YANPET Report

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YANBU Industrial College
Department of Mechanical Engineering
CO-OP Training Program
Final Technical Report
[Company: YANPET CO., Yanbu Al Sinaiyah]
MET 320
The Cooperative training report presented to the YANBU Industrial College
By
Anas Marwan Kaki (302038)
In partial fulfillment of the requirements for the award of Associate degree in
Mechanical Engineering (Manufacturing specialization)
COOP 20123
September 2013.
MET
D
E P A R T M E N
T
MECHANICAL
ENGINEERING
T
ECHNOLOGY

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In the name of Allah the Beneficent, the Merciful. All praise is to him, who
taught by the pen, and taught man what he did not know.
Peace be upon Mohammad, the unlettered prophet, whom he set as a teacher, guide
and mercy to all mankind.

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Acknowledgment
At the beginning I would like to thank almighty Allah for his guidance and protection
throughout my life and for helping me to complete my final report and for finishing all my
courses successfully.
Also, I would like to thank YANBU Industrial College and Mechanical Engineering
Department for giving me this opportunity to get an experience on working in the field and
dealing with others and for giving me all the supports. Thank you to the industrial affairs
department and to the COOP/summer training coordinator in the mechanical department. A
special thanks to Engr. CHANDRAKANT SHITOLE for all the supports and helps during my
coop training period.
Furthermore, I would like to thank YANPET COMPANY for giving me the chance to get
trained in it. Also I would like to thank all the members in the Vibration Department for all
their support during the training period. A special thanks to my superintendent Mr. MAJED
AL-HARBI.
Finally, I would like to thank all my friends for supporting me during my study period. A
thank you goes to my parents for all their support through my educational years.

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Introduction
On 4/9/2013, I was finished my co-op training period at Saudi YANBU Petrochemical
Company (YANPET) which was for 14 weeks.
However, I have to submit a report to YANBU Industrial College (YIC) that describes the
main activities and experiences that I have gained and learned from YANPET Company
during my training period.
So that, I wrote a report that contains four chapters. The first chapter talks about an
introduction to YANPET Company, such as an information about YANPET, production of
YANPET, YANPET vision & mission, and YANPET units.
The second chapter talks about safety, such as basic safety rules, work permits, and personal
protective equipment (PPE).
The third chapter talks about a theoretical background about my department (Vibration
Analysis), such as definition of vibration and vibration analysis, application of vibration
analysis, vibration characteristics, vibration analysis charts, and the causes of vibration.
Also this chapter talks about the different activities that I did during my co-op training period.

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Table of Contents
Chapter 1
1. INTRODUCTION
1.1. About YANPET ………………………………………………………….....13
1.2. YANPET Vision & Mission………………………………………………...13
1.3. Production of YANPET……………………………………………………..13
1.4. YANPET Plants……………………………………………………………..14
1.4.1. Utilities and Offsite…………………….........................................14
1.4.2. Olefins…………………………………………………………….14
1.4.3. Ethylene Glycol………………………………………..................14
1.4.4. Polymer………………………………….......................................14
Chapter 2
2. SAFETY
2.1. What is safety………………………………………………………………..16
2.2. Basic Safety Rules…………………………………………………………...17
2.2.1. Follow Safe Practices……………………………………………..17
2.2.2. Avoid Unsafe Activities…………………………………………..17
2.2.3. Protect Yourself…………………………………………………..18
2.3. Work Permits………………………………………………………………...18
2.3.1. Hot Work Permit………………………………………………….19
2.3.2. Cold Work Permit……………………………………...................20
2.3.3. Confined Space Entry Permit……………………………………..21
2.4. Personal Protective Equipment (PPE)………………………….....................22
2.4.1.1. Head Protection………………………………………………….23
2.4.1.2. Eye Protection…………………………………...........................23
2.4.1.3. Ear Protection……………………………………………………24
2.4.1.4. Body Protection………………………………………………….24
2.4.1.5. Hand Protection………………………………………………….25
2.4.1.6. Foot Protection…………………………………..........................25
2.4.1.7. Respiratory System………………………………………………26
2.4.1.8. Safety Harness………………………………………...................26

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Chapter 3
3. Theoretical Background
3.1. What is vibration…………………………………………………………….28
3.2. Machine Vibration………………………………………..............................28
3.3. Vibration Analysis…………………………………………………………..29
3.4. Application of vibration analysis…………………………………………....29
3.5. Vibration Characteristics………………………………………....................29
3.6. Vibration analysis charts……………………………….................................30
3.6.1. Trend chart………………………………………………………..30
3.6.2. Spectrum chart…………………………………………………....31
3.6.3. Time waveform chart………………………………………….….31
3.7. Causes of Vibration…………………………………………….....................31
3.8. Work Done No.1……………………………………………….....................32
3.8.1. Work Objective and Goal...............................................................32
3.8.2. Theoretical Background..................................................................32
3.8.3. Safety Requirement.........................................................................34
3.8.4. Work Details…………………………………………...................34
3.8.5. Man power and device used………………………………………35
3.8.6. Sequence of Work……………………………………...................36
3.8.7. Result…………………………………………………..................36
3.8.8. Conclusion……………………………………………..................36
3.9. Work Done No.2 ……………………………………………………………37
3.9.1. Work Objective and Goal...............................................................37
3.9.2. Theoretical Background..................................................................37
3.9.3. Safety Requirement……………………………………………….38
3.9.4. Work Details…………………………………………...................39
3.9.6. Sequence of Work……………………………………...................41
3.9.7. Result…………………………………………………..................41
3.9.8. Conclusion……………………………………………..................41
3.10. Work Done No.3…………………………………………………………….42
3.10.1. Work Objective and Goal………………………………………...42
3.10.2. Theoretical Background…………………………………………..42

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3.10.3. Safety Requirement…………………………………………….....43
3.10.4. Work Details……………………………………………………...43
3.10.6. Sequence of Work………………………………………………...45
3.10.7. Result……………………………………………………………..45
3.10.8. Conclusion………………………………………………………..45
3.11. Work Done No.4…………………………………………………………….46
3.11.4. Work Details……………………………………………………...47
3.11.6. Sequence of Work………………………………………………...49
3.11.7. Result & conclusion………………………………………………49
3.12. Work Done No.5…………………………………………………………….50
3.12.4. Work Details……………………………………………………...51
3.12.6. Sequence of Work………………………………………………...52
3.12.7. Result & conclusion………………………………………………53
Chapter 4
4. Conclusion & References
4.1. Conclusion…………………………………………………………………...55
4.2. References…………………………………………………………………...56

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List if Figures
Figure 1.1: Utilities & Offsite Plant………………………………………………………....14
Figure 1.2: Olefins Plant…………………………………………………………………….14
Figure 1.3: Ethylene Glycol Plant…………………………………………………………...14
Figure 1.4: Polymer Plant…………………………………………………………………...14
Figure 2.1: Safety first……………………………………………………………………….16
Figure 2.2: Hot work permit………………………………………………………………....19
Figure 2.3: Cold work permit………………………………………………………………..20
Figure 2.4: Confined space entry permit…………………………………………………….21
Figure 2.5: Personal Protective Equipment (PPE)…………………………………………..22
Figure 2.6: Head protection………………………………………………………………….23
Figure 2.7: Eye protection……………………………………………...................................23
Figure 2.8: Ear protection……………………………………………………………………24
Figure 2.9: Body protection………………………………………………………………….24
Figure 2.10: Hand protection………………………………………………………………...25
Figure 2.11: Foot protection…………………………………………………………………25
Figure 2.12: Respiratory system……………………………………………………………..26
Figure 2.13: Safety harness…………………………………………………………………..26
Figure 3.1: Movement of a pendulum………………………………………………………..28
Figure 3.2: Machine vibration………………………………………………………………..28
Figure 3.3: Vibration analysis………………………………………………………………..29
Figure 3.4: Vibration parameters…………………………………………………………….30
Figure 3.5: Trend chart………………………………………………………………………30
Figure 3.6: Spectrum chart…………………………………………………………………..31
Figure 3.7: Time waveform chart……………………………………………………………31
Figure 3.8: Centrifugal compressor………………………………………………………….33
Figure 3.9: Centrifugal compressor diagram………………………………………………...33
Figure 3.10: Journal bearing side wall wear out…………………………………………….35
Figure 3.11: Journal bearing side wall………………………………………………………35
Figure 3.12: Damage on impeller holder……………………………………………………35
Figure 3.13: (SKF device) for measuring compressor vibration…………………………….35
Figure 3.14: Steam turbine…………………………………………………………………..38

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Figure 3.15: Steam turbine diagram………………………………………………………....38
Figure 3.16: Steam turbine spectrum………………………………………………………..39
Figure 3.17: Seized ball bearing……………………………………………………………..40
Figure 3.18: Shaft rubbing marks…………………………………………………………...40
Figure 3.19: (SKF device) for measuring turbine vibration………………………………....40
Figure 3.20: Extruder………………………………………………………………………...42
Figurer 3.21: Extruder spectrum……………………………………………………………..43
Figure 3.22: Extruder locking gib………………………………………................................44
Figure 3.23: (SKF device) for measuring extruder vibration………………………………...44
Figure 3.24: Centrifugal pump……………………………………………………………….46
Figure 3.25: Centrifugal pump diagram……………………………………………………...47
Figure 3.26: Centrifugal pump spectrum…………………………………………………….48
Figure 3.27: (SKF device) for measuring the pump vibration……………………………….48
Figure 3.28: (Temperature gun) for measuring pump temperature….....................................48
Figure 3.29: Inline blender…………………………………………………………………..50
Figure 3.30: Inline blender's gearbox spectrum………………………..................................51
Figure 3.31: (SKF device) for measuring gearbox vibration……………….………………..52

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Nomenclatures
YANPET: SAUDI YANBU PETROCHEMICAL COMPANY
SKF: SVENSKA KULLAGERFABRIKEN
PE: Polyethylene
PP: Polypropylene
MEG: Mono Ethylene Glycol
DEG: Di Ethylene Glycol
TEG: Tri Ethylene Glycol
PEG: Polyethylene Glycol
HDPE: High Density of Polyethylene
PPE: Personal Protective Equipment
PDM: Predictive Maintenance
CPS: Cycle per Second
CPM: Cycle per Minute
RMS: Root Mean Square
In/sec: Inch per second
mm/sec: Millimeter per second
: Meter per Second Square
: Inch per Second Square
HZ: Hertz

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1.1. About YANPET
Saudi YANBU Petrochemical Company (YANPET) is one of the SABIC manufacturing
companies. It was created as a joint venture between SABIC and Exxon Mobil on 19 April
1980. It is located in the Kingdom of Saudi Arabia, in YANBU Industrial Citi. YANPET
Company was established to make the Kingdom as a major and more important producer of
petrochemicals and to diversify its economic base.
1.2. YANPET Vision and Mission
Vision
To be known as the best company producer of petrochemicals in the world.
Mission
Pursue excellence to accomplish a credible and gainful plant operation through total
commitment to safety and sustainability, while meeting the stakeholder's anticipations.
Also their mission is to attract and keep an eligible workforce through engagement, while
providing continuous training and career development opportunities.
1.3. Production of YANPET
YANPET Company produces many different products. These are:-
 Ethylene.
 Ethylene Glycol.
 Polyethylene (PE).
 Polypropylene (PP).

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1.4. YANPET Plants
1.4.1. Utilities and Offsite
The function of this plant is to supply and support YANPET's
Operating Units (Olefins, Ethylene Glycols, Polymers and
Packaging). The objective of this unit is to generate, distribute
and maintain sustainability of all required Utilities (Steam, Air,
Water and Others).
1.4.2. Olefins
This plant consists of two units (Ethylene I and Ethylene II). The
function of these two plants is to produce polymer grade
Ethylene by the thermal cracking of Ethane, Propane and A- 180
and plant recycle stream.
1.4.3. Ethylene Glycol
This plant consists of two units (Ethylene Glycol I and
Ethylene Glycol II). The objective of these units is to produce
different glycols. These are: Mono Ethylene Glycol (MEG), Di
Ethylene Glycol (DEG), Tri Ethylene Glycol (TEG) and
Polyethylene Glycol (PEG).
1.4.4. Polymer
This plant consists of four Units (Wet End 30, Dry End 30,
Wet End 230 and Dry End 230. The main function of these
Units is to produce High Density of Polyethylene (HDPE) and
Polypropylene (PP).
Figure 1.1
Figure 1.3
Figure 1.4
Figure 1.2

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2.1. Safety
Safety is the most important thing in our lives. It is the first thing that we must think about
when we want to begin a new job. Some works specially plant works carry unreliable risks
while working, So that, the worker must be trained how to expect and express the risks which
may will happen during the work and getting ready for such kinds of risks. Safety preparing
was stated under standard rules and steps which must be explained carefully and clearly for
the employees and workers at the area in which the work is being done to reduce the chance
of accidents also minimize all kind of losses. All the workers in any company must wear
personal protective equipment (PPE) that protects them from dangers and hazards. Also they
have to be attention to all safety signs and follow them. In this chapter I will talk about
different safety topics that’s must be understood and followed by all the workers.
Figure 2.1

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2.2. Basic Safety Rules
This section contains safety rules applicable to all areas that shall be followed at all times.
2.2.1. Follow Safe Practices
 All persons in vehicles shall wear seat belt and carrying YANPET driving
license at all times.
 Use only proper tools and equipment maintained in a safe working condition.
Homemade tools are prohibited.
 Maintain good housekeeping in your work area at all times.
 Smoking is not permitted unless in designated areas only.
 Matches and lighters are prohibited in restricted area.
 Eating and resting is permitted in designated areas only.
 Use proper manual lifting techniques, or obtain assistance or mechanical lifting
aids when lifting loads.
 All operating machinery and electrical switchgear shall have all safety guards,
switches and alarms in place and functional.
 All fire extinguishers and other emergency equipment shall be in good
condition, inspected regularly and kept clear of any obstruction.
 All chemical or hazardous material containers shall be properly labeled and
stored.
2.2.2. Avoid Unsafe Activities
 Climbing or standing on equipment, piping, valves or unstable surfaces (such
as chairs) to perform work is prohibited.
 Finger rings, watches, jewelry, loose clothing, unsecured long hair, and other
loose accessories shall not be worn when you are working on any rotating
equipment.
 Do not apply compressed air or other gases to yourself or others.

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 No work shall be started in any area or on any equipment without consent of
the YANPET person-in-charge.
 Electrical devices (such as mobile phones and pagers) are not allowed inside
YANPET Company.
 Fighting on YANPET Company is prohibited.
2.2.3. Protect yourself
 Approved hard hats without defects shall be worn in designated areas.
 Approved safety footwear shall be worn in field operations, process areas and
other designated areas.
 Approved safety eyewear with side protection shall be worn where designated.
 Approved additional hazard-specific eye/face protection (e.g. grinding,
welding, drilling or scrapping) shall be worn where designated.
 Proper personal protective equipment (PPE) shall be worn when handling
chemicals or hazardous material.
 Approved hearing protection shall be worn in high noise areas.
 Proper hand protection shall be worn when performing tasks that may present
a hand injury risks.
2.3. Work Permits
Any type of work must be performed by using a permit. There are three types of permits.
These are:-
1. Hot work permit.
2. Cold work permit.
3. Confined space entry permit.

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2.3.1. Hot Work Permit
Definition:
Works that involve ignition sources for flammable mixtures.
A Hot Work Permit is required for the following operations:
Examples:
1. Welding.
2. Grinding.
3. Electrical equipment or use of unapproved electrical devices.
4. Entry of heavy vehicles in electrically classified areas.
5. Sandblasting.
6. Drilling.
7. Chipping.
8. Soldering and brazing
Figure 2.2

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2.3.2. Cold Work Permit
Definition:
Work activity that does not involve any source of ignition for flammable mixtures.
A Cold Work Permit is required for the following activities:
Examples:
1. Use of hand tools ( such as vibration monitoring)
2. Maintenance work not involving arc welding or open flame in the plant.
3. Installing and removing scaffolding.
4. Air conditioning servicing.
5. Brushing & painting.
6. Housekeeping.
Figure 2.3

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2.3.3. Confined Space Entry Permit
Definition:
Confined Space Entry is the entry of personnel into any space or structure that can be very
small and does not have enough ventilation.
A Confined Space Entry Permit is required for the following activities:
Examples:
Internal cleaning and inspection of:
- Tanks - Towers - Vessels - Boilers
- Furnaces - Duct - Excavation area
Figure 2.4

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2.4. Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) is designed to protect employees from injuries that can
be result when you are dealing with chemical, electrical, mechanical, or any other workplace
hazards.
Personal Protective Equipment (PPE) include:-
 Head protection.
 Eye protection.
 Ear protection.
 Body protection.
 Hand protection.
 Foot protection.
 Respiratory system
 Safety harness.
Figure 2.5

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2.4.1. Head Protection (Hard Hat)
Hard hats can protect you from head impact, penetration injuries, and electrical injuries such
as those caused by falling or flying objects, fixed objects, or contact with electrical conductors.
2.4.2. Eye Protection (Safety Glasses)
Besides safety glasses and goggles, PPE such as special helmets or shields can protect you
from the hazards of flying fragments, large chips, hot sparks, optical radiation, splashes from
molten metals, as well as objects, particles, sand, dirt, mists, dusts, and glare.
Figure 2.6
Figure 2.7

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2.4.3. Ear Protection (Ear Plugs)
Wearing earplugs or earmuffs can help to protect your ears from any damage. Exposure to
high noise levels can cause irreversible hearing loss or impairment. Clean earplugs regularly,
and replace those you cannot clean.
2.4.4. Body Protection
Body protection such as coverall is used to protect the worker's body against hazards. So, it
must be worn by all the workers when they are working in any industrial area.
Figure 2.8
Figure 2.9

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2.4.5. Hand Protection (Gloves)
Gloves can protect your hands from different hazard. So, they must be worn when you are
dealing with chemicals, hot metals, sharp tools, etc.
2.4.6. Foot Protection (Safety shoes /Boots)
Safety shoes and boots can help to prevent injuries by protecting employees from hazards
such as falling or rolling objects, sharp objects, wet and slippery surfaces, molten metals, hot
surfaces, and electrical hazards.
Figure 2.10
Figure 2.11

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2.4.7. Respiratory system (Air Filtration)
Respirators can help to prevent illness and injury to workers by protecting them against
adverse health effects caused by breathing air contaminated with harmful dusts, fogs, fumes,
mists, gases, smokes, sprays, or vapors.
2.4.8. Safety Harness
The harness is used as a falling protection. It must be worn when working at height. So, the
workers must wear it to protect them from getting injured.
Figure 2.13
Figure 2.12

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(50)
A
BC
A B A C A
DispVelAccel
Figure 5. At B, acceleration is maximumto the left and displacement
maximumto the right, a 180 phase shift. Acceleration amplitude varies
as the square of frequencyfor a given value of displacement.
o
Avg RMS
Peak
Peak
to
Peak
Time
Amplitude
Avg = 0.637 xPeak
RMS = 0.707 xPeak
Figure 6. The simple relationships which exist between average, RMS
and Peakamplitude values for sine waves are not valid for
combination or randomwaveforms.
Acceleration Acceleration
3.1. What is Vibration
Vibration is a mechanical oscillation around the equilibrium point. These oscillations can be
periodic like the movement of a pendulum, or can be random, like the vibration of a tire on a
bumpy road.
3.2. Machine Vibration
Machine vibration is simply defined as the back and-forth movement of machines or machine
components. Most of the time machine vibration can lead to machine damage.
Shown below are some examples of machine vibration.
Figure 3.1
Figure 3.2

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3.3. Vibration analysis
Vibration analysis is a Non-destructive technique that used to know the amount of
deterioration in a component of equipment without destroying or dismantling the equipment.
Vibration analysis is the most important technique
used for predictive maintenance (PDM). This
technique is used to detect and to find out the faults
early enough before breakdown or an expensive
failure occurs to the equipment.
3.4. Application of Vibration Analysis
Vibration analysis is a technique that can be used on all rotating machineries like:-
- Pumps
- Motors
- Compressors
- Gear Boxes
- Diesel/Gasoline Engines
- Turbines.
3.5. Vibration Characteristics
 Frequency
 Amplitude
Frequency:
It is the number of times oscillation that occur for a given time period. It is measured in CPS
(HZ) or CPM.
Amplitude:
It is the magnitude of vibration signal. It has three parameters, these are: - (Displacement,
Velocity, and Acceleration)
Figure 3.3

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- Displacement: is the amount of movement that takes place. It is measured in peak-to-
peak or microns.
- Velocity: is the rate of change of displacement with respect to time (the speed of the
vibration). It is measured in mm/sec or in/sec.
- Acceleration: is the rate of change of velocity with respect to time. It is measured in
or
3.6. Vibration analysis charts
There are three types of charts that are used to show the condition of the haul equipment and
the condition of the components inside the equipment. These are: - (The trend, the spectrum,
and the time waveform)
3.6.1. The Trend:
The trend chart is used to show the overall level of the equipment. By using the trend
chart, the analyzer will be able to see and identify any dramatic increase or decrease
to the vibration of the equipment. See figure 3.5.
Axes: RMS vs. Date
Figure 3.4
Figure 3.5

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3.6.2. The Spectrum:
The Spectrum displays the frequencies at which a machine component is vibrating.
By using the spectrum, the analyzer will be able to know the exact fault that caused
the vibration. See figure 3.6.
Axes: Amplitude vs. Frequency
3.6.3. The Time Waveform:
The time waveform is used to help diagnose machine problems. A waveform does not
display the individual frequencies at which vibration occurs. It displays only the
overall effect. See figure 3.7.
Axes: Amplitude vs. Time
3.7. Causes of Vibration
There are a number of mechanical faults, as well as electrical faults, that can be detected and
cause vibration. Such as:-
 Unbalance.
 Misalignment.
 Looseness.
 Bent shaft.
 Cavitation.
 Resonance.
 Rotor rubs.
 Rolling element bearing faults.
 Gear faults.
 Some electrical motor problems.
Figure 3.6
Figure 3.7

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3.8. Work Done No.1
Equipment: Centrifugal Compressor (2K-7701G)
3.8.1. Work Objective and Goal:
 To measure the vibration on the compressor and identifying the faults that
caused the vibration.
 To make the compressor working normally.
3.8.2. Theoretical Background
 Plant and its function
Utilities Unit 60, its function is to supply and support YANPET producing units
(Ethylene, Ethylene Glycols, Polyethylene and Packaging).
The Unit objective is to generates, distributes and maintain sustainability’s of all
required Utilities (Steam, Air, Water and Others) for process plants and non-process
unit in the complex.
 Equipment and its description
Equipment: Centrifugal Compressor (2K-7701G)
Type: multi-stage
Compressors are the equipment used to pump and move different types of gases (e.g.
air & natural gas). They reduce the gas volume by forcing it into a smaller area,
therefore increasing its pressure.

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3.8.3. Safety requirements
Wear all the personal protective equipment that is needed for this work order. These are:-
1. Coverall.
2. Safety shoes.
3. Safety helmet.
4. Safety glasses.
5. Ear plug.
6. Gloves.
3.8.4. Work details
 Problem background
- Compressor had abnormal sound and tripped many times due to high vibration
in 1st
stage.
 Observation
- High abnormal noise coming from the compressor.
- We observed high vibration on the compressor from the 1st
stage casing.
 Recommendation
- Remove the compressor to the workshop for complete overhaul.
 Finding after inspection (cause of problem)
- After they removed the cover of the 1st
stage, they found comletely damge on
impeller holder, it was deattched completely.
- Also they found the journal bearing side wall wear out, and some rubbing
marks on the shaft.

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3.8.5. Manpower and device used
- Manpower: 2 persons
- Device used: Vibration collector (SKF)
Figure 3.13
Figure 3.11
Figure 3.10
Figure 3.12

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3.8.6. Sequence of work
1) First, we received a call from the utility plant. They told us that the compressor (2K-
7701G) had abnormal sound and tripped.
2) After that, we plugged in the SKF device to the computer that has all the data about all
the equipment in the plant. So, we transferred all the data that belong to this
compressor to our SKF device.
3) Then, we went to that plant to measure the vibration level of the compressor by using
the SKF device. So, we found that the compressor has high vibration.
4) After that, we went to our department to see and identify what is the fault that caused
the vibration.
5) We plugged in the SKF device to the computer and transferred the new data that we
measured.
6) After that, we send a report to the utility plant telling them about the details of the
problem and some recommendation to solve the problem.
3.8.7. Result
- The journal bearing was replaced.
- The impeller and the impeller holder were replaced and fixed regularly.
- Compressor vibration readings were checked again after repair and all the readings
were within the range.
3.8.8. Conclusion
The compressor was working normally and without abnormal sound. Also, the work was done
successfully and without any injuries.

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3.9. Work Order No. 2
Equipment: Steam Turbine (GT1201B)
3.9.1. Work objective and goal
 To do predictive maintenance on the steam turbine.
 To perform vibration monitoring system on the turbine.
 To avoid steam turbine from being damage.
 Plant and its process
Ethylene Glycol (Unit I), its process consists of two phases:-
First: Ethylene is converted to ETHYLENE OXIDE by a catalytic oxidation reaction
(HALCON PROCESS).
Second: Ethylene Oxide is converted to GLYCOLS by a reaction with water.
Equipment: Steam Turbine (GT1201B)
Type: single stage
Steam Turbine is the equipment that used to transfer thermal energy (from steam) into
mechanical energy to generate rotary motion. It is used to drive other pieces of
equipment (e.g. pumps & compressors) by rotating a shaft.

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1. Coverall.
2. Safety shoes.
3. Safety helmet.
4. Safety glasses.
5. Ear plug.
6. Gloves.
Figure 3.15
Figure 3.14

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3.9.4. Work details
 Problem background:
- The steam turbine was running with high abnormal noise.
 Observation:
- High vibration at the turbine Non Drive End (NDE) bearing.
- The spectrum was showing indication of bearing failure.
 Recommendation:
- Isolate the turbine for maintenance.
- Remove the top half cover of bearing housing.
- Inspect the bearing condition.
 Finding after inspection (cause of problem):
- They found the ball bearing was completely damaged.
- Also they found some rubbing marks on the shaft.
- They said that the main cause of these damages is because the turbine was
running dry (without oil).
Figure 3.16

41
- Device used: vibration collector (SKF)
Figure 3.19
Figure 3.17
Figure 3.18

41
1) First of all we received a call from the Ethylene Glycol plant. They told us that the
steam turbine (GT1201B) is running with abnormal noise.
2) After that, we plugged in the SKF device to the computer that has all the data about
all the equipment in the plant. So, we transferred all the data that belong to this steam
turbine to the SKF device.
3) Then, we went to that plant to measure the vibration level of the steam turbine by
using the SKF device. So, we found that the steam turbine has high vibration.
4) After that, we went back to our department to see and identify what is the fault that
caused the vibration.
measured. Then we saw the spectrum and found that the vibration was due to bearing
failure.
6) After that, we send a report to the utility plant telling them about the details of the
3.9.7. Result
- The ball bearing was replaced and the shaft was repaired.
- The oil was filled.
- Steam turbine vibration readings were checked again after repair and all the readings
were within the range.
3.9.8. Conclusion
The steam turbine was running normally and without any abnormal noise. Also, the work was
performed successfully and without any accidents.

42
3.10. Work Done No.3
Equipment: Extruder (2Y-3123-V1)
 To find out the faults that caused the vibration.
 To avoid the extruder from being fail.
 To do predictive maintenance.
3.10.2. Theoretical background
Polymer Dry End 230, the objective of this unit is to produce high density of
Polyethylene and Polypropylene pellets.
Equipment: Extruder (2Y-3123-V1)
The objective of the Extruder is to receive polymer resins and additives, then melt,
homogenize and extrude them as polyethylene pellets.
Figure 3.20

43
1. Coverall.
2. Safety shoes.
3. Safety helmet.
4. Safety glasses.
5. Ear plug.
6. Gloves.
3.10.4. Work details
- Extruder (NDE) vibration alarm.
 Observation
- High vibration reading, about 0.15 in/sec slightly increased.
- We observed that the locking gib of the extruder (NDE) base support was
slightly loose.
- The spectrum was showing indication of looseness.
Figure 3.21

44
 Recommendation
- Tight the bolts of the locking gib.
- Shims are required between the base and the locking gib.
 Finding after inspection (cause of the problem)
- The locking gib of the extruder (NDE) base support was loosed.
- Device used: vibration collector (SKF)
Figure 3.23
Figure 3.22

45
1) First, we received a call from the polymer unit. They told us that the extruder (2Y-
3123-V1) had a vibration alarm from the NDE side. They saw the alarm from the
computer in the control room.
equipment to the SKF device.
3) Then, we went to that plant to measure the vibration level of the extruder by using the
SKF device. So, we found that the extruder has high vibration.
the vibration.
measured. Then we saw the spectrum and found that the vibration was due to
looseness in the locking gib of the extruder (NDE) side.
6) After that, we send a report to the polymer plant telling them about the details of the
3.10.7. Result
- The shims were put between the base and the locking gib.
- The bolts were tightened on the locking gib by using a spanner.
- The vibration readings of the extruder were checked again after repair and all the
readings were within the range.
3.10.8. Conclusion
The extruder was running normally and without any alarm. Also, the work was performed
successfully and there were no injuries.

46
3.11. Work Done.4
Equipment: Centrifugal Pump (2Y-3123-V12A)
 To determine the sources of high vibration.
 To minimize unplanned shutdown.
3.11.2. Theoretical background
Equipment: Centrifugal pump (2Y-3123-V12A)
Centrifugal Pumps are the equipment which used to move and deliver different types
of liquids at high level, high pressure and high flow rate from one point to another.
Figure 3.24

47
1. Coverall.
2. Safety shoes.
3. Safety helmet.
4. Safety glasses.
5. Ear plug.
6. Gloves.
- Centrifugal pump abnormal sound.
 Observation
- High vibration reading about 0.33 in/sec.
- The spectrum was showing indication of misalignment.
- We measured the temperature of the equipment, and we found that the
temperature was fine, about 71 deg. C.
Figure 3.25

48
 Recommendation
- Check the alignment of the coupling.
- Check the condition of the rubber coupling.
- They found the rubber coupling was damaged.
- Manpower: 3 people
- Devices used: 1. Vibration collector (SKF).Figure 3.27
2. Temperature gun. Figure3.28
Figure 3.28Figure 3.27
Figure 3.26

49
1) First, we received a call from the polymer unit. They told us that the centrifugal pump
(2Y-3123-V12A) had high abnormal sound and over heat.
equipment to the SKF device, also we took the temperature gun with us to measure the
temperature of the pump.
3) Then, we went to that plant to measure the vibration level of the pump by using the
SKF device. So, we found that the pump has high vibration.
4) Also, we checked the temperature by using the temperature gun, and we found the
temperature was fine.
the vibration.
measured. Then we saw the spectrum and found that the vibration was due to
misalignment in the coupling area.
3.11.7. Result and Conclusion
- The rubber coupling was replaced.
- The coupling area of the centrifugal pump was aligned.
- The pump was running without any abnormal noise and all the vibration levels were
ok.
- The work was done successfully.

51
3.12. Work Done.5
Equipment: Gearbox of Inline Blender (2Y-4122B-V10)
 To maintain vibration monitoring system on the equipment.
 To diagnose the faults the caused the vibration.
Equipment: Gearbox of Inline Blender (2Y-4122B-V10)
The Inline Blender is used to mix various grades of polymer resin with some chemical
additives and transfer them to the extruder.
Figure 3.29

51
1. Coverall.
2. Safety shoes.
3. Safety helmet.
4. Safety glasses.
5. Ear plug.
6. Gloves.
- Abnormal sound and knocking in the gearbox of the inline blender.
 Observation
- We observed high vibration on the gearbox of the inline blender.
- The spectrum was showing indication of gear misalignment.
Figure 3.30

52
 Recommendation
- Replace the defected gearbox with spare one.
- Check the alignment between the motor and the gearbox, also between the
gearbox and the inline blender.
- Fill the oil and check its level to the required level.
- After they opened the gearbox, they turned the shaft manually and found
misalignment between matching gear (excessive gear backlash) due to
overload running.
- They found some teeth of the gears were broken.
- Device used: vibration collector (SKF) device
1) First, we received a call from the polymer unit. They told us that the gearbox of the
Inline Blender (2Y-4122B-V10) has abnormal sound.
equipment to the SKF device.
3) Then, we went to that plant to measure the vibration level of the gearbox by using the
SKF device. So, we found that the gearbox has high vibration.
the vibration.
Figure 3.31

53
measured. Then we saw the spectrum and found that the vibration was due to gear
misalignment.
3.12.7. Result and conclusion
- The gearbox was replaced.
- The alignment between motor and gearbox, and between gearbox and inline blender
was checked.
- The oil was filled.
- The gearbox returned back to normal operation and without abnormal sound.
- The vibration was checked again after repair, and all the reading were normal.

55
4.1. Conclusion
In this report, I mentioned a brief introduction about YANPET Company. Also, I talked about
different safety topics that should be understood and applied in YANPET Company. After
that, I provided an overview about my department. At the end, I mentioned the work activities
that I have done during the 14 weeks of my training period.
Actually, the training period was very helpful for me and I have learned many things during
it. I have learned very useful information not only about my specialization but also about
different specializations. Of course meeting new people in job field and working with group
was very interesting experience for me.
Finally, I would like to thank almighty Allah for finishing my co-op training period and for
completing this report.
I hope that this report will gain your interests.
Thanks.

56
4.2. References
 www.google.com
 www.wikipedia.org
 http://yanpetweb1.sabic.com
 http://www.reliabilityweb.com/forms/beginners_guide_vibration.pdf
 http://www.ask.com/question/what-is-vibration-analysis
 http://www.indiana.edu/~emusic/acoustics/frequency.htm
 http://www.dliengineering.com/vibman/thewaveformvsthespectrum.htm
 http://www.forbesmarshall.com/fm_micro/downloads/shinkawa/FUNDAMENTALS
OF VIBRATION By FM - Shinkawa.pdf
 MET 105.
 SHE Handbook.
 Training manual from the company.
 My progress reports
 My daily logbook.

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