________________20

Figure 4.1: Liquid _______________________________________23

Figure 4.2: Putting the Liquid ____________________________________________23

Figure 4.3: Magnetic Particle _____________________________________________24

Figure 4.4: Thermography Camera ________________________________________________24

Figure 4.5: Videoscope system ___________________________________________24

Figure 4.6: Hardness testers _____________________________________________________25

Figure 4.7 Qualification of a good inspector_________________________25

Figure 4.8 Explosion Proof Camera _______________________________________26

Figure 4.9 Oil Breather ___________________________27

Figure 4.10 DE Casing ________________________27

Figure 4.11 Bearing for Casing __________________________________________27

Figure 4.12 restriction of oil circulation ________________________28

Figure 4.13 Cleaned Bearing Housing __________________________________28

Figure 4.14 DE and NDE Bearing Cover and Bushing ____________________________28

Figure 4.15 Internally cleaned Bearing Housing_______________________28

Figure 4.16

Figure 4.17 New assembly of bearing housing. _______________________________29

Acknowledgements:
I would like to be grateful and thankful for the people who support me and tech me during my
COOP training. Thank to everyone who provided any kind of assistance to me in form of advice
and suggestion. Especially my family, they support me in any step that I move every single day
of my life. Thanks to Royal Commission for giving me the opportunity to use their facilities from
primary level to college level in Yanbu Industrial College. I would like to thank everyone for
giving me the chance to work and learn with them, I got a lot of knowledge and experience. I
am also thankful for having the chance to meet so many professional's people. Also, I would like
to thanks Natpet company for the opportunity to train under their supervision, I gain a lot of
knowledge and experience. Special thanks to my supervisors: Supervisor Hani Ali and supervisor
Abdulrahman Mohammed

Abstract/Summary:
I'll talk about several things and summarize everything in the report. First, we will talk about
engineering and it has many types of engineering, such as manufacturing engineering for
manufacturing things, maintenance engineering for repairing and maintenance of parts, and
electrical engineering for all machines. And there are many equipment's in engineering that are
used in the machines contain important things such as the Bearing, Mechanical Seal, Gas, and
others. Secondly, I learned from the Petrochemical Company, Natpet, which specializes in the
production of polypropylene. I also learned about some of their equipment, such as pumps and
compressors and the heater. Thirdly, and the most important thing is safety, which everyone
must learn and follow in every possible way, especially in large factories that have many
machines. You must wear safety, such as safety shoes, safety glasses, safety helmets, and safety
gloves. These are the most important things that will protect you from the dangers.

Chapter I: Introduction

National Petrochemical Industrial Company (NATPET):

NATPET is a closed joint stock company incorporated in the Kingdom of Saudi Arabia with its
head office in Jeddah and Propylene/Polypropylene Complex in Yanbu Industrial City to produce
Propylene, Polypropylene and its derivatives, having a name plate production capacity of
400,000 tons per year of polypropylene. The authorized and paid-up capital comprised 107
million shares of SR10 per share as at 31 December 2018. NATPET uses UOP's Oleflex®
technology to convert propane gas into propylene and then transports the propylene to a
400,000 t/y polypropylene plant that uses the amazing Spheripol ® technology from polyolefins
leader LyondellBasell. NATPET's plant is equipped to produce a wide variety of PP grade
product blends (homopolymers, random and phase change copolymers) to serve diverse
market segments such as rigid and flexible packaging, fibers, raffia, FMCG, automotive and
more.

BONAR-NATPET
Bonar-Natpet is a joint venture (JV) between NATPET and Low & Bonar PLC (listed on London
Stock Exchange) of the United Kingdom, to produce geotextile products for the fast-growing
civil engineering infrastructure markets in the Middle East and the Indian subcontinent. The
plant has a capacity of 17,300 tons/year of staple fiber and 9,600 tons/year of nonwoven
geotextiles.

Product uses:
Polypropylene is the fastest growing material suitable for a wide variety of articles. It’s used in
making House ware, Furniture, Food packaging, Medical, Cosmetic, Hosiery, Stationery Items,
Fiber, Packaging, Caps and Closures, Films & sheets, Automotive, Engineering parts & tools.

Major Raw Materials & Source

• Propane & Natural Gas-From Saudi Aramco Refinery.

• Ethylene -From SABIC- Yanked.

• Nitrogen - From SABIC Gas.

• Water - From Royal Commission.

• Power (electricity) - From Marafiq.

NATPET Yanbu - Operation and Management Departments.

1. Industrial Security, Health, Safety and Environment and Fire

2. PDH-Operation

3. PP & Utilities-Operation

4. Maintenance & Reliability

5. Technical, Project & Inspection (TPID)

6. Process Engineering and Technology

7. Laboratory & Product Development

8. Training and Career Development

9. H.R. and Administration

10. Material and Procurement

11. Logistics

12. Information Technology

Chapter 2: Safety

1 Safety
Safety is the condition of being protected from harm or other non-desirable outcomes. Safety
can also refer to the control of recognized hazards in order to achieve an acceptable level of
risk. In any community safety is very important but in Schlumberger safety is number one in the
list so I will talk about what company provide for us in term of this .

2.2 SIPP
SIPP is Schlumberger Injury Prevention Program. It is based on preventing injury before it
happened using body control Techniques. Body Control Techniques is a method that use to
control the body without getting an injury. it divided into seven parts:
[Link] of Strength
The key to Line of Strength is to orientate your feet in the direction of the force.

2. Side Stepping
With Side Stepping we maintain stability by orientating our Line of Strength in the direction we
are moving. Notice how the combination of techniques is used to take control. Side Stepping,
Smart Grip, Safe Working Zones and Watch You Head.)

3. Safe Working Zones

The technique of Safe Working Zones taught us to keep the load close to our bodies (in the
Green Zone). Learn to avoid working in the Red Zones.

4. Smart Grip
Use your Strength Fingers to activate the large muscle groups giving yourself more stability and
control.

5. Watch Your Head

With Watch Your Head remember to maximize your eye movement ant to minimize your head
movement to maintain balance.

6. Bracing
By activating the large muscle groups of the legs we can prevent unequal forces across the discs
in the spine.

7. Spinal Alignment
Lift with the largest muscles you have, the thigh/leg muscles

2.3 NEST
New Employee Safety Training (NEST) is a training vehicle for new Schlumberger employees on
safety and the environment. The purpose of programs such as NEST is to begin an employee's
tenure with a strong emphasis on safety and an appreciation for the environment. Concern for
safety and the environment should be as much a part of corporate culture as are service to
clients and return to stockholders. A formal training program is an organized way to accomplish
these goals.

The NEST curriculum includes five days of training in the areas of radiation, explosives, driving,
water survival, firefighting, first aid and cardiopulmonary resuscitation (CPR), governmental
regulations, hazardous materials and personal protective equipment. The program consists of
classroom and protective equipment. The program consists of classroom and hands-on training
and testing.

WHAT IS H2S GAS?

Hydrogen Sulfide (H2S) is a gas commonly found during the drilling and production of crude oil
and natural gas, plus in wastewater treatment and utility facilities and sewers. The gas is
produced as a result of the microbial breakdown of organic materials in the absence of oxygen.
Colorless, flammable, poisonous and corrosive, H2S gas is noticeable by its rotten egg smell.
With toxicity like carbon monoxide, which prevents cellular respiration, monitoring and early
detection of H2S could mean the difference between life and death.

IMPACT ON SAFETY (SHORT-TERM)

Gas is a silent threat, often invisible to the body’s senses. Inhalation is the primary route of
exposure to hydrogen sulfide. Though it may be easily smelled by some people at small
concentrations, continuous exposure to even low levels of H2S quickly deadens the sense of
smell (olfactory desensitization). Exposure to high levels of the gas can deaden the sense of
smell instantly. Although the scent of H2S is a characteristic, smell is not a dependable indicator
of H2S gas presence or for indicating increasing concentrations of the gas. H2S irritates the
mucous membranes of the body and the respiratory tract, among other things. Following
exposure, short-term, or acute, symptoms may include a headache, nausea, convulsions, and
eye and skin irritation. Injury to the central nervous system can be immediate and serious after
exposure. At high concentrations, only a few breaths are needed to induce unconsciousness,
coma, respiratory paralysis, seizures, even death.

Impact on facilities
Heavier than air, H2S gas accumulates in low lying areas of poorly ventilated spaces. In oil and
gas applications, sour gas (products containing H2S gas) in the presence of air and moisture
may form sulfuric acid, capable of corroding metals. Facility equipment, including the internal
surfaces of various components, faces reduced durability and impact strength, potentially
leading to premature failure.

Detection of H2S gas

Hydrogen sulfide is a fast-acting poison, impacting many systems within the body. Wearable gas
sensors are necessary for early detection and alerting, as the body’s senses are not reliable
indicators. Importantly, gas detectors such as Blackline's G7 wireless gas detector, should be
considered as they alert live monitoring personnel of worker H2S gas exposure. Devices with a
fast response time and sturdy construction are important for use in harsh environments where
H2S may occur. Additionally, as H2S may desensitize and render the body unconscious in no
time at high concentrations, connected personal monitoring equipment is crucial.

Chapter 3: Theoretical background

I apply my training with Natpet and assigned for one department name as well services in
mechanical and condition monitoring.

Applications and Benefits:

1-High-power pumping services.

2- Quick to fix and install things.

Benefits:
1-Full redundancy ensures the ability to complete a job.

2-Downtime reduced or eliminated by reliability of equipment.

3-Ability to mix all types of machines.

Types of pumps:
 Pump

Positive
Dynamic
displacement

Axial Centrifugal Rotary Reciprocating

Figure 3.1 types of pumps

What is a positive displacement pump?

A positive displacement (PD) pump moves a fluid by repeatedly enclosing a fixed volume and
moving it mechanically through the system. The pumping action is cyclic and can be driven by
pistons, screws, gears, rollers, diaphragms or vanes.

How does a positive displacement pump work?

Although there are a wide variety of pump designs, the majority can be placed into two
categories: reciprocating and rotary.

Reciprocating positive displacement pumps:

A Reciprocating Positive Displacement pump works by the repeated back-and-forth movement
(strokes) of either a piston, plunger or diaphragm (Figure 1). These cycles are called
reciprocation.

figure 3.2 reciprocating pumps

Rotary positive displacement pumps
Rotary positive displacement pumps use the actions of rotating cogs or gears to transfer fluids,
rather than the backwards and forwards motion of reciprocating pumps. The rotating element
develops a liquid seal with the pump casing and creates suction at the pump inlet. Fluid, drawn
into the pump, is enclosed within the teeth of its rotating cogs or gears and transferred to the
discharge. The simplest example of a rotary positive displacement pump is the gear pump.
There are two basic designs of gear pump: external and internal.

An external gear pump consists of two interlocking gears supported by separate shafts (one or
both of these shafts may be driven). Rotation of the gears traps the fluid between the teeth
moving it from the inlet, to the discharge, around the casing. No fluid is transferred back
through the center, between the gears, because they are interlocked. Close tolerances between
the gears and the casing allow the pump to develop suction at the inlet and prevent fluid from
leaking back from the discharge side. Leakage or “slippage” is more likely with low viscosity
liquids.

figure 3.3 Rotary pumps

What is A Dynamic Pump?

This article explains the working of a negative displacement pump and different types of
dynamic pump. So, a pump is a mechanical device that uses to transfer fluids from one place to
another place. According to the working principle, pumps divide into two categories. The first
type of pump is a Positive displacement pump while the second type is the dynamic pump. In
the previous article, we discussed positive displacement pumps. So, in this article, we will
examine dynamic displacement pumps.
 figure 3.4 dynamic

Axial pump:
The axial pump includes in the most famous types of dynamic pump. These pumps use for
pumping incompressible liquids and for high flow rates at the comparatively short delivery
head. So, the energy transfer from the axial pump takes place only through the flow-related
process.

Centrifugal Pump:
This type of dynamic pump is commonly used in a variety of applications. These types of
dynamic pumps are inexpensive to manufacture, robust, and more efficient compared to
positive displacement pumps. After the pump has been operated, the fluid pressure increases
from the inlet to the outlet of the pump. Changes in the fluid pressure push fluid into the
storage tank.

figure 3.5 centrifugal

 Types of turbines
Turbine
Gas Water Steam Wind
Turbine Turbine Turbine Turbine
figure 3.6Type of

turbine

T turbine:
is a device that harnesses the kinetic energy of some fluid - such as water, steam, air, or
combustion gases - and turns this into the rotational motion of the device itself. Turbines are
generally used in electrical generation, engines, and propulsion systems and are classified as a

type of engine. figure 3.7 turbine

Gas Turbine:
gas turbine is a combustion engine at the heart of a power plant that can convert natural gas or
other liquid fuels to mechanical energy. This energy then drives a generator that produces the
electrical energy that moves along power lines to homes and businesses.

Water turbine:
rotary machine that converts kinetic energy and potential energy of water into mechanical
work.

Water turbines were developed in the 19th century and were widely used for industrial power
prior to electrical grids. Now, they are mostly used for electric power generation. Water
turbines are mostly found in dams to generate electric power from water potential energy.
 figure 3.8 water turbine

steam turbine
is a machine that extracts thermal energy from pressurized steam and uses it to do mechanical
work on a rotating output shaft. Its modern manifestation was invented by Charles Parsons in
1884.[1][2] Fabrication of a modern steam turbine involves advanced metalwork to form high-
grade steel alloys into precision parts using technologies that first became available in the 20th
century; continued advances in durability and efficiency of steam turbines remains central to
the energy economics of the 21st century.

wind turbine
is a device that converts the wind's kinetic energy into electrical energy.

figure 3.9 wind turbine

 Types of compressors:

figure 3.10 Types of compressors

Types of Heat Exchangers:

1- Shell and tube heat exchangers

2- Double pipe heat exchangers

3- Plate heat exchangers

4- Condensers, evaporators, and boilers

 figure 3.11 heat Exchangers

Types of seals:

Spring

Bellow

Gland

figure 3.12 type of seals

A mechanical seal
 is a device that helps join systems or mechanisms together by preventing leakage (in a
pumping system), containing pressure, or excluding contamination. The effectiveness of a seal
is dependent on adhesion in the case of sealants and compression in the case of gaskets. The
seals are installed in pumps in a wide range of industries including chemicals, water supply,
paper production, food processing, and many other applications.

A stationary seal may also be referred to as 'packing'

Bearings:

figure 3.13 Bearing

Bearing:
is a machine element that constrains relative motion to only the desired motion, and reduces
friction between moving parts The design of the bearing may, for example, provide for free
linear movement of the moving part or for free rotation around a fixed axis; or, it may prevent a
motion by controlling the vectors of normal forces that bear on the moving parts.

bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly
according to the type of operation, the motions allowed, or to the directions of the loads
(forces) applied to the parts.
Types of Bearing:

Ball Bearings:
A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races.

figure 3.14 Ball Bearing

2- Roller Bearing:
support and guide rotating or oscillating machine elements – such as shafts, axles or wheels –
and transfer loads between machine components.

figure 3.15 Roller Bearing

Disassemble Steps for Pump:

1- Pick up the casing.
2- Pick up the Impaler.
3- We need to pick up the lack.
4- Open Mechanical seal.
5- Shaft.
6- Take off the mechanical seal.
The Benefit of road Packing:
Is The hydrocarbon is isolated from oil and installed in a piston road.

the Benefit of Lipsi:

There is a compressor and its function are to isolate the oil.

Different Between the Vertical Reciprocating compressor And

Horizontal Reciprocating compressor?

Vertical Reciprocating compressor:

Two stage Double Acting

4 Valve Oil pump

2 Rood packing 2 sliding

He can do two jobs in the same time take the air and pumps the air.

Horizontal Reciprocating compressor:

Single Acting 12 Valve

press up and pump down

Fly weal connects the motor and pump with Equipment.

Note:
We are using Grease for equipment Weigh
 Chapter 4: Training work

Liquid Penetrant:
The liquid penetrant examination method is an effective means for detecting

discontinuities which are open to the surface of nonporous metals and other

materials. Typical discontinuities detectable by this method are cracks, seams,

laps, cold shuts, laminations, and porosity.

figuer4.1 Liquid

figure 4.2 Putting the Liquid

Magnetic Particle :
The magnetic particle examination method is applied to detect cracks and other discontinuities
on the surfaces of ferromagnetic materials. Typical types of discontinuities that can be detected
by this method are cracks, laps, seams, cold shuts, and lamination. In principle, this method
involves magnetizing an area to be examined and applying ferromagnetic particles (the
examination’s medium) to the surface.

figure 4.3 Magnetic Particle

Thermography Camera T-640:

A thermography camera (also called an infrared camera or thermal imaging camera) is a
device that forms an image using infrared radiation, similar to a common that forms an image
using visible light.

figure 4.4 Thermography Camera

Videoscope system:
A flexible videoscope or video Borescope id=s an advanced type of borescope that houses a
very small CCD chip embedded into the tip of the scope. The video image is relayed from the
distal tip and focusable lens assembly back to the display via internal wiring. Borescopes use
hard optical relay components to transfer the image to one’s eye through an eyepiece.

figure 4.5 Videoscope system

Hardness testers:
Hardness is a measure of how resistant solid matter is to various kinds of permanent shape
change when a compressive force is applied. Some materials (e.g. metals) are harder than
others (e.g. plastics). Macroscopic hardness is generally characterized by strong
intermolecular bonds, but the behavior of solid materials under force is complex; therefore,
there are different measurements of hardness: scratch hardness, indentation hardness and
rebound hardness.

figure 4.6 Hardness testers

Qualification of a good inspector:

A good inspector should:

•Understand and read mechanical drawing.

•Make basic mathematical calculation.

•Use micrometers, gages, computers and precision measuring instruments.

 figure 4.7 Qualification of a
good inspector

Explosion Proof Camera:

It is an Explosion proof which can be used in hydrocarbon areas.

figure 4.8 Explosion Proof Camera

Problems:

Problem Description:
abnormal sound from blower and coupling.

Observation
Kick-start the blower to identify the issue and found that the blower DE abnormal sound
(bearing failure).

Possible Causes
• The breather was dirty and plug, due to these the oil cup will not function. The oil cup will not
release the oil due to higher pressure in the bearing housing casing.
• The oil level become low and start the bearing to deteriorate, contaminating the oil and
restrict the oil circulation in the DE side.

Plug Oil Breather causing the internal pressure higher than the atmospheric pressure due to
these scenarios the oil up does not function.

figure 4.9 oil Breather

DE side contamination of metal from the bearing restricting the oil circulation.

figure 4.10 DE casing

As Found Observation
The DE bearing inner race temperature increases, damaging the bearing cage and
contaminating the oil. This event requires a long period to lead to this condition.

Inner race discoloration due to high temperature and bearing cage damage.

figure 4.11 bearing for casing

DE bearing cover and the bearing cage part that restrict the oil circulation.
 figure 4.12 restriction of oil circulation

Action
• Remove old bearing and clean shaft.

• Cleaning of bearing housing.

• Cleaning of DE and NDE bearing cover.

• Shaft Run-out reading.

• Measurement of shaft and bearing housing.

Cleaned Bearing Housing. 20 DE and NDE Bearing Cover and Bushing

figure 4.13 figure4.14

Internally cleaned Bearing Housing. Shaft with new bearing.

figure 4.15 figure4.16

New assembly of bearing housing.

 figure 4.17

Chapter 5: Conclusion
I have been improved during 14 weeks in Natpet. I gain a lot of knowledge about how the work
done in heater and pumps and compressor. My communication skills improved because the
diversity in the company. Now I am able to do work under pressure or long period hours. The
experience I got from the company it will help in my career in the future after I graduate from
college this year. The cooperative training gives the opportunity to understand the control
system. Also, it increased my knowledge in the mechanical part. Finally, I would like to thank
the college for support me, I would like to thank the company and my supervisor and all
technicians for their efforts to prepare me well theoretically and practically.

References
1- [Link]
2- [Link]
%20machine,reduces%20friction%20between%20moving%20parts.&text=The%20simplest
%20form%20of%20bearing,is%20used%20to%20reduce%20friction.
3- [Link]
4- [Link]
5- [Link]
6- [Link]
7- [Link]
pumps