Aden Refinery Co.(ARC)
Summer Practice Course MCT200
Held At Aden Refinery Co.
Submitted by:
Karam Ahmed A. Jabbar
Std #20223390
Near East University
Faculty Of Engineering
Mechatronics Department
Aug. 2023 summer Practice MCT-200
CONTENT:
Page #
[1] About Aden Refinery Co ..................................................................................... 4
[1.1] Tasks and roles ...................................................................................... 4
[1.2] Main departments .................................................................................. 4
[2] Introduction .......................................................................................................... 5
[2.1] Scope Of Work ...................................................................................... 5
[3] Control Instrument Service ................................................................................... 6
[3.1] Pneumatic Valve Positioners (3582 Series) ........................................... 6
[3.1.1] Principle operation of 3582 Series Valve ............................... 6
[3.1.2] Maintenance & troubleshooting of Control Valve ................. 9
[3.2] Tank-Radar gauge system (RTG 3900 Series) ...................................... 9
[3.2.1] Summary of Functions ............................................................ 9
[3.2.2] Tank-Radar gauge system components .................................. 10
[4] Machinery Workshop ........................................................................................... 12
[4.1] Lathe machine Description ………………………………………...… 12
[4.2] M400 center Lathe Machine Specifications .......................................... 12
[4.3] Lathe Machine components ................................................................... 12
[4.4] Working Principle of the Lathe Machine .............................................. 13
[4.5] Products which can be made from lathe machine …………….. …….. 13
[5] Mechanical Workshop .......................................................................................... 15
[5.1] Introduction of Pumps ........................................................................... 15
[5.2] Main purposes ....................................................................................... 15
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[5.3] Components of a Pumping System ...................................................... 15
[5.4] Classification of Pumps ....................................................................... 15
[5.4.1] Positive Displacement Pumps .............................................. 15
[5.4.2] Dynamic Pressure Pumps ..................................................... 15
[6] Rewinding Workshop ......................................................................................... 17
[6.1] Steps to rewind electric motor ............................................................. 17
Conclusion ……....................................................................................................... 20
Appendix #1 ............................................................................................................. 21
Table [3.1] specification of pneumatic valve positioner .......................................... 6
Table [4.1] M400 center Lathe Machine Specifications ………............................. 12
Figures [3.1] Schematic diagram of 3582 Series Valve Positioners........................ 8
Figures [3.2] Principle of operation ……………………………………………..... 8
Figures [3.3] RTG 3930 Parabolic Antenna Gauge ………………………….….. 11
Figure [4.1] M400 canter Lathe Machine …………………………………….….. 14
Figure [5.1] Classification of Pumps ……………………………………….……. 16
Figure[6.1] Electric Motor's parts …………………………………………….….. 17
Figure[6.2] Wiring Connection ………………………………………………..…. 19
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[1] ABOUT ADEN REFINERY COMPANY
The groundwork of Aden Refinery Company (initially know as British Petroleum
Company) was started on November 1, 1952, and completed in a record time of 21 months.
It was originally designed to refine about 5 million tons of crude oil every year. The
refinery was inaugurated by her majesty Queen Elizabeth –II on July, 1954. Subsequently, the
Aden Refinery was linked to Aden Bunkering facilities in Aden harbor through 19 miles long
pipelines to supply bunkering fuels to the ships visiting Aden harbor.
The refinery was later upgraded to 8 million tons capacity, in the sixties. In May 1977
B.P. handed over the refinery to the government of Yemen. Since that date the refinery operates
under the name of Aden Refinery Company (ARC). In accordance of law number 15 for 1977.
[1.1] Tasks and roles
Since the establishment of the company, successful co-operation with others was achieved.
At present the main activities can be summarized as follows:

Processing of crude oil to satisfy the local market requirement of petroleum products.

Storage of crude oil and petroleum products for others.

Transport of petroleum products from the refinery to local ports utilizing the refinery
owned or hired vessels.

Trading with petroleum products.

Operating of power station to satisfy refinery requirement of power and other utilities.

Selling bunker fuel to customers directly or indirectly.
[1.2] Main departments

Safety and Fire.

Oil Harbour.

A.R.C Fleets-Pearl of Crater .

Refinery main units .

The refinery company owns a power plant with a three generators each generating 7.5
MW , which has been repaired and prepared to begin the process of refining any crude to
be received by the refinery, and also has a diesel-powered station generating 3.5 MW.
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[2] INTRODUCTION
The Summer Training Program plays an important role in the educational and
professional development of individuals. It provides innumerable advantages, including practical
application of theoretical knowledge, skill development, industry exposure, networking
opportunities, resume upgradation, allows individuals to obtain valuable experience and build
problem-solving and critical-thinking skills, etc.
Participating in a Summer Training Program permits individuals to minimize the gap
between theory and practice. Students aim to do this by applying their academic knowledge to
real-world situations. It offers hands-on experience and assists individuals to build and upgrade
their skills.
Summer training also provides exposure to the industrial environment, allowing them to
obtain insights into industry practices, trends, and expectations. It contributes to the development
of a professional network of mentors and industry experts. This leads to future partnerships,
internships, and career possibilities.
[2.1] Scope Of Work:
My first summer training will take place at the Aden Refinery Training Center, and the
center will arrange and distribute my training period among the maintenance management
departments, as follow:
Control Instruments Service (CIS), From Jul, 30th To Aug, 3rd .
Central workshop:
Machinery workshop, From Aug, 6th To Aug, 10th .
Mechanical workshop, From Aug, 13th To Aug, 17th .
Motor rewinding workshop, From Aug, 20th To Aug, 24th .
By the end of the training period, the summer training report will be delivered as soft and hard
copy.
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[3] CONTROL INSTRUMENT SERVICE (CIS):
The nature of the work in this section is divided into two parts, one section works in the
workshop to maintain. Test, and calibrate the devices, and the other section works in the fields to
maintain and repair on-line equipment.
We went with a technician to some fuel tanks and we learned how to connect sensors to
know the level of liquid inside the tank and related data processing devices, which will be
discussed later in this report.
[3.1] Pneumatic Valve Positioners (3582 Series):
We worked on Pneumatic Valve Positioners (3582 Series, made by FISHER)
Area Classification
ATEX Group II Category 2 Gas and Dust, CUTR for Groups II/III Category 2 Equipment
Certifications
ATEX, CUTR, PED
Communication Protocol 3-15 or 6-30 psi, 0.2 -1.0 or 0.4 -2.0 bar Pneumatic Signal
Diagnostics
No
Input Signal
Pneumatic
Max Outlet Pressure
50 psi
Mounting Type
Actuator Mounted
Operating Temperature
Standard Temperature, High Temperature
Position Control
Modulating
Safety Certification
NIL
Supply Media
Air, Natural Gas
Table [3.1] specification of pneumatic valve positioner.
[3.1.1] Principle operation of Pneumatic Valve Positioners:
Refer to figures [3.1] & [3.2],
1- Pneumatic Valve Positioners accept a pneumatic input signal from a control device.
2- In a diaphragm-actuated, sliding stem control valve package, supply pressure is supplied
to the relay and fixed restriction.
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3- If the flapper is not restricting the nozzle, the air can bleed out faster than it is being
supplied, because the diameter of the nozzle.
4- When the input signal increase the bellows expand and moves beam.
5- The beam pivots the flapper and restricts the nozzle.
6- The nozzle pressure increases and move the relay diaphragm assembly to open supply
port.
7- The increased output pressure to the actuator causes the actuator stem to move
downward.
8- Stem movement is fed back to the beam by means of a cam.
9- As the cam rotates, the beam pivots about the feedback axis to move the flapper slightly
away from the nozzle.
10- The nozzle pressure decreases and reduces the output pressure to the actuator until
equilibrium is reached.
11- When the input signal decreases, the bellows contracts (aided by an internal range spring)
and the beam pivots about the input axis to move the flapper away from the nozzle.
12- Nozzle pressure decreases and the relay permits the release of diaphragm casing pressure
to atmosphere.
13- The actuator stem moves upward.
14- Through the cam, stem movement is fed back to the beam to reposition the flapper closer
to the nozzle.
15- When equilibrium conditions are obtained, stem movement stops and the flapper is
positioned to prevent any further decrease in diaphragm case pressure.
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[3.1.2] Maintenance & troubleshooting of Control Valve
1. Inspect the control valve along with its associated accessories.
2. Inspect for physical damage or air leakages. Fix them if any problems are detected.
3. Apply constant air supply to the control valve.
4. Inspect instrument air supply to valve positioner coming from Air Filter Regulator.
5. Ensure the set pressure of the Air Filter Regulator is matching with the value specified in
the Control Valve datasheet.
6. If air pressure is less than required then the valve moves very slowly.
7. If air pressure goes high or more than required then there is a chance of actuator damage.
8. To avoid this damage & slow working kindly adjust the air pressure to the required value.
9. Evaluate the condition of the isolation valve located in the air supply header in absence of
an air supply.
10. Keep the isolation Valve in closed condition.
11. Send the confirmation for control valve operation from the control room based on field
condition.
12. Check the current signal on the electro-pneumatic positioner, if the valve remains
stationary.
13. If there is no current signal available, check cable connections by referring loop drawing
on both the field side and the marshaling cabinet side.
[3.2] Tank-Radar gauge system (RTG 3900 Series):
Tank-Radar gauge system (RTG 3900 Series, made by EMERSON) has been installed on
oil tank #302.
[3.2.1] Summary of Functions:
Tank-Radar Rex system measures and calculates tank data for:
• Inventory calculations
• Custody transfer
• Oil movement
• Loss control
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• Operational & blending control
• Leak detection and overfill protection.
The system is configured with the functions as required by the user. Available functions are:
• Level, temperature, and water interface level measurement.
But they use RTG 3930 module, which it used for general use and in demanding
environments, fig.[3.3] shown RTG 3930 parabolic antenna gauge.
The Radar Tank Gauge (RTG) measures the distance to the surface of the product in the tank.
Using tank distances stored locally in the memory of the gauge, it calculates the level of the
liquid’s surface. The level is communicated on the digital TRL2 field bus to the Field
Communication Units and to the PC workstations or other host computers.
[3.2.2] Tank-Radar gauge system components:
The Tank-Radar Rex System can include various integrated equipment, such as
• Water Interface measurement sensors integrated with temperature sensors.
• Vapor pressure transmitters.
• Hydrostatic pressure transmitters.
• Tank-Master PC workstations in network.
• Local data display on the Data Acquisition Units or on the Remote Display Units.
NOTE:
All equipment designed to meet explosion proof and intrinsically safe applications.
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[4] MACHINERY WORKSHOP
[4.1] Lathe machine Description:
Lathe Machine is known as one of the oldest machine tools in the production machine.
A lathe is a machine which is one of the most versatile and widely used machine tool all over the
world.
A lathe machine is a machine tool which removes the undesired material from a rotating
workpiece in the form of chips with the help of a tool which is traversed across the work and can
be feed deep into the work.
Nowadays, Lathe Machine has become a general-purpose machine tool, employed in production
and repair work, because it permits a large variety of operations to be performed on it.
[4.2] M400 center Lathe Machine Specifications:
MFR by
Model
Swing
Supply
Rated full load current
Main motor
Electrical Diagram
Harrison & Sons LTD
M400 centre lathe
16 ins
460V, 3-phases. 50HZ
10 HP
EWD 403.1
Table [4.1] M400 center Lathe Machine Specifications.
[4.3] Lathe Machine components:
Fig. [4.1] shown lath machine parts,
BED: The bed of the lathe machine is the base on which all the other parts of the lathe are mounted.
The bed is made from Cast iron or nickel cast iron alloy.
Headstock: The main function of the headstock is to transmit power to the different parts of the
lathe. It supports the main spindle in the bearing and align it properly. It also houses a necessary
transmission mechanism with speed changing levers to obtain different speeds.
Tailstock: Tail stock is a movable casting located opposite to the headstock on the way of the
bed. The basic function of the tailstock is:
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1. To support the other end of the work when being machined.
2. To hold a tool for performing operations like drilling, reaming, tapping, etc.
The body of the tailstock is adjustable on the base which is mounted on the guideways of the bed
and can be moved forward and backward.
Cross Slide: The top surface of the cross slide is provided with T slots to enable fixing of rear
tool post or coolant attachment.
Compound Rest: Compound rest supports the tool post and cutting tool in its various positions.
Compound rest is necessary for turning angles and boring short tapers and forms on forming
tools.
Tool Post: The tool post is mounted on the compound rest. It is used to hold the various cutting
tool holders.
The Apron: Apron consists of the gears and clutches for transmitting motion from the feed rod to
the carriage.
Chuck: Chuck is basically used to hold the work piece, particularly of short length and large
diameter or of irregular shape which can’t be conveniently mounted between centers.
[4.4] Working Principle of the Lathe Machine:
A Lathe works on the principle of rotating the work piece and a fixed cutting tool. The work
piece is held between two rigid and strong supports called center or in a chuck or in face plate
which revolves.
The main function of the lathe is to remove the metal from a job to give it the required shape and
size. The normal cutting operations are performed with the cutting tool fed either parallel or at
right angles to the axis of the work.
[4.5] Products which can be made from lathe machine:
A variety of products can be made from the lathe machine. Some of them are: Nuts, bolts, piston,
Ram, pump part, electric motor parts, sleeves, Air craft parts, gun barrels, candlesticks, train
parts, cue sticks, wooden bowls, baseball bat, crankshaft and many more things.
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[5] MECHANICAL WORKSHOP
[5.1] Introduction of Pumps:
Pumps convert mechanical energy into hydraulic energy. Electrical energy is generally used to
operate the various types of pumps.
[5.2] Pumps have two main purposes:
1. Transfer of liquid from one place to another place (e.g. water from an underground into a
water storage tank).
2. Circulate liquid around a system (e.g. cooling water or lubricants through machines and
equipment).
[5.3] Components of a Pumping System:
* Pump casing and impellers.
* Prime movers.
* Piping used to carry the fluid.
* Valves, used to control the flow in the system.
* Other fittings, controls and instrumentation.
[5.4] Classification of pumps:
Most of pumps can be broadly classified into two categories as mentioned below:
i. positive displacement.
ii. dynamic pressure pumps.
Fig.[5.1] shown sub classification of pumps.
[5.4.1] Positive Displacement Pumps:
Designed to displace a more or less fixed volume of fluid during each cycle of operation. The
flow capacity is thus fixed by the design, size, and operating speed of the pump.
The discharge line from the pump should never be closed off without allowing for recycle
around the pump or damage to the pump could result.
[5.4.2] Dynamic Pressure Pumps:
Force is imparted which accelerates the fluid normally by rotation of impeller.
They are normally used for moderate to high discharge rate. The pressure differential range for
this type of pumps is in a range of low to moderate. They are popularly used in a system where
low viscosity fluids are used.
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[6] REWINDING WORKSHOP
The electric motor rewinding workshop is one of the main sections in the electrical department in
which the burnt/defective motors and transformers of all types and sizes are rewound.
Fortunately, it happened that there was a burnt out motor that needs to be rewound, as I did the
rewinding process with the help of a technician specializing in that, and the steps of the work
were as follow:
[6.1] Steps to rewind electric motor:
1. Record the information of the motor from the name plate (induction motor, 3-phases 440V, 50
HZ, 4 KW, 1500 RPM).
Punch marking the drive-end and non drive-end covers of the motor, to be reinstalled in the same
position, then we take off plastic cooling fan, covers, and rotor. Fig.[6.1] shown motor parts.
All the work is concentrated in the motor stator part where it contains the coils that need to be
rewound.
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2. We note the number of poles, the number of coil slots, and the coil span. Then we remove the
straps from the coils and draw the way the coils are connected to each other.
3. We remove a set of coil in a proper way to match it to the frame used with the winding
machine to create a new coil that has the same dimensions as the old coil. We also calculate the
number of coil turns and measure the size of the wire using a micrometer and record them.
4. We cut off the old coils and remove them from the motor stator, then clean the slots from the
old insulator papers and install new ones.
5. We use winding machine to rewind new coils, then we install them in the slots according to
the prerecorded numbers and information.
6. We connect each of the four coils in series or as we found them, as their connection results in
two wires that form the first phase, four more coils for the second phase, and the last four coils
for the third phase. Coil connections are soldered with a soldering iron, after removing the
insulation from the ends of the wires with a sharp tool. Fig.[6.2] shown coils connections.
7. We isolate the coils of each phase from the coils of the other phase by inserting insulation
papers, then all the coils are tie-raped together at the top and bottom.
8. The coils are checked with the MEGGER device to ensure that there is no contact with the
motor body and among the coils themselves.
9. The motor windings are dipped into a varnish tank and then set to cure in an oven. Typically, a
new motor winding should be dipped twice (double dip and bake) to ensure the varnish fully
covers the windings. This technique is called Dip and Bake Varnishing.
Finally, new bearings were fitted to the rotor shaft, the motor parts reassembled and a test run
was performed.
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CONCLUSION
During my summer training period at the ARC facility, I noticed the extent to which such oil &
gas facilities use non-flammable equipment and devices with high specifications. Is it worth this
high degree of safety and protection? Are there any varying degrees of protection?
Extraction, processing, transportation, and storage of oil & gas all present potential dangers to
workers. From mechanical and industrial machinery to harsh physical environments, to the
product and by products themselves, the risk potential for injury is high to both workers and the
environment.
This demands a high level of attention and detail to ensure the health and safety of not just
workers but the environment and the population at large. The product is both flammable and
explosive. The equipment is industrial, dangerous, and expensive. HSE must be a top priority
because failure can result in a catastrophic loss of life, property, and resources.
The importance of safety cannot be over emphasized.
People say – If you think safety is costly, try accident.
Safety help prevent injury/dead to individuals, Helps prevent damage to property and equipment,
Ensure a happy and healthy workforce, Safe money from payment of compensations, hospital
bills, death right, etc, Protect firm/organization from legal actions.
Appreciate the importance of safety, act safe, and encourage others to do same.
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APPENDIX #1
Ingress Protection (IP):
The IP rating or IP code classifies the degree of protection provided by an enclosure, for electrical
equipment with a rated voltage not exceeding 72.5 kV.
IP ratings are defined by the international standard EN 60529 (British Standard BS EN 60529:1992).
The IP rating consists of the letters IP followed by two digits, the higher the number the better the
protection.
The first digit indicates the level of protection that the enclosure provides against the ingress of solid
foreign objects.
The second digit defines the protection of the equipment inside the enclosure against various forms of
moisture (drips, sprays, submersion etc.)
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