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P ri n ce Mo h a m m a d B in Fa h d Un i ve rs i t y
College of Engineering
Department of Mechanical Engineering
Internship Report
at
[ARAMCO]
Reporting Period:
[23/6/2012 - 4/8/2012]
Submitted by:
[Ziad M. Al-Oqifi]
[200700609]
[submission date (15/9/2012)]
Mechanical Engineering Department
Summer 2012
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
Abstract
"It's time for the student to become an engineer", after 5 years of studying
mechanical engineering and solving problems on class, now it’s the time where
student can marriage between the knowledge in the class with the real life
problems.
This report is about summarizing my experience of about 2 months that I spent
on ARAMCO. The main source of information on this report came from expertise
on ARAMCO, manuals that we used to work on and my supervisor. This report is
going to cover my work since I attend the workplace until I left, on a period of 2
months. This report also covers things that I made on the work place to solve
some problems.

Acknowledgements
The training was about attending classes at ARAMCO (ITC), in the mechanical
skills training at Ras-Tnura. Every course has an instructor where he is an
employee at ARAMCO where most of the assistance where from those instructors
and they were so helpful.
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Table of Content
Page
Abstract
2
Acknowledgments
2
Table of contents
3
List of Figures
3
List of Tables
3
Introduction
4
The Company
4-5
Activities and responsibilities
Major tasks or projects
6 - 11
Conclusion
12
References
13
Appendix A
-
Appendix B
-
Student Log Sheet

6
23
Student Feedback Form
20-21
Progress Technical Reports
14-19
List of Figures
Page

Com pany Hierarchy (figure 2)
5
e. learning courses (Figure 3)
11
Air Compressor design (figure 1)
22
List of Tables
Page
My schedule (figure 4)
24
Figure 5, air compressor
25
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
Introduction
The work that has been presented to me was different from other trainees. The
work was changing every week to make the advantage of understanding most of
the machinery operations at ARAMCO. I worked on Assembling a Project, pumps,
reciprocating compressors, Transmutation systems, bearing and lubrication,
Technical sketching and finally, measurements.
The objective of this training is to connect the knowledge of the materials that we
got at University with the industrial environment. Also understand that some
theories on the book may not work accurate on real life applications.

The Company
Saudi Aramco Company is the biggest oil company in the world.
Some of its features:
 Type of company: fully integrated global petroleum enterprise.
 Missions: exploration & producing, refining, distribution, shipping and marketing.
 No. 1 in the world in the following:
o Crude oil reserves: 259.8 billion barrels as of year-end 2008 (one-quarter of
the global total).
o Crude oil production: 3.3 billion barrels in 2008.
o Sustained crude oil production capacity: over 10.5 million barrels per day.
o Crude oil exports: 2.6 billion barrels in 2008.
o Natural gas liquids (NGL) exports: 289 million barrels in 2008.





Discoverer and producer of world's largest oil field: Ghawar Field, Eastern Province,
Saudi Arabia.
Discoverer and producer of world's largest offshore oil field: Safaniya Field, Arabian
Gulf.
No. 4 in world gas reserves: 239.5 trillion cubic feet (tcf) as of year-end 2008.
No. 8 in worldwide refining capacity: 4 million bpd:
o 1.4 million bpd at domestic refineries
o 705,000 bpd at domestic joint ventures
o 1.9 million bpd at international joint ventures
Owns and operates the world's second largest tanker fleet.
No. 1 Oil Company in the world for the 17th straight year, according to Petroleum
Intelligence Weekly.
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My working location was at Ras-Tanura, on the (ITC), in the industrial training division,
mechanical skills training unit. My supervisor is Mr. Mohammed Al-Faraj, and the hierarchy
as following (figure 2) :
My department was at the mechanical skills department, where it teaches students that are
graduated from high school. They give students 2 years of preparation to send them to the
working place. I was working with those students, while an employee is instructing us. My
work used to start from 7:00 AM, tell 4:00 PM. During holy RAMADAN I used to work from
7:00 AM tell 1:00 PM.
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
Activities and responsibilities
I worked on 8 different tasks during my presence at ARAMCO. The duration of
each task was about a week, where every week I got a new employee to work
with. I worked with students who graduated from school; also I worked with
employees who have an experience on the field. My task was to absorb what
students and instructors do. Sometimes I help on maintain parts or designing and
solving some problems. I worked with 5 different groups, and I believe it was the
most exciting moments on my life.

Major tasks or projects
During my internship at ARAMCO (ITC), I was assigned to 8 assignments. Each
assignment should be done by one week. The assignment also should be done with a
group, as shown:
1. Assemble Project:
This task was the most exiting task. The aim of this task is to manufacture an
air compressor engine that can work on 80 PSI. We did manufacture it from
the row material (Steel) to a working engine, as shown in figure 1 ( page ) :
As shown, the two figures are presenting the air engine that I worked on during
my first week. The air engine got 12 items to be manufactured as listed:
1.1 The base: and it was manufactured by taking square steel and cut it by
using a special too to cut the steel. Then chamfering its edges.
1.2 Fly Wheel: The fly wheel is the holder of the crankshaft. It was
manufactured my simply facing cylindrical steels sides by using the lathe
machine. Then drill a hole on the middle.
1.3 Cylinder Block: The cylinder block is the pistons house, where it allows it
to go up and down. Also it allows air to entire the block on top to give the
required energy to push the piston down. Also it allows air to escape
(exhaust). It was manufactured by taking a squire steel block. After that
we drilled a whole on the top of the block to allow the shaft to fit in.
After that we did some hand tools to make a small cut on the block face.
Then we drilled another hole for the air to get into the crank block to the
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Cylinder block. Also another whole s required for the exhaust. Finally two
drills was taking place on the bottom of the block to allow the piston to
fit in and the other one to let the crank shaft fits in.
1.4 Crank Block: The crank block is the holder of the cylinder block. It was
manufactured by using hand tools to make the surface finish. Then we
made a drill (not throw all) to fit the shaft that holds the cylinder block.
Then another drill is required to for the air (exhaust and inlet). Finally we
made a drill on the bottom of the item to connect it with the base.
1.5 Piston: The piston the working item that converts the pressure on to
vertical motion. The piston was made by using the lathe machine to make
pistons head and then facing the object to the required diameter. After
that we used the hand tools to make the end of the piston (the piston
crank holder) to convert it from its cylindrical shape on to a cubical
shape.
1.6 Crank Shaft: The crankshaft is the item that converts the vertical motion
on to a rotational motion. also it holds the piston by going thru the crank
block. It consists of two items. The crank and the shaft. The crank was
made by making a drill to form the shape. And the shaft was
manufactured by using the lathe machine to face its surface to the
required diameter.
1.7 Spring Holder: This item is made from brass, it holds the spring from
touching the crank block. It was provided without doing any
manufacturing to it.
1.8 Spring: The spring was also provided to us manufactured.
1.9 Nut: The not also was provided manufactured.
1.10
Grub Screw: This item was provided and its objective is to connect
the flywheel with the crank shaft.
1.11
Cap Screw: This item is also connecting the base with the crank
block.
1.12
Stud: The stud is the item that connects the crank block, cylinder
block, spring holder, spring and the nut together. The only manufacturing
process that we made was to form the helical shape by using a cutting
tool to fit the nut on to it.
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At the end of the project tested it and it was working. The objective of this
project is to understand how manufacturing works, and also how to assemble a
project.
2. Pumps:
The second week I worked on pumps. Our work that was presented to us is to
disassemble the pump, then inspect its parts after that we reassemble the
pump. I worked on two types of pumps, the centrifugal pumps and the gear
pumps.
The centrifugal pumps are used to pump high volume fluids on low pressure.
(from the manual) . The manual I couldn’t take it with me where there will be
not much information is going to be provided on this section.
During my second week, I was introduced to the pumps and alignment unit.
The objective of this unit is to inspect the pump and fix its problems. We
began by disassembling the centrifugal pump that used to pump oil. The head
of pump is about 400 ft. while it was a medium size. The pump takes the
rotational force from a motor that runs by electricity that can provide around
1 hp. That was the first time I'm watching a pump this big, the bullets itself
was around the size of my fingers. After dissembling the pump we used to
inspect each part by taking measurements of the diameters and measuring
the run-out. The impeller also must be inspected, due to fluid failure may
accrued during the operation because of cavitations or erosion. It can be
simply inspected by looking to the impels itself. While we was disassembling
the pump, the bearings couldn't come out. So we used stress machine to
force the baring to come out. After that we inspect the bearings, by rotating
it and measuring its run out. After that we inspect the shaft by measuring its
diameter and it's run-out. If any part fails on the inspection process, writing a
report is required to ask for a new part.
After the disassembling and
inspection process, we reassemble the pump. Most of the parts will fit with
no problems. But, putting the bearing on to the shaft is the main problems,
where we can't press it again. By using the idea of heat transfer, if a metal
heated up, its volume will increase. So that we put the two bearings on to the
oven, then we marked it with a special pen that used to show whether the
bearings are heated enough or not. If the pens mark melted, it means the
bearing is ready to be installed. After that the bearing will fit easily on the
shaft. After reassembling the pump we used to rotate its shaft to make sure
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that everything is ok.
The same also we did with the gear pump, where it used to pump gases. But
the main difference on the gear pump is that it was smaller than the
centrifugal pump. And it does need fewer tools to disassembling and
assembling
the pump. The objective of this assignment is to understand
how pumps work and how to maintain the pump.
3. Reciprocating Compressors.
The same procedure that was made on the pumps is repeated on the
reciprocating compressors. But, the compressor has more parts and it does
require more time to inspect it. The compressor that I worked on is an air
compressor that works by using an electric motor that provides around 1hp
to the compressor by using a V-belt that has 4 pistons. We used to
disassemble the compressor, then we inspect its part and finally we
reassemble the compressor. During the assembling process we add oil to the
compressor and run it for a certain amount of time, around one hour, to
check whether there is leakage on the compressor or not. After that we
continue the assembling process. After assembling the compressor, we used
to connect the motor with the compressor by using a V-Belt, where it does
need an alignment between the compressor and the motor to make
transferring the motion easier between the two devices. After the alignment
process we used to run the compressor.
The objective of this assignment is to understand how to assemble a
compressor and maintain the problems that may happen on the future.
4. Transmission Systems.
After the compressor I moved to another unit that called transmission
system. On this unit have three things to do, theoretical part, disassemble
and reassemble a right angle gear and maintaining a fin fan.
4.1: Theoretical part:
The theoretical part was conducted by attending a class, where the
employee shares his experience with a group of people including me. We did
learn many things where the book was provided. The theoretical part covers
the importance of the transmission systems, type of transmission systems,
how transmission works, where they are applied and how to maintain. Where
there are many formulas to know.
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4.2: Disassemble and reassemble:
After understanding the basics of transmission systems we moved to the
workshop to work on a right angle gear that used to move a fan that used to
cool fins. We begin by disassembling the gear box then we used to inspect its
part. I worked solo on disassembling the gear, where I was trying to fix a
broken one. After the disassembling process I inspected the gear, where I
found a huge amount of run-out on the shaft by using a DTI to measure the
end float of the pinion shaft. I removed the shaft by using a lift. After that I
calculate the mounting distance, where it's written by the manufacturer on
the gear, it’s the distance between the shaft and the pinion. After calculation
I found the mounting distance around 2.4 inches, where it should be 2.250
inch. I did ask for help, after inspection we found that the pinion was
replaced, where it's not for this gear box, where I reported also for the
broken shaft. After that, I was asked to reassemble the gear box and
transform it to fix its problems.
4.3: Fin Fan:
After inspecting the gear box, I was assigned to work with a group of three
people. Our task was to inspect the fans that the gear box moves it. We begin
by shutting down the electricity for safety. Then we clime to a room where
there was a fan on the bottom of the room and a fins on the top, to cool the
fins that carries water to cool gases. First we clean the fans and inspect them
by looking to make sure that there are no cracks. After that we maintain the
pitch angle where it was 20 deg , and we was asked to make it 60 deg by
using an angle tool that calculates the angle of the blade. After that we
calculate the distance between the fan and the walls. Then we make sure
that retainer ring is locked. And finally we operate the fans.
5. Bearing and lubrications.
This week was the beginning of holy Ramadan, where most of the units
assigned at classes with no workshops, where lectures took place rather than
entering the workshop.
6. Technical Sketching.
The technical sketching unit wasn’t available, during the week where I was
assigned to this unit; the instructor was absent where I moved to
measurement.
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7. Measurements.
On this unit, I was assigned to use the micrometers to measure things. We
was taught about the kinds of micrometers and where they are applied.
8. Mechanical Unit Activity.
During my last week the supervisor assigned me to do online courses, due for
the absence of most of the employee, where the students also where on a
vacation. I took 6 courses as shown:
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
Conclusion
In conclusion, applying knowledge on the working place is the core of the learning
process. We study to solve real life problems. What I sow on the industrial is a real life
application of what I study. And I found many things that are related to my major during
my training. Manufacturing and solving problems on an engineering way are the most
skills that I learned from this program. Finally, learning without applying is like adding
books that are not useful, they take place, but they never add to the environment.
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
References
Most of the books or manuals were not allowed to be taken by me.
Most of the information that I took about the company is from ARAMCO website.
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
Appendices
The first TECHNICHAL REPORT:
Summary
The ITC is a mechanical training unit that train students to become technicians. It’s a two
years program that will allow students to become a member of ARAMCO as a technician. My
job is to absorb what happens on the lecture and the workshop and understand how
mechanical devises works, rather than watching it from the books or videos. So it’s a real life
experience where I can see the relation between technicians and engineers. But, I'm not
allowed to work on the workshop for the safety.
Background
My work is to absorb hoe mechanical structures work. From the schedule, I was assigned to
attend an assemble project. The function of this course is to manufacture an air engine from
the row material to an engine that runs by 80 psi of compressed air. I start my training on
6/23/12, on ARAMCO (RAS TANORA). Where my supervisor's information is on the flowing:
Supervisor name: Mohammed Al-Faraj
Badge: 208727
Mobile: 00966 505846117
Email: [email protected]
Department name: Industrial training department, Mechanical skills training unit. ( ITC ).
The training schedule is the flowing:
DATE
TIME
ACTIVITY
6/23/12
7-3:15
Orientation
6/24/12 - 6/27/12
7-3:15
Assemble Project
6/30/12 - 7/04/12
7-3:15
Pumps & Alignment
7/07/12 - 7/11/12
7-3:15
Reciprocating Compressors
7/14/12 - 7/18/12
7-3:15
Transmutations Systems
7/21/12 - 7/25/12
7-12:30
Bearing & Lubrication
7/21/12 - 7/25/12
7-12:30
Technical Sketching
7/28/12 - 8/01/12
7-12:30
Measurements
8/04/12 - 8/08/12
7-12:30
Mechanical Unit Activity
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Progress
Early at morning we begin by a lecture that will take around one hour. On the lecture we
learn how to manufacture each part as shown:
First we learned how to manufacture the crank block, where its going to hold all of the
objects. Then we manufacture the crank wheel. After that we made the crank shaft. Then
we manufactured the piston cylinder block. After that we made the piston. Finally we
made the flywheel. We made that on 5 days, from Saturday until Wednesday.
The group faced many problems. One of the, major problems is the piston can't enter the
cylinder, where the readings was perfect. So what we have discovered is to sheer part of
the material of the piston to make the cylinder fit easily with the piston. Most of the
problems we faced where on the sizing.
Plans
as what have been discussed on the previous paragraph, we made each part spartanly.
Due to the less equipments and big numbers, we used to sprite. Few people was working
to make the shaft, others were making the cylinder and so on.
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Appendices
This work done by the student, by using (solid works)
1. It shows the final structure of the engine. Also it provides help for those who don’t
know how to assemble the project. (video wa
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The second TECHNICHAL REPORT:
 Summary
Its week 2&3 on my schedule, where my assignment is both reassemble
pumps, alignment and reciprocating compressor.
Background
On week 2: My job was to absorb how to align motors with pumps, also
disassemble diaphragm, radial, axial and gear pump. Also we inspect the
pump to check whether it's running or not.
On week 3: My job was to dismantle 4 cylinders compressor, where it can
be powered by 1 horsepower. Also my job was to check whether the
compressor is working or not, also if its making noise and leakage.

Progress
On week 2: First we disassemble the radial pump. After that inspect the pumps
parts and measure the part. The inspection process is to check wither the
pumps parts are good enough to do the work. If they are not good we used to
maintain the damaged part. One of the problems we faced is to remove the
barring from the pumps shaft, where we use hydraulic press to remove the
barring from the shaft. Also one of the problems is when we reassemble the
pump the shaft is not rotating. The analyses of this problem is that sometimes
the shaft is bend or the baring is not performing well or the impeller is making
friction with the casing.
On week 3: we disassemble the 4 cylinder compressor. Also we check the parts
and take measurements of the parts to make sure they are performing well.
One of the problems we had is that the cylinders are not moving, and the
problem was segmenting ring was made of Teflon while it should made of
Carbon. Also one of the problems we faced is to align the V-belt that connects
the motor with the compressor.
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
Plans
Both pumps and compressors are scheduled to finish on assembling and inspecting on one
week for each. The first week was the pump and the second week is the compressors.
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The Third TECHNICHAL REPORT:
Summary
It's almost the half way thru. Its week four where my schedule is to look at transmissions
systems and fin fan inspection. Where at the end of the fourth week I did finish both the
transmission and the fin fan inspection. However, on week five it was the beginning of
Ramadan where the superviser assigned an easy task for me. My task was to study the
barring and lubrication. At the end of Wednesday I did finish this course.
Background
On week 4, my task was to inspect a right angle bevel gear. ARAMCO uses it for the fin fan
that cools gas on pipes. The procedure was to disassemble the gear box. Then inspect the
broken parts. After that we take measurements of the shaft being right angle to the bevel
gear and the barring that holds the shaft. If everything is correct we reassemble the gearbox.
If there is a problem we order parts from the superviser. After the gearbox inspection, I went
to the fin fan and inspect its fans and take clearance measurements between the fan and the
housing, after that I make the fan angle due to the orders that we got from the superviser. If
there is a problem we report that.
Progress
On week 4, for the first 3 days my task was to inspect the gearbox. I was assigned to
disassemble a broken gearbox and determine the problem. It took me around 3 hours to
disassemble the gearbox. Then I reported that the shaft is broken, but it wasn’t the reason
why the shaft was working, after taking all measurement I did notes that the bevel gear is
not perfectly fitting with the pinion. After disassembling the pinion gear and take the
barrings off I found that this pinion was broken and replaced by another one that doesn’t
belong to this gearbox. So I did order a new pinion gear, then I reassembled the gearbox and
it was working perfectly. On the 4th and 5th days I was working on the fin fan. While I was
measuring the clearance I found that one fan was broken so I did order a new fan.
Plans
As shown I did finish with the schedule as planned, except for the fin fan part that I did order
it didn’t arrive yet, where someone else is going to woke it out.
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The student feedback from: Appendix D:
Student Feedback Form
Please fill in the form carefully and ensure that it is attached at the back of your Final Technical
Report before uploading onto the Blackboard for your Advisor to grade.
Name of Student: Ziad m. Al-Oqifi
Student ID: 200700609
Department:
Mechanical
Period of internship: 6/23/12 – 8/8/12
Company Name: ARAMCO
Department student
Mechanical Unit Activity
was attached to:
Describe briefly your work experience:
My experience during the that period can be descried under two things:
1. It was the first time I'm entering a real life workshop that operates in a full safety
pattern.
2. The ability to connect the study with the real life application where I used the
principles of heat transferee and fluid and also manufacturing.
Was nature of work assigned challenging?
Was your work environment satisfactory?
Was the work technical in nature?
Were you treated as a member of a professional team?
Were you able to learn from others?
Were you able to talk to your supervisor when needed?
Would you recommend that we continue to assign students
to this company in future?
Would you work for this company after graduation?
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
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Overall, how do you rate the company in providing you
with this training?
Good
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Figure 1: this work was done by the student, by using solid works to showto the
students the assembling process.
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