Professional Documents
Culture Documents
Report PDF
Report PDF
College of Engineering
Department of Mechanical Engineering
By:
Student Name: Abdulla Abdulqader Salem
Student Id: 20177258
Course Code: Meng 390
Fall 2022
Aknowledgement
At first, the fulfillment of this program would not be possible without the help of our god
in which his mercy encouraged me to fulfill this course, besides that, I would like to express
my deep and sincere gratitude to the employees of Bahrain Petroleum Company especially
plant engineering department for giving me the chance to have my industrial training in
their respected organization during this circumstances pf Covid-19. I'd also want to express
my gratitude to all of the supervisors and engineers who allowed me to utilize all of the
essential equipment and resources to perform each assignment efficiently.
SUMMARY
This paper summarizes the experiences gained during the Bahrain Petroleum Company's
industrial training session from March 13 to May 12. Field engineering and supervision,
civil & structural design, off-site & utilities engineering, and OPD north engineering were
the four departments to which the student was allocated for one to two weeks, depending
on how relevant it was to mechanical engineering. The report details the work completed
and information gained in each of the departments. The work and tasks largely focused on,
but were not limited to, observing the procedures utilized to complete the projects allocated
to each section, as well as the standards and softwares used to achieve this goal.
Table of Contents
Aknowledgement ................................................................................................................ 2
SUMMARY ........................................................................................................................ 3
1. INTRODUCTION ..................................................................................................... 7
1.1. The Purpose ...................................................................................................... 7
1.2. Background ....................................................................................................... 7
1.3. Tasks Performed ............................................................................................... 8
2. THE COMPANY PROFILE ..................................................................................... 9
2.1. Company Overview .......................................................................................... 9
2.2. Vision................................................................................................................ 9
2.3. Mission ........................................................................................................... 10
2.4. Values ............................................................................................................. 10
2.5. Purpose ........................................................................................................... 10
2.6. Promise ........................................................................................................... 10
2.7. Tagline ............................................................................................................ 10
3. TRAINING DEPARTMENTS ................................................................................ 11
3.1. Field Engineering & Supervision ................................................................... 11
3.2. Civil & Structural Design ............................................................................... 14
3.3. Ofssite & Utilities ........................................................................................... 15
3.3.1.1. Sage CRM............................................................................................ 15
3.3.1.7. Tanks ................................................................................................... 17
3.3.1.9. Pipes..................................................................................................... 18
3.3.2. Utilities .................................................................................................... 18
3.4. Opd North Engineering (Refinery Engineering) ............................................ 20
3.4.1. P&ID ....................................................................................................... 20
3.4.2. Isometric .................................................................................................. 21
3.4.3. General arrangement drawing ................................................................. 21
3.4.4. Pipe flo .................................................................................................... 22
4. CONCLUSIONS AND RECOMMENDATIONS .................................................. 23
4.1. Conclusion ...................................................................................................... 23
4.2. Recommendation ............................................................................................ 23
4.2.1. To the organization.................................................................................. 23
4.2.2. To the university...................................................................................... 23
APPENDIX [A] ................................................................................................................ 25
APPENDIX [B] ................................................................................................................ 27
LIST OF FIGURES
Figure 1: Bapco logo ........................................................................................................... 9
Figure 2: remote control fire monitor, RCM [3] ............................................................... 12
Figure 3: Joy compressor [4] ............................................................................................ 12
Figure 4: Trip valve [5] ..................................................................................................... 13
Figure 5: Pipe rack [6] ...................................................................................................... 14
Figure 6: Refinery tanks [11] ............................................................................................ 17
Figure 7: Bund wall [10] .................................................................................................. 17
Figure 8: P&ID drawing [16]............................................................................................ 20
Figure 9: General arrangemnt drawing ............................................................................. 21
1. INTRODUCTION
This report intends to convey the trainee's experience gathered during his industrial training
at BAPCO. In addition, the trainee's type of work and tasks are briefly discussed in this
report. Finally, this paper summarizes the advantages and accomplishments obtained
during the industrial training program at Bapco.
1.2. Background
The Bahrain Petroleum Company (Bapco) was registered on 11th January 1929. Since
then, Bapco has grown to be a powerful organisation that continues to play a key role in
Bahrain’s development as a pioneering industrial force. Bahrain was the first country in
the Arabian Gulf where oil was discovered in 1932. Bapco was instrumental in that
discovery and helped in setting up the building blocks of the region’s hydrocarbon industry
when it commenced the export of oil on 7th June 1934, and then began refining it from
1936.
Bapco has been at the forefront of developing Bahrain’s human capital, preparing Bahrainis
to meet the demands of the oil industry, enhancing their capabilities, and helping them
emerge as globally competitive professionals. Bapco’s success over the last 90 years has
been shaped by the support of countless national and international employees in writing
the company’s growth story.
Originally owned by the Standard Oil Company of California, Bapco today, is wholly
owned by the Government of Bahrain. Since its early beginnings, Bapco has been
recognized as one of the Kingdom’s anchor companies, and as such, remained a key
contributor to the GDP and a reliable income generator for the economy [1].
1.3. Tasks Performed
There were four sections the trainee was assigned to, which are: Field engineering &
supervision, civil & structural design, off-site & utilities engineering and OPD north
engineering. The tasks were mostly focused, but they weren't restricted to: conducting
introductory courses in the domain of health and safety to reach the optimum level of
awareness especially related to the Hydrogen Sulphide Standard and personal safety
equipment, site visits were made to be familiar with the nature of the work flow in the
industry and getting introduced to several mechanical apparatuses either static or rotary
equipment, handling documents (drawings , technical data sheet, etc) in order to be familiar
with the configuration of piping system illustrated in the P&ID or isometric, observe the
standards and codes that has been followed by the organization for the fullfilment of the
project and perform an analysis for the purpose of slecting the optimum appartus for the
required application based on the principal of mechanical engineering. The above
assignments are briefly illustrated in appendix [], which shows the weekly breakdown
activity.
2. THE COMPANY PROFILE
2.2. Vision
To sustainably manage and operate an integrated energy business, leveraging best practices
and creating value for shareholders, customers and employees [2].
2.4. Values
2.5. Purpose
Bringing energy to the world for the enduring prosperity of the Kingdom of Bahrain [2].
2.6. Promise
2.7. Tagline
2.8. Strategy
2.9. Sustainability
A world class safe and sustainable enterprise that provides a solid foundation for realizing
Bahrain’s Economic Vision 2030 [2].
2.10. People
Well-trained, highly skilled and motivated workforce of Bahrainis and multi-cultural
professionals reflecting the diversity of Bapco’s customer base [2].
3. TRAINING DEPARTMENTS
To optimize the employed knowledge relevant to mechanical engineering major, the
trainee has been asssigned to four sections Field Engineering& Supervision, Civil &
Structural, Ofssite & utilities, Refinery Engineering (OPD North Engineering). The work
done and accomplishments in each section are detailed in the following sections.
The trainee went through this section for a period of 12 days, by means the trainee assigned
with four engineers 3 days with each one of them. Each engineer illustrate his current
projects and what is his contribution as a mechanical field engineer in such project. Starting
by the first engineer Jojy Paul field engineer mechanical, he illustrate PPE(personal
protective equipment) required to be able to enter the plant. Furthermore, he shows what
are the projects he handls which was 2 Caustic water tank in the GTU (Gasoline Treatment
Unit). This project aims to expand the tank volume by add one extra shell to the existing 2
shell to meet the BMP (Bapco Modernazation Programe) demand. So the duties of the field
enfineer as follow draining and cleaning of the tank, inspection blasting and cleaning of
bottom plate, nozzle fit up and welding inspection. Beside that, issuing permits to the
contractors and monitior the site safety regulations are also resbonsiblities of the field
engineer. Furthermore, site visit to low lift pump house where the water has been extracted
from the sea throughout five pumps and distrbuted to the distillation plant for further
treatment therefore it can be used in the refinery. In fact, this site visit aims to monitor the
support of the disscharge pipe since it must be reinforced because this station has beem
installed since 40s. in addition, site visit to awali pump station to support the team prior to
comissioning of the station while performing draining of the tank a leak has been identified
so directly the field engineer guide the contractor to replace the gasket to compensate such
leak actions. Moreover, Mr. Jojy illustrate and explains how the excavation certificate and
work permit are to be issued and based upon what criteria.
Next three days the trainee started with Mr. Abhilash field engineer mechanical. The firtst
day starts with illustration of the hydrogen sulphide standard in which this course aims to
inform you on the hazards of H2S, provide a detailed
overview of the intention of Bapco’s new H2S standard
and provide you with the knowledge to formally
communicate this information to your employees who
need to enter H2S designated areas. After that, Mr.
Abhilash shows what are the projects he handls
introducing new feed line for 3&4 sour water stripper,
replacement of remote control fire monitor in sitra
wharf, replacement of membranes in waste water
treatment plant and lifting mobile compressor in the
Figure 2: remote control fire monitor, RCM [3]
power plant. In the first day, after finishing H2S training
essentials a site visit has been conducted to Sour water
stripper 3&4 plant to further illustrate the piping system
project throughout the P&ID drawings beside
explaining the mechanical devices associated with that
plant. In addition, site visit to sitra wharf where Bapco
export its product globaly or even for local use this visit
aims to illustrate the rule of remote control fire monitor
in case of accident exist so such facility must be
monitored on regular basis, therfore, the area owner Figure 3: Joy compressor [4]
found that this system is getting old and need to be
replaced. Beside that, Mr. Abhilash provides the trainee with some specification related to
gasket issued by API(american petroleum institute). Furthermore, site visit to waste water
treatment plant in which this plant collect all wasted water that came from the process unit
and distalled it to be reused again, so, this site visit aims to clearly observe how the
distillation process performed throughout the membrane. Last day, site visit to power plant
where 3 joy compressor has been installed, so, the field engineer explain the configuration
of the compressor and what is used for beside taking a tour around the power plant to see
the mechanical devices associated with this plant.
After these three days, the trainee assigned with Mr. Binoy Andy field
engineer mechanical. Mr. Binoy illustrates the projects he was handling
which is mainly one project Asphalt tanks pump replacement. This project
aims to replace the existing positive displacement pumps to meet the
optimum demand, so, Mr. Binoy explain how the piping system will be
transferred to the new installed pump. As you know asphalt has high
viscosity so pumping such fluid is so hard therefore a steam tracing system
is installed on the asphalt pipe stream to keep asphalt at certain temperature
therefore it can be pumped. Second day, site visit to 5 CDU (crude
distillation unit) for illustration of completed project , so, Mr. Binoy explain
the P&ID drawing of this project which is replacement of emergency trip Figure 4: Trip valve [5]
valve. Furthermore, the third day started with taking a tour around the
refinery in which illustration conducted by Mr. Binoy regarding the main units in the
refinery CDU & VDU (crude distillation unit, vacuum distillation unit) followed by the
secondary units Offgas treating, LPG treating, Platformer, Kerosine treating, Diesel
hydrotreater, Hydrocracker, FCCU, Visbreaker and the mechanical devices associated with
these units. Finally , the trainee assigned to the last field mechanical engineer Mr. Jaffer
Eid. He also illustrate the projects to be handeled by him which is mainly structural
facilities such as platforms installation, beside piping system among the refinery which is
fire line for safety purposes, so, he explains the terminologies of some structural drawings
and isometric as well. Besides that, he provides some standard related to heat exchanger
TEMA (Tubular Exchanger Manufacturers Association) in which this standard provides
the configuration pf various types of the shell and tube heat exchanger, guidelines for the
construction, operation and maintenance.
3.2. Civil & Structural Design
The offsite section is resbonsible for the network conecting the refinery which are mainly
sitra tank farm for the final products that is ready for local use or for export globaly beside
refinery tanks farm that holds either crude oil coming from tatweer or from saudi arabia
and the rest tanks holds the products that is collected from the refinery unit ready to be
pumped to sitra tanks farm. Some of the product is not pumped to sitra tanks such as asphalt
since asphalt is heavy product its transferred using trucks and the same thing for the LPG
liquified petroleum gas only for local use. For utility section, this section maily resbonsible
for providing water, sewer, fire and welfare services to the refinery It is the company's
beating heart, supplying various sorts of water and gases throughout all the refinery units.
Besides that, they prepare the projects documents, drawings, details using different
softwares Sage CRM, Smart plan dashboard, Autocad, pipe flo, etc. After preparing the
required documents, Field engineering section receive it and start the execution process but
they keep contact with each other to monitor the progression of the projects.
The CRM Project Manager takes all the main concepts of Project and Time Management
and delivers a pragmatic and highly effective management tool which is installed on top of
the Sage CRM platform. It is completely integrated into Sage CRM so that it leverages all
the benefits of CRM including design of user interface, searching, reporting and document
management [7].
As part of the details of a Project, a dedicated Analysis tab is provided to give cross section
analysis of the Time sheet data against the Project. This allows for a very thorough analysis
of trends and patterns which can help to make proactive decisions on the running of the
project. This also allows for typical metrics required for summary reporting [7].
3.3.1.3. Project status
The Project Status screen is specifically around the controlled values of the project that
determines it's progress, status and calculations on schedule [7].
Tasks are where all the breakdown and planning effort is applied to the Project. Each Task
is a piece of work which has been listed by the Project. Manager as an identifiable effort
which needs to be allocated to a Resource, scheduled with a start date and a status
maintained on an ongoing basis. It also needs to be given an allocation of days so that the
allocated Resource knows what time they have available to complete this Task [7].
The 'Milestone Check' tab enables you to view project tasks and their associated milestones
with ease [7].
3.3.1.6. Timesheets
Timesheets are the basis by which you draw down on the allocation of Days planned and
set up by Project Tasks. Timesheets allow your Resources to log their work entries on a
daily basis, cross referencing Projects and Tasks to help regulate the schedule and progress
of the Project. Rather than maintaining the Project purely by Task updates. Timesheets give
you the realistic scenario of what is actually happening versus what should be happening.
Web Portal Users (licensed users or resources) may access their Project Tasks and enter
new Timesheets against a project using Greytrix Project Manager Web Portal. This allows
users and resources (e.g. Field Agent’s) to view and enter information into CRM without
the need for them to have full access to the CRM system [7].
3.3.1.7. Tanks
Starting by the supply of crude oil to the refinery, either by tatweer petroleum or Aramco
throughout line AB to the crude tanks in the refinery and from the refinery tanks farm the
crude is pumped to CDU & VDU (crude distillation unit & vacuum distillation unit). After
the discharge from these units various products obtained Crude off-gas deliverd to the LPG
treating, Naptha to the platformer, kerosine to the kerosine treating, diesel to the disel
hydrotreater and so on. All of these streams is connected by a network of pipes designed
and constructed based on ASME and Caltex standards. There is also a stream for
kerosine/jet fuel from sitra tanks farm to the airport in arad for fueling the airplanes. Each
pipe in the refinery has different color for identification purposes for example red pipe for
fire quenching fluids, orange pipe toxic and corrosive fluids, yellow pipe flammable and
oxidizing fluids, brown pipe combustible fluids, green pipe portable cooling boiler feed
and other water, blue pipe compressed air.
3.3.2. Utilities
Refineries require a comprehensive array of supporting utilities to process crude oil into
refined product. Large amounts of electricity are required to provide power to equipment,
lighting, heating and computer systems. This electricity may come from the main grid
however it is often generated directly from a captive power plant dedicated to the
plant. Large amounts of purified water are required to support steam generation, heat-
exchangers and cleaning processes. Water must be treated after use to remove any
contaminants or residual heat before any discharge into the sea or municipal water
system.Utilities are critical life support to the refinery, reliability and efficiency of these
systems are of the upmost importance to maximize uptime and minimize operating cost.
3.3.2.1. Water
Within a refinery, the water network is as unique to the refinery as its processes. This
section describes the typical sources of water supplied to a refinery and the typical
discharges of water from a refinery. It also provides an overview of the types of
contaminants contained in the raw water and the methods used to remove these
contaminants. Many of the processes in a petroleum refinery use water, however, not each
process needs raw or treated water, and water can be cascaded or reused in many places. A
large portion of the water used in a petroleum refinery can be continually recycled with in
a refinery. There are losses to the atmosphere, including steam losses and cooling tower
evaporation and drift. A smaller amount of water can also leave with the products. Certain
processes require a continuous make-up of water to the operation such as steam generating
systems or cooling water systems. Understanding water balance for a refinery is a key step
towards optimizing water usage, recycle and reuse as well as optimizing performance of
water and wastewater treatment systems [12].
3.3.2.2. Air
Compressed air is an important element for many processes within the petrochemical and
oil refining industries. First, compressed air acts as a medium for the transfer of energy,
which is critical to power equipment such as drills, jack hammers and air-powered tools,
among others. Compressed air is also used elsewhere in refineries to move material such
as paint, oils, cylinders for industrial and automation, and brakes on large
equipment.Compressed air is also utilized in a refinery for breathing gas when operations
face confined space requirements. Additionally, it controls precise measurements and
calibration in the production of gases and liquids during operation of specific machinery
and instrumentation. The term “Instrument Air” refers to an extremely clean supply of
compressed air that is free from contaminates such as moisture & particulates. A system
may utilize instrument air for various types of pneumatic equipment, valves & electrical
controls. High efficiency filtration eliminates issues with pneumatic valves and
electrical/pneumatic controls caused by suspended liquids, such as compressor oil and
particulates that are often present in plant air, also known as service air [13].
3.4. Opd North Engineering (Refinery Engineering)
In this section same duties has been done as offsite & utilities but the difference is that
OPD section responsible for preparing the projects dor the process units unlike offsite in
which they are responsible for the projects of the network connecting the refinery tanks
and pipes. Besides that, illustration has been done for different types of the drawings
isometric, P&ID and general arrangement drawing but mainly some tasks has been given
to the trainee to find the routes in the P&ID beside recognizing the symbols exist in the
drawing. Furthermore, some tasks were given about hydraulic analysis in which the
principal of fluid mechanics has been applied for selecting the right pump for real refinery
piping system.
3.4.1. P&ID
General arrangement drawings (GA’s) present the overall composition of an object such as
a building. Depending on the complexity of the building, this is likely to require a number
of different projections, such as plans, sections and elevations, and may be spread across
several different drawings. They may be referred to as 'location drawings' as they show
the location of various components and assemblies within the overall design, but this can
be confused with location drawings indicating the geographical location of the building.
General arrangement drawings are likely to be prepared at each stage of development of
a building design, showing the overall relationship between the main elements and
key dimensions. The level of detail will increase as the project progresses and they may
need to be supplemented by more detailed drawings, showing
specific elements and assemblies. On very simple projects these may be included on
the general arrangement drawings themselves, but generally, separate drawings will be
required. General arrangement drawings may include references to additional information,
such as specifications and detail drawings, however they should not
duplicate information included elsewhere as this can become contradictory and may cause
confusion [17].
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4. CONCLUSIONS AND RECOMMENDATIONS
4.1. Conclusion
4.2. Recommendation
It is suggested that the organization provide students with more opportunity to complete
their industrial training course. In order to perform successfully and maintain strong
industrial relations between supervisors and operators, the organization should also
increase and assure more oversight over employees and interns.