RC COLLEGES & INSTITUTES AT YANBU

(Yanbu Industrial College)

Centralized Committee for Coop and Summer Training

Cooperative Training Report

EEET (340)

Yanbu National Petrochemical Company (Yansab)

Prepared by:

Yousef naji saleh alshehabi

ID No. 3608515

Reviewed By
Dr Zainudin Kornain

Semester 3, 2018-2019

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 II
Acknowledgments

I would like to thank Allah for his guidance and protection through all my life and
all the people who helped me to reach this moment. I could not have completed
this training without them. And to mention some of them, they are:

My parents

Hemdi Alsubhi
Head of polymer maintenance department in Yansab

Abdulaziz Aljohani
Instrument supervisor of the polymer maintenance workshop at Yansab

Ehsan Sheikh
Instrumentation technician at Yansab.

Odi Aljehani
My cousin.

Mosab Aljehani
Coop trainee

Ahmed Bagasi
Close friend.

Osama hmod
Instrumentation and control technician.

Mohammed Zabani
Close friend

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 III
Table of Contents
Title Page Page
Acknowledgement II
Table of Contents III
List of Figures IV
Abstract V

CHAPTER 1 7
1.1 Introduction 8
1.1.1 History of Yansab 8
1.1.2 Products and market 8
1.1.2.1 Ethylene 8
1.1.2.2 Propylene 9
1.1.2.3 Linear Low-density polyethylene 9
1.1.2.4 High-density polyethylene 9
1.1.2.5 Polypropylene 9
1.1.2.6 Ethylene glycol 10

CHAPTER 2 11
1.2 Safety & Health 12
1.3 Environment Safety 12
1.4 Personal Protective Equipment (PPE) 13
1.4.1 What is PPE? 13
1.4.2 Hand Protection 13
1.4.3 Eye protection 13
1.4.4 Ear protection 14
1.4.5 Head and feet protection 14
1.4.6 Respiratory protection 14

CHAPTER 3 16
1.5 Valves 17
1.5.1 What are valves? 17
1.5.2 Types of valves based on operation 17
1.5.3 Parts of the Gate valve 18
1.5.4 Types of actuators 19

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 1.6 Valves Types 19
1.6.1 Types based on stem movement 19
1.6.2 Types Based On Wedge 20
1.6.3 Plug valve 21
1.6.4 Advantages of Lubrication Plug Valve 21
1.6.5 Diaphragm Valves 22
1.6.6 Ball body 23
1.6.7 Globe valve 23
1.6.8 Needle valves 24
1.6.9 Check valves 24
1.6.10 Butterfly Body 25
1.6.11 Pressure reducing valves 25
1.6.12 Bolting-Tightening Recommendations 26
1.6.13 Gasket 26
1.6.14 Gasket Selection Criteria 26
1.6.15 Gasket types 27

CHAPTER 4 28
Field work order 1 29
Field work order 2 30
Field work order 3 32
Field work order 4 34
Field work order 5 35
Field work order 6 36
Field work order 7 37
Field work order 8 38
Field work order 9 39
Field work order 10 40
Field work order 11 41
Field work order 12 42
Field work order 13 43
Field work order 14 44
Field work order 15 45
Field work order 16 46

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 Field work order 17 47

CHAPTER 5 48
Conclusion 49
Reference 50

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 IV
Table of Figures

Title Page
Figure 1 Safety Gloves Mechanical Resistance 13
Figure 2 Safety Gloves Chemical Resistance 13
Figure 3 Eye Shield 13
Figure 4 Safety Glasses 13
Figure 5 Ear Plugs 14
Figure 6 Ear Muffs 14
Figure 7 Safety Shoes 14
Figure 8 Safety Helmet 14
Figure 9 Respiratory Protection 14
Figure 10 Part of Gate Valve 17
Figure 11 Pneumatic Actuator 18
Figure 12 Hydraulic Actuator 18
Figure 13 Electrical Actuator 18
Figure 14 Double-disk Gate Valve 19
Figure 15 Multiport Valve 20
Figure 16 Plug Valve 20
Figure 17 Diaphragm valve 21
Figure 18 Ball body 22
Figure 19 Globe valve 22
Figure 20 Needle Valve 23
Figure 21 Lift Check Valve 23
Figure 22 Swing Check Valve 24
Figure 23 Butterfly Body 24
Figure 24 Pressure Reducing Valve 24
Figure 25 Bolting Tightening Method 25
Figure 26 Instrument Tag 30
Figure 27 34
Figure 28 35

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 V
Abstract / summary

The objective of this training is to put into practice the theoretical knowledge we have learned
in the field of instrument maintenance. This will help us to be more prepared to work in similar
jobs in other company after graduation, and to be more confident about our skills and
knowledge.

The training is mostly about maintenance of instrument equipment such as valves, sensors,
transmitters, controllers, and tubing. We performed all types of maintenance like corrective
maintenance, periodic maintenance, and preventive maintenance.

The company helped the student-trainees to work in different areas and workshops. In the
Yanbu National Petrochemical Company, there are four areas where I worked. The first area is
the instrument maintenance workshop. In this area, we usually do the routine maintenance for
the valves, calibration.

The second area is located at the plant it is called reactor area. This is where we have huge
reactor where most of reactions occurs. The area contains lots of valves, transmitters, tubes that
must be maintained in good condition all the time.

The third area at the plant called finishing. In this area where plastic will be in its final form.
The area consists of two lines and two driers after that the pellets are directed to product
handling unit.

The fourth area is called central maintenance building. This area where valves are overhauled,
we change gasket and test our actuator, valves then send it back to the plant for installation.

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 CHAPTER 1
Yanbu National
Petrochemical Company

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1.1 INTRODUCTION

1.1.1 History of Yansab

Yanbu National Petrochemical Company (Yansab) is a SABIC, affiliate company in Saudi

Arabia, and it is the largest SABIC petrochemical complex even one of the largest
petrochemical complexes around the world. SABIC owns 55% of Yansab capital. SABIC
affiliates Ibn rushd and Tayef hold 10% of Yansab capital. 35% of Yansab is public stocks.

1.1.2 Products and market

Yansab focuses on manufacturing of petrochemical product such as (ethylene, ethylene glycol,

high density polyethylene, low linear density polyethylene, polypropylene, butene 1, butene 2,
MTBE and BTX).

1.1.2.1 Ethylene
It is an organic compound that is widely used in the chemical industry, and Yansab produces
1300,000 MT of ethylene annually. Much of this production goes toward polyethylene, a
widely used plastic containing polymer chains of ethylene units in various chain lengths.
Ethylene is also an important natural plant hormone and is used in agriculture to force the
ripening of fruits.

1.1.2.2 Propylene
is another unsaturated organic compound that Yansab produce with capacity of 400,000 MT
annually. Propene is the second most important starting product in the petrochemical industry
after ethylene. It is the raw material for a wide variety of products. Manufacturers of the plastic
polypropylene account for nearly two thirds of all demand. Polypropylene end uses include
films, fibers, containers, packaging, and caps and closures. Propene is also used for the
production of important chemicals such as propylene oxide, acrylonitrile, cumene,
butyraldehyde, and acrylic acid.

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1.1.2.3 Linear low-density polyethylene
Linear low-density polyethylene is one of Yansab major products with capacity of 400,000
MT annually. LLDPE has penetrated almost all traditional markets for polyethylene; it is
used for plastic bags and sheets (where it allows using lower thickness than comparable
LDPE), plastic wrap, stretch wrap, pouches, toys, covers, lids, pipes, buckets and containers,
covering of cables, geomembranes, and mainly flexible tubing. In 2013, the world market for
LLDPE reached a volume of $40 billion.
1.1.2.4 High-density polyethylene
High-density polyethylene is another Yansab major products with capacity of 400,000 MT
annually. HDPE is resistant to many different solvents and has a wide variety of applications
such as (3D printer filaments, Ballistic plate, Bottle caps, Boats, Milk jugs and many others.
HDPE is preferred by the pyrotechnics trade for mortars over steel or PVC tubes, being more
durable and safer: HDPE tends to rip or tear in a malfunction instead of shattering and
becoming shrapnel like the other materials. Milk bottles, jugs, and other hollow goods
manufactured through blow molding are the most important application area for HDPE,
accounting for one-third of worldwide production, or more than 8 million tones.

1.1.2.5 Polypropylene
Polypropylene is another major product that Yansab produce with capacity of 400,000 MT
annually. Polypropylene (PP) is a thermoplastic “addition polymer” made from the
combination of propylene monomers. It is used in a variety of applications to include
packaging for consumer products, plastic parts for various industries including the
automotive industry, special devices like living hinges, and textiles. According to some
reports, the current global demand for the material generates an annual market of about 45
million metric tons and it is estimated that the demand will rise to approximately 62 million
metric tons by 2020. The major end users of polypropylene are the packaging industry, which
consumes about 30% of the total, followed by the electrical and equipment manufacturing,
which uses about 13% each. Household appliances and automotive industries both consume
10% each and construction materials follows with 5% of the market. Other applications
together make up the rest of the global polypropylene consumption.

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1.1.2.6 Ethylene glycol
Ethylene glycol is another major product that Yansab produce with capacity of 770,000 MT
annually. The most valued applications of the ethylene glycol market are polyester fibers,
widely used in textile industries; PET resins, used for packaging of liquids and beverages in
bottles; and automotive antifreeze, used in automobiles. The ethylene glycol demand, in
terms of value and volume, depicts the current and future projections according to the parallel
economic and industrial outlook. This analysis covers important developments, expansions,
agreements, and mergers & acquisitions of the leading global companies.

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CHAPTER 2
SAFETY

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1.2 Environment Safety

Yanbu National Petrochemical Company is fully committed to comply with all applicable
environmental laws and regulations and apply responsible standards and work practices.
Yansab is committed to continuously improve its environmental performance throughout its
activities and processes. Yansab will communicate environmental matters and share its
experience with concerned organizations to facilitate improvements in industry performance.

1.3 Safety & Health

Yansab is fully committed to conduct its business in a manner that protects and preserves the
safety of its employees, contractors, visitors and assets Yansab strives to prevent all process
and non-process related incidents, through continuous awareness of safety importance and
active participation of every employee. Yansab is committed to continuous efforts to identify
and eliminate or mitigate risks associated with its activities.

Yansab is fully committed to employ the following measures to achieve and maintain healthy
environment to its employees and community: Identify and evaluate health risks related to its
operations that potentially affect its employees and contractors or the public; Implement
programs and appropriate protective measures to control such risks, including appropriate
monitoring of its potentially affected employees; Communicate in a reasonable manner
knowledge about health risks, gained from its health programs and related studies, to
potentially affected individuals or organizations; Determine at the time of employment and
thereafter, as appropriate. Provide or arrange for medical services necessary for the treatment
of employee occupational illness or injuries and for the handling of medical emergencies;
Comply with all applicable laws and regulations and apply responsible standards aiming at
preserving health of employees and community; Undertake appropriate reviews and
evaluations of its operations to measure progress and improve practices to ensure compliance
with this health policy.

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1.4 Personal Protective Equipment (PPE):

1.4.1 What is PPE?

It is a device for rescuing users from the dangers of health and safety in the workplace. You
can include gears such as safety helmet and hard hat, gloves, eye protection, visibility clothes,
safety shoes, safety harness. One of the functions of this section is to provide all required PPE
to the employees, as well as signs of what and where to wear the right PPE.

1.4.2 Hand Protection

The working in the plant deals with dangerous gases and liquids and the use of some tools, so
to prevent that hazard the safety gloves must be used.

Figuer1: Safety Gloves Figuer2: Safety Gloves

(Mechanical Resistance) (Chemical Resistance)

1.4.3 Eye protection

The working in the plant deals with dangerous gases and liquids and the use of some tools,
like drill machine, can cause hazard to the eyes. So to prevent that hazard the safety glasses
or goggles must be used.

Figure 3: Eyes Shield Figure 4: Safety Glass

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1.4.4 Ear protection

The working area in the workshop is noisy, affects the hearing of the worker and causes
headache and lost balance. So to prevent that hazard the ear muffs or ear plugs must be used.

Figure 5: Ear Plug Figure 6: Ear Muffs

1.4.5 Head and feet protection

While working in the field some tools may fall. So, to prevent that hazard, safety helmet
and safety shoes must be used.

Figure 7: Safety Shoes Figure 8: Safety helmet

1.4.6 Respiratory Production

Danger: Atmosphere of dust, steam, gas, and oxygen deficiency. Optional, replaceable
filtering face piece, half or full-face mask, air feed helmet, and breathing apparatus.

Figure 9: Respiratory protection

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 CHAPTER 3
Theoretical Background

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1.5 Valves

1.5.1 What are valves?

A valve is a device that regulates, directs or controls the flow of a fluid (gases, liquids, fluidized
solids, or slurries) by opening, closing, or partially obstructing various passageways.

Valves are used in piping system to stop, divert or regulate the flow. The valves can be operated
by manual through a gearbox or by hand wheel and also can be operated by motor depending
on the size of the valves.

Valves are manufactured in different pressure ratings as cast iron, ductile cast iron, steel,
stainless steel, bronze material, brass and special alloy steel etc.

1.5.2 Types of Valves Based on Operation

• On/Off valve: These valves are used to allow or stop the flow. The requirement of these
valves are to have minimum resistance to flow in the fully open position and to show
tight shut – off (closing) characteristics when fully closed. Example: Gate valve, Ball
valve, Plug valve, Butterfly valve etc.

• Regulating valves: These valves are used to regulate the flow such as Needle valve,
Globe valve etc.

• Back flow prevention valves (Non return valve): These valves are used to allow the
flow in one direction only for example Check valve.

• Pressure regulation valves: These valves are used to maintain a constant reduced
pressure in a piping system that supplied from high-pressure source usually used to
regulate instrument air supply to suit the supply pressure of different actuators.

• Pressure relief (release) valve: These are used to save piping and equipment from extra
pressure that is not suitable for the equipment or the pipe and they are used as safety
valves.

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1.5.3 Parts of the Gate valve:

1-Body: The valve's body is the outer casing of most or all of the valve that contains the
internal parts or trim.
2-Disk (Gate): A disc or valve member is a movable obstruction inside the stationary body
that adjustably restricts flow through the valve.
3-Stem: The stem transmits motion from the handle or controlling device to the disc.
4-Bonnet: A bonnet acts as a cover on the valve body. It is commonly semi-permanently
screwed into the valve body or bolted onto it.
5-Gland (packing): The purpose of valve packing is to prevent leakage, Is often used
between the stem and the bonnet to maintain a seal.
6-Gland packing or packing follower: used to ensure that an inner bore of the packing is
sealed against the valve stem or shaft.
7-Seat ring: The seat is the interior surface of the body which contacts the disc to form a
leak-tight seal.
8-Hand wheel: used to operate the valve manual not used in controlled valves.
Gate valves are used in water, gases, oil, steam, and other fluids.
9-Actuator: is a mechanism or device to automatically or remotely control a valve from
outside the body.
10-Trim: The internal elements of a valve are collectively referred to as a valve's trim.

Figure 10: Parts of Gate Valve

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1.5.4 Types of actuators:

Actuator is used to provide the force required to adjust the position of stem or rotor. By using
actuator, we can open valve’s with very fast speed even if the flow force is high.

• Pneumatic: A Pneumatic actuator mainly consists of a piston or a

diaphragm which develops the motive power. It keeps the air in
the upper portion of the cylinder, allowing air pressure to force
the diaphragm or piston to move the valve stem or rotate the
valve control element. Figure 11: Pneumatic Actuator

• Hydraulic: A hydraulic actuator is a hydraulic cylinder or

hydraulic motor that converts hydraulic power into mechanical
work; the mechanical motion produced may be linear, rotary, or
oscillatory.
Figure 12: Hydraulic Actuator

• Electrical: Electrical Actuator is an electromechanical device that

converts electrical energy into mechanical energy. Most electric
actuators operate through the interaction of magnetic fields and
current-carrying conductors to generate force.
Figure 13: Electrical Actuator

1.6 Valves Types

1.6.1 Types based on stem movement

Raising stem: Stem raises up or down while operating the valve. In this type stem threads are
out of contact with the fluids or gases. These valves are required more amount of space when
opened even then it is preferred because the position of stem indicates at once whether the
valve is open or not.

Non raising stem: Stem movement is restrained by thrust collar. This type of valve requires
less headroom space than the raising stem.

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1.6.2 Types Based On Wedge

Wedge type: Either a tapered solid or tapered split wedge is used. When the valve closes the
gate, disk is wedged on both side against the seat.

Double disk type: The disks are forced against the valve seats by a wedging mechanism as
the stem is tightened.

Figure 14: Double-disk Gate Valve

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1.6.3 Plug valve:

Full flow is allowed when the opening in tapered plug is aligned (in line) in the direction of
flow. This type of valve can open or close with quarter (90 degree) turn of the plug.

The plug valves having lubricated and non-lubricated designs.

In lubrication-seal valve, channels for the admission of the lubricant surround the ports to
insure positive sealing against internal or external leakage.

The lubricant pressure developed by a turn of lubricant screw or injection of lubricant with a
pressure gun exerts a powerful hydraulic jacking action on the plug, momentarily lifting it from
the seat and making it easy to turn.

1.6.4 Advantages of Lubrication Plug Valve

- Keeping the valve in free working condition.

- Free turning even of the largest sizes and against heavy differential pressure
- Maintenance of positive seal against internal and external leakages.
- Protection of working surfaces against wear and tear.

The plug type multiport valve is having advantages of simplification of piping and simplifies
operation. One 3-way or 4-way multiport valve may be used in place of two, three, or four
straight valves.

Figure 15: Multiport Valve Figure 16: Plug Valve

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1.6.5 Diaphragm Valves

The resilient, flexible diaphragm is connected to the “compressor” plug by a stud molded into
the diaphragm. The valve stem moves up and down the compressor plug. The diaphragm is
lifted high when the compressor is raised and is pressed tight against the body weir when the
compressor is lowered.

These valves are suitable for moderate throttling application and excellent leak tight
characteristics even if liquids containing suspended solids.

• Advantages of diaphragm valves are:

- The operating mechanism is not subject to the corrosive action of chemical since the
diaphragm is isolates the working parts from fluid stream.
- No possibility of stem leakage.
- Lubricants can’t contaminate the fluid in line.
- Smooth, streamlined flow without pockets is possible.
- Packing glands, disk holders, seats involving metal to metal contact are eliminated

Figure 17: Diaphragm valve

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1.6.6 Ball Body

The ball valve operation will be achieved by quarter turn of ball like in plug valve. The main
parts are:

• Body
• Stem
• Spherical plug
• Seat ring

Figure 18: Ball body

1.6.7 Globe valve

In these valves the disk has a flat face which is pressed against the seat opening like a cap. The
shorter disk travels advantage in saving operator time. These valves are mainly used to control
the flow. This valve seat is in a plane parallel to the line of flow. Maintenance of globe valves
is easy because the disks and seats are readily repaired or replaced. These valves exhibits
slightly higher pressure drop than straight through valves (gate, plug, ball, etc.)

Figure 19: Globe valve

Page 23 of 50
1.6.8 Needle valves

The end of the stem is needle pointed. The needle fits accurately into its seat and thus assures
tight closure with least efforts. Very accurate control of flow is possible with these valves.
These valves are used for instrument, gage, and meter line service.

Figure 20: Needle Valve

1.6.9 Check valves: These valves are opened by fluid flow and quickly closed by gravity
(self-weight) or reversal flow. These are two types based on flop operation.

Lift check valve: In this type flop will lift by flow force and close by fluid weight or self-
weight. These valves must always be placed so that the direction of lift is exactly vertical.

Swing check valve: The flow will open with force of the forward flow and closed by reverse
flow.

Figure 21: Lift Check Valve Figure 22: Swing Check Valve

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1.6.10 Butterfly Body

These are low-pressure valves. These valves require a quarter turn

from close to full open position. These valves are having advantage
of fast operation and low differential pressure drop. These are not
used for pressure tight service.

Figure 23: Butterfly Body

1.6.11 Pressure reducing valves

These valves are used to maintain a constant reduced pressure in a piping

system, which is supplied from high-pressure source. In the simple
diaphragm type the amount of opening of the valve is controlled by the
pressure on the reduced pressure side which conducted through a pilot
line to a rubber diaphragm attached to the valve side. A weighted lever
opposes the pressure exerted on the diaphragm. When the pressure is
less than required pressure, the pressure on diaphragm through balance
pipe is less, which results to the more area open, by allowing more flow.
The pressure to be maintained is adjusted by shifting the weight
Figure 24: Pressure Reducing Valve
of lever by adding / removing weight.

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1.6.12 Bolting-Tightening Recommendations

A four (4) stage tightening method is recommended as

follows:

1. Tighten the bolts at 30% of the final load using the

diametrical sequence,
2. 60% of final load following diametrical sequence’
3. 100% of final load following diametrical sequence,
4. 100% of final torque on adjacent bolts. Figure 25: Bolting Tightening Method

(For Bolt Diameters of 1¼” and above - gasket manufacturers recommend the use of
hydraulic bolt tensioner for example… Hydra tight)

1.6.13 Gasket

Gaskets are used to make a fluid or gas resistant seal between two surfaces without any leak.

1.6.14 Gasket Selection Criteria

• Temperature: In most selection processes, the temperature of the fluid at the gasket joint
should be considered first. When system operation temperatures are approaching a
particular gasket materials maximum continuous operating temperature are limit, an
upgrade to superior material is suggested.

• Application: The most important information under application is the type of flange
and bolts used. The number, size, and grade of bolts used in the application determines
the load available.
• Media: Selection the proper gasket materials which suitable for the media to sealed
(water-fuel-steam-chemical) increasing the life time of gasket.

• Pressure: Next to be considered is the internal pressure of the fluid at the gasket joint.

Page 26 of 50
1.6.15 Gasket types

• Rubber gasket: Rubber gasket can keep good sealing function even though the flange
is damaged and not plain and smooth. As rubber has property of special expand and
permeate resistance, it plays the effectiveness sealing role to resist gas and liquids to
through and formation.

• PTFE gasket: It one of the most chemically-resistance materials available, PTEF can
fit for extreme sealing with sheet gasket.

• Flexible graphite gasket: Flexible graphite consist of pure carbon also available with
reinforcement such as AISI 316 stainless steel, carbon steel etc. which increase the
tensile strength of the material.

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 CHAPTER 4
TRAINING WORK

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Work Order 1
General LLDPE Process Information

Material’s description:
• LLDPE Piping and Instrumentation Diagram.

Details:
First, Ethene is compressed due to the compression heat is produced so the compressed
Ethene is cooled by the help of cooling system. Second, the compressed Ethene is passed to
reaction vessel where the initiator (catalyst) start the polymerization process to form
Polyethene. Third, the mixture of Polyethene and unreacted Ethene is passed through
separation vessels where the unreacted Ethene is recycled, and stabilizers are added to the
polyethene. Finally, the polyethene is passed to an extruder to form pellets of Linear Low
Density Polyethene after that the pellets are passed to product handling unit.

Reactor: Keeps the Ethene at a certain temperature and pressure to ensure the best reaction
possible.

Catalyst: Used to increase the reaction time and ensure best productivity possible.

Observations:

✓ General process knowledge.

✓ Analyzing Piping and Instrumentation Diagram.
✓ Understand how the process flow.

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Work Order 2
Instrument Tags

Equipment Description:
• Metal instrument tags.

What is instrument tag:

Instrument Tags is essential for everyday job it helps organizing the location and the function
of each instrument. In every company around the world there is a specific standard followed
by the company to assign instrument tags. The figure shows instrument tag and examples of
it.

Figure 26: Instrument Tag

Observations:

• XV: On/Off Valve (solenoid) work automatically with logic as well as manual.
• KV: On/Off Valve (solenoid) opens for specified given time.
• PDS: Product Discharge system.
• PDT: Pressure Differential Transmitter.
• TT: Temperature Transmitter.
• TV: Temperature Valve.
• PI: Pressure Indicator Gauge.
• TI: Temperature indicator Gauge.
• FG: Flow Gauge.
• PT: Pressure Transmitter.
• LT: Level Transmitter.

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• CV: Control valve open in specific given range between 0-100%.
• LS: level switch, switch that gives indication of specific level setpoint determined by
operation.
• TS: Temperature switch, switch that gives indication of specific value of temperature
determined by operation.

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Work Order 3
PM and CM

Equipment Description:
• Theory only.

Observations:
Preventive Maintenance Activity (PM): a standard procedure used to increase
productivity by maintaining the important instruments before the interruption of
production and major breakdown.

Here are other important benefits of a properly operated preventive maintenance

program:

◾ Equipment downtime is decreased and the number of major repairs is reduced

◾ Better conservation of assets and increased life expectancy of assets, thereby

eliminating premature replacement of machinery and equipment.
◾ Reduced overtime costs and more economical use of maintenance workers due to
working on a scheduled basis instead of a crash basis to repair breakdowns.
◾ Timely, routine repairs circumvent fewer large-scale repairs.

◾ Improved safety and quality conditions for everyone.

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Corrective Maintenance (CM): Some instruments require shutdown of the process to
make maintenance activities, some instruments require MOC requirement for modification
for maintain activity.

Planned corrective maintenance: Planned corrective maintenance likely the result of a

run-to-failure maintenance plan. In this case, the maintenance team has decided that certain
equipment will be serviced when it breaks down. An example would be planning to replace a
lightbulb once it burns out.

Unplanned corrective maintenance: Unplanned corrective maintenance is usually the

result of an unexpected breakdown. An example here would be a piece of machinery
breaking down due to a replacement part failing after being replaced during a routine PM.
Corrective maintenance will need to be performed to get the machinery back in working
order.

Advantages of corrective maintenance: When corrective maintenance is planned as part

of a maintenance strategy, it allows those responsible for reliability to focus on other
endeavors until a breakdown or condition trigger occurs.

Disadvantages of corrective maintenance: When corrective maintenance is unplanned,

it can cause many disadvantages. If the cost of downtime in a given facility is very high,
technicians will be racing against the clock to complete corrective maintenance, which could
mean that work is carried out improperly or unsafely. It can also cause backlog if the
maintenance team has to address corrective repairs rather than their usual planned PMs.

Work Order 4

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Disassembly of XV On/Off valves

Equipment’s:

• Two spanners size 7/8 Inch.

Main Components:
• Actuator.
• Body.
• Limit switch box.
• Instrument air pipe.

Work steps:
A. First a permit must be obtained from the operation after the operation give the green
mark to start the task.
B. First make sure it is the right XV to be removed.
C. The air supply must be off.
D. Then the limit switch is removed by untying all bolts connected to the valve.
E. After the limit switch is removed untie bolts of the body connected to the pipe slowly
making sure no gas is leaking out of the pipe (if any leakage informs the operator
immediately).

Page 34 of 50
Work Order 5

ON/OFF Valves overhauling:

Equipment’s:
• Two spanners size 1/2 Inch.
• Leak testing machine.
• Grease (lubricant).
• Gasket.
• Towels.
• Grease dissolving solvent.

Main Components:
• Actuator.
• Body
Work steps:
A. The actuator is separated off the body. Starting with the actuator the bolts are
removed slowly if the actuator contains springs, if the actuator contains springs and
the bolts removed rashly it may apply strong force in the opposite direction of the
valve which may result in injury.
B. after all the bolts are removed the inside parts such as O-rings, springs, pistons,
diaphragms are taken out of the actuator and cleaned if needed.
C. After cleaning the actuator off the grease, the old gasket is removed and replaced with
new ones.
D. If there are any damaged parts, spare part must be obtained to be replaced with
damaged ones.
E. Grease must be applied on the internal parts of the actuator then all parts are placed in
its correct place and tied together.
F. The body is disassembled and cleaned.
G. if any of body internal parts are damaged it must replace with new one’s parts such as
plug, ball is often damaged duo to wear and tear.
H. Grease is applied on the gasket and placed in it is correct place.
I. Assemble the parts together.
J. After that the body is placed in a test bench to make sure that there is no leakage when
the ball is at close position.
K. Finally, the body is attached to the actuator and tested.

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Work Order 6

Reliability valve troubleshooting.

Equipment’s:
• Soup + water used to detect any leakage.

Main Components:
• Actuator.
• Body
• Piping

Work description:
• Making sure that the valves has no fluid leakage.
• Stroke test to ensure that the valve is working well.
• Write comments on specified issues for different valves tubing, indication...
etc.
• Ensure that the valve is installed at the correct direction.
• Request replacement of any damaged parts.

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Work Order 7

Blowback troubleshooting.

What is blowback?

The purpose of Nitrogen blowback is to clear accumulated dust at the filter to increase pump
efficiency.

Equipment’s:
• WD-40 Spray.
• Pipe wrench.
• Spare solenoid valve.
• Spare Diaphragm.

Job Details:

First, we inspect and listen to operation complain that one of blowback diaphragm line are
not working. Then, we analyze which blowback diaphragm not working after that we asked
operation to isolate nitrogen line and hydrocarbon line. After, that we find out the solenoid
valve is not responding. So, we replaced it with new one as well as the diaphragm. Finally,
we tested the loop again and it works fine without any problems.

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Work Order 8

Valve stuck troubleshooting.

Valve repair record:

The valve was sent for overhauling during last shutdown.

Valve problem:

The valve operation Is not working fine it shows that the valve is not closing correctly when
attached to the pipe. After manually open and close the valve several times the body start
working fine.

Possible Problems:

• New gasket is not installed probably.

• Not enough force.
• Caused by the process material.

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Work Order 9

Communicator 475.

What is hart communicator?

Hart communicator is a device that allows you to communicate and configure HART and
Fieldbus devices that are connected to the communicator.

What can you do with hart communicator?

• Field Calibration.

• Diagnostics.

• Adjust configure.

• viewing internal variables.

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Work Order 10

How to check PDT Calibration.

Equipment’s:
• Hart communicator 475.
• One spanner size 1 inch.
• Pressure calibrator.
• Plastic tube.

Job Details:

1. First make sure that the operator is aware of what you are going to do.

2. Connect the field communicator.

3. Take not of required parameters (URV, LRV, PV, Analog output).

4. Close the process isolation valve on high and low sides.

5. Open vent plug to release restricted pressure.

6. Connect the pressure calibrator to the high side.

7. Close the vent plug on high side to restrict the pressure again and low side is open to
atmosphere.

8. Apply pressure step by step (25%, 50%...etc.) of transmitter calibrated range to check the
response transmitter.

9. Compare the supplied pressure to the reading of the communicator.

10. After making sure that the transmitter is functioning properly line up the transmitter.

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Work Order 11

Troubleshooting PDT

Equipment’s:
• Hart communicator 475.
• One spanner size 1/2 inch.
• Pressure calibrator.
• Plastic tube.
• Datasheet.

Problem:

The Differential Pressure Transmitter indicates error AL-41 (Out of Range).

Troubleshooting:

We increased the range of the calibration to see if the value would change the reading found
as 137 kPa but it seems that increasing the range won’t rectify the reading, and the error is
still appearing. After looking at the Transmitter Tag we found out that the transmitter is
working with 150% higher pressure above its actual range.

Solution:

Replace the transmitter with pressure range in between process pressure range.

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Work Order 12

Pressure Transmitter showing IOP

Equipment’s:
• Screw driver.
• HMI.

Description of the problem:

The transmitter indicates Input Output Problem (IOP) on HMI.

Troubleshooting:

We were looking for another transmitter at the same line from the HMI to observe if this
issue is caused by the HMI or it is real actual problem after that we checked the wires of the
transmitter if it is connected properly.

Solution:

Tying the wires of the transmitter the error disappeared.

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Work Order 13

Replacement of two Temperature Elements (TC)

Equipment’s:
• Screw driver.

Description of the problem:

Operation indicates that two transmitter which previously replaced, the two elements are
connected to the wrong transmitter.

Troubleshooting:

We traced the elements and locate the correct transmitter.

Solution:

Two wires coming of the element we attached the wires to the transmitter the green wire (+)
at pin (2) and white (-) at pin (1) referring to back plate of the transmitter.

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Work Order 14

Troubleshooting one of Temperature Transmitter showing wrong reading.

Equipment’s:
• Screw driver.
• One spanner size 1/2 inch.

Description of the problem:

The transmitter indicates 35C° but the actual temperature is between 180 C°-230 C°.

Troubleshooting:

We assumed that the thermowell extension is wear damaged. After replacing the thermowell
the problem still exists. So, we went to the next possible problem the element must be
defective.

Solution:

We replaced the element and the problem is solved.

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Work Order 15

Spare parts organizing

Job supplies

• List of detailed items.

Job task:

• Organize spare parts

Job description:
We identified all instruments that were requested during the shutdown. After the instruments
are identified we sent it for return store.

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Work Order 16

Installing Vibration Transmitter and loop test

Equipment’s:
• Screw driver.
• One spanner size 1 inch.
• Frequency generator.
• Vibration Calibrator.

Job task:

• Install and test Vibration Transmitter

Job description

We tried to install the VT but we faced problem with VT thread is damaged we had to fix that
and install the VT. After we installed the VT, we tested the VT by Vibration Calibrator but
the operation required us to simulate RPM by frequency generator.

Problem faced:

• Damaged thread.

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Work Order 17

Install silencer and booster for valve

Equipment’s:
• One spanner size 1 inch.
• Teflon.

Job task:

• Install and test silencer

Job description

• Replace old silencer.

• Install new booster.

Problem faced:

• None.

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 CHAPTER 5
Conclusion and references

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Conclusion

During my 14 weeks Coop training I have learned a lot about the industrial work in an industrial
plant. I have gained and collected valuable information that will help me in my future work.
Also, I learned a lot about my field of specialization and I believe I will be able to work in the
industries such as Yanbu National Petrochemical Company (Yansab).

Knowing the routine of the industrial work is very important. After I finished this training, I
am able to practice different maintenance practices as a technician should. I learned how to
perform maintenance for pumps, valves, transmitter, sensors, tubes, HMI… etc. Also, I came
to realize the effect of design.

Teamwork is very important and makes the work much easier. I have reinforced some
important value such as, safety, Integrity, commitment, excellence and collaboration.

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References

http://www.yansab.com.sa/en/our-company
Wikipedia website www.wikipedia.org
https://www.yokogawa.com/solutions/products-platforms/field-instruments/pressure-transmitters/

https://www.emerson.com/documents/automation/manual-rosemount-644-temperature-transmitter-
hart-en-89604.pdf
https://www.fluke.com/en/learn/best-practices/temperature-calibration/hart-smart-temperature-
transmitter-calibration
https://www.yokogawa.com/solutions/products-platforms/field-instruments/level-meters/level-
transmitters/eja110a/
https://www.yokogawa.com/solutions/products-platforms/field-instruments/level-meters/level-
transmitters/eja110e/

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