About This Book
What is it?
This is a specially tailored technical English textbook. It is made up of the following:
1. Aim and objective
Requirement or expectations from the compiler. The trainees are free to come up with their expectations, or suggestions.
2. Glossary
More than 5000 commonly used words or phrases are garnered and sorted out by the inherent logic rather than alphabetically. They will be explained or illustrated lively and vividly.
3. Reading
Three to five pieces of relevant articles are included in each chapter. A huge resource of manuals, textbooks from our library are always available for the trainees.
4. Listening
The listening materials are as below:
A. A/V materials accumulated since 1993 when Nan Hai Training Center (the predecessor of FSL) was setup.
B. Presentation by or conversation with our foreign experts.
5. Writing
Under the guidance of instructors, the trainees will learn how to write log book, handover notes, PO, daily reports, etc.
6. Assessment and comment
A. The trainees will make presentations.
B. The trainees will do a written test.
C. The trainees will make a self-assessment.
D. Comment, criticism or suggestions to the instructor.
For whom?
It is for the people who are or will be working in the oil/gas industry.
By whom ?
This book was compiled by experienced experts, engineers who worked in the fields of Chevron, Phillips, JHN, Statoil, BP for years.
How to conduct?
A. In-depth, lively and vivid explanations or illustrations from our instructors.
B. Application-oriented.
C. The trainees will see, touch and use our equipment in the workshop or library to understand, use and memorize the words or phrases.
After the course?
The trainees will not only have a good command of the words, but also will be very conversant with essential knowledge for their future job.CONTENT
Chapter Page
1.0 General
1.1 Aim and objectives 7
1.2 Glossary
1.2.1 Overview 8
1.2.2 Facility 8
1.2.3 Organization 8
1.2.4 Transportation 9
1.2.5 Miscellaneous 9
1.3 Reading
1.3.1 Introduction materials of offshore oil industry 11
1.4 Listening 12
1.5 Writing 12
1.6 Assessment and comment 13
2.0 HES
2.1 Aim and objectives 14
2.2 Glossary
2.2.1 Qualification and certificate 15
2.2.2 Personnel transportation 15
2.2.3 New arrivals 15
2.2.4 Personal protective equipment 15
2.2.5 Working system 16
2.2.6 Undesirable events 17
2.2.7 Pollution 17
2.2.8 Health and medical 17
2.2.9 Warning signs 18
2.2.10 Emergency response 18
2.3 Reading
2.3.1 Work permit 20
2.3.2 Scaffolding 21
2.3.3 Risk/hazard identification 22
2.3.4 Basic rigging and slinging 23
2.3.5 Environment control 27
2.4 Listening 30
2.5 Writing 30
2.6 Assessment and comment 31
3.0 Crude oil and Gas Production.
3.1 Aim and objectives 32
3.2 Glossary
3.2.1 Petrol chemistry and physics 33
3.2.2 Symbols and abbreviations 33
3.2.3 Well control 34
3.2.4 Separation 34
3.2.5 Sampling and analysis 34
3.2.6 Secondary recovery 34
3.2.7 Ancillary and utility 34
3.2.8 Miscellaneous 35
3.3 Reading
3.3.1 Introduction 36
3.3.2 Crude Oil Degassing 37
3.3.3 Principles of Operation 37
3.4 Listening 38
3.5 Writing 38
3.6 Assessment and comment 39
4.0 Mechanical Engineering
4.1 Aim and objectives 41
4.2 Glossary
4.2.1 Basic hand tools 42
4.2.2 Engineering measurement and drawing 42
4.2.3 Engineering Materials and properties 43
4.2.4 Lubrication and hydraulic 43
4.2.5 Fastening devices 43
4.2.6 Gaskets, packing, seals and bearings 44
4.2.7 Manual valves 44
4.2.8 Belt drives, shaft coupling and alignment 44
4.2.9 Pumps and compressors 44
4.2.10 Offshore crane 45
4.2.11 Internal Combustion engines 45
4.2.12 Miscellaneous 46
4.3 Reading
4.3.1 Principle of Operation 47
4.3.2 Combustible Engine 48
4.3.3 Positive Displacement Pump 49
4.4 Listening 50
4.5 Writing .50
4.6 Assessment and comment 51
5.0 Electrical Engineering
5.1 Aim and objectives 52
5.2 Glossary
5.2.1 Electric theory 53
5.2.2 Electrical tools 53
5.2.3 Power generation 53
5.2.4 Switchgear and power distribution 53
5.2.5 Electrical equipment 53
5.2.6 Basic Electrical parts 54
5.2.7 Battery and UPS 54
5.2.8 Electronics 54
5.2.9 Electrical safety 54
5.3 Reading
5.3.1 Poly Phase Transmission 55
5.3.2 Battery 56
5.3.3 Induction Motors 58
5.4 Listening 59
5.5 Writing 59
5.6 Assessment and comment 60
6.0 Instrumentation And Control
6.1 Aim and objectives 61
6.2 Glossary.
6.2.1 Theory 62
6.2.2 Instrumentation tools 62
6.2.3 Signal and Measurement 62
6.2.4 Controller 63
6.2.5 Control device 63
6.2.6 Tubing and fitting 63
6.2.7 PLC and DCS 63
6.2.8 F/G detection and protection 64
6.2.9 Miscellaneous 64
6.3 Reading
6.3.1 Process Control 65
6.3.2 The Differential Pressure Cell 66
6.3.3 Flapper Nozzle System 67
6.3.4 Measurement 68
6.4 Listening 69
6.5 Writing 69
6.6 Assessment and comment .70
7.0 IT and Telecom
7.1 Aim and objectives 71
7.2 Glossary
7.2.1 Computer 72
7.2.2 Network 72
7.2.3 Telecommunication 72
7.2.4 Miscellaneous 72
7.3 Reading
7.3.1 Computer 74
7.4 Listening 75
7.5 Writing 75
7.6 Assessment and comment 76
8.0 Marine
8.7 Aim and objectives 77
8.8 Glossary
8.8.1 Ship’s crew list 78
8.8.2 Location 78
8.8.3 Pipeline 79
8.8.4 Equipment 79
8.8.5 Entering port 80
8.8.6 Cargo work 80
8.8.7 Cargo survey 81
8.8.8 Ballast 81
8.8.9 Standard wheel order 81
8.9 Reading
8.9.1 Cargo handling equipment 82
8.9.2 Mooring equipment 83
8.9.3 Loading of ships 84
8.9.4 Discharging of ships 85
8.10 Listening 86
8.11 Writing 86
8.12 Assessment and comment 87
9.0 Corrosion Control
9.1 Aim and objectives 88
9.2 Glossary.
9.2.1 Theory 89
9.2.2 Paint 89
9.2.3 Equipment and tools 90
9.2.4 Miscellaneous 90
9.3 Reading
9.3.1 Development in paint and coating 91
9.3.2 Introduction to paints and coating 93
9.3.3 Three types of coating 95
9.3.4 The electrochemical nature of corrosion 98
9.4 Listening 99
9.5 Writing 99
9.6 Assessment and comment 100
1.0 General
1.1 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking, reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
1.2 Glossary
1.2.1 Overview
oil, crude oil, petroleum, onshore, offshore,
beach, block, exploration, seismic survey,地震勘探
reserve, reservoir, LNG, LPG
1.2.2 Facility
facility, installation, platform, FPS, FPSO,
drilling rig, drilling derrick boat, supply boat, replenish liner, standby boat, tanker, shuttle tanker,
barge, accommodation, cabin, living quarters, galley, mess room, radio room, changing room, recreation room, HVAC room, laundry, heli-deck, pipe deck, drilling derrick, main deck, cellar deck, sub-cellar deck, boat boarding platform, control room, switchgear room, MCC room, work shop, well bay, well head, skid, module, engine room, boiler room,
BTM, SPM, cargo, ROV, boiler,
stairway, escape route
1.2.3 Organization and human resource
On shore
department, administration department, finance department,
production department, maintenance department, IT department,
procurement department, warehouse, logistics department,
president, vice president, managing director,
superintendent, manager, supervisor, engineer,
coordinator, accountant, dispatcher, secretary, receptionist, driver, staff,
Offshore
(Production):
senior field supervisor, OIM, platform supervisor, platform manager, production supervisor, production manager, maintenance supervisor, safety officer, operator, lead operator,
senior operator, radio operator, crane operator, doctor, technician, instrument technician, electrician, mechanical technician (mechanic), lab technician, roustabout
(Drilling):
drilling supervisor, tool-pusher, driller, rough neck, mud engineer
(Catering):
chief steward, camp-boss, chief cook, chef, cook, steward, stewardess, laundryman
1.2.4 Common symbols
, . ? “ :
* # @ & \
/ - _ = ≠
< > ≤ ∑ л
( ) + - % ‰
Δ № √ ½ 3/8
1.2.5 Miscellaneous杂项
(Nouns):
upstream, downstream, upward, down ward, specification, simulator, demonstrator, diagram, drawing, schematic, legend, title block, figure, rule, regulation, discipline, trouble-shooting, fault finding, phenomenon, symptom, philosophy, option, alternative, criterion, criteria, priority, moisture, plane, contractor, vender, manufacturer, spare part, preventive maintenance （PM）, PPM,
corrective maintenance, predictive maintenance, coefficient, variation, formula, container, tank, tote tank, bucket, pail, hook, hook up, tendency,
head, header, manifold, weight, specific gravity, volume, density, diameter, radius
(Verbs):
interfere, interpret, increase, decrease,
damage, screw up, accelerate, decelerate, exhaust,
trim, isolate, bypass, inhibit, over-ride,
accumulate, confirm, demonstrate, deteriorate, improve,
eliminate, rule out, update, upgrade, modify,
repair, furbish, service, overhaul,
mount, assemble, corrode, erode, rotate, revolve, swivel, scratch, shrink, heat shrink, expand, contract, compress, produce, make,
manufacture, assemble, disassemble, dismantle, take apart, fabricate, prefabricate, exceed, twist, kink, expedite, facilitate, authorize, follow up,
(Adjective):
absolute, abnormal, normal, acceptable, fixed, adjustable, adequate, adjacent, appropriate, approximate, artificial, atmospheric, ancillary, auxiliary, available, average, ambient, circular, continuous, consistent, constant, intermittent, critical, crucial, essential, important, indispensable, vital, clockwise, counter clockwise, anti-clockwise, coarse, rough, fine, delicate, rugged, stable,
unstable, static, dynamic, kinetic, effective, efficient, faulty, mal-functional, false, feasible, workable, flexible, rigid, horizontal, vertical, idle, intense ( intensity ), identical, similar, inherent, permanent, temporary, objective, out-dated, simultaneous, radioactive, equivalent, manual, organic, inorganic, relevant, reliable, severe, miscellaneous, positive, negative, neutral, upward, downward, backward, forward, axial,
radial, spiral, helical, bench mark, micro, macro, balance,
2.3 Reading
2.3.6 NHEC
CONHEC
China Offshore Oil Nanhai East Corporation (CONHE), founded on June 29 1983, is a legal entity 100% owned by China National Offshore Oil Corporation(CNOOC). Through international cooperation and local expertise, COHNE carries out a variety of tasks ranging from offshore oil and gas exploration, development and production in the Eastern Sea waters of the Pearl River Mouth Basin in the South China sea.
CONHE has been authorized by CNOOC to carry out completely the foreign cooperated contracts and agreements in the Eastern Sea waters. Since its foundation, CONHE has cooperated successfully with 43 multi-national companies from 11 countries including the United States, Japan, UK, France, Italy and Norway, etc. Some of the cooperating companies are; BP-Amoco, Chevron, Texco, Agip, Phillips, Shell and Statoil. In 1996, output of the crude oil was more than 10 million tons. The Eastern Sea waters in the South China Sea has continuously kept such output with 12 oilfields under production for the past 6 years and has become China’s fourth largest crude oil production base following the Da QING, SHENG Li and Liao He oilfields.
2.4 Listening
2.4.1 Energy to the world (10min)
2.4.2 Listen to presentation made by our foreign consultant.
2.4.3 Short articles will be read by our instructor or trainees appointed.
2.5 Writing
▪ The trainees are kindly required to write a CV.
▪ The Trainees will be asked to write an introductory article about the previous company they served. The following points need to be covered:
A) Name
B) Location
C) Main products.
D) History or future.
▪ Write an article about Devon, why and how you entered Devon.
▪ Under the guidance of instructors, the trainees will practice logbook writing.
▪ Choose one electrical apparatus (household or industrial), describe its structure, operation principle, etc.
2.6 Assessment and comment
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral(informal) comment, criticism or suggestion will be collected, discussed or analyzed.
3.0 HES
3.1 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking , reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
2.2 Glossary
2.2.1 Qualification and certificate
Offshore qualification certificate, first aid, fire fighting
lifeboat and life raft operation, under water helicopter escape,
survival on sea, man power tracking system,
basic offshore health environment and safety
2.2.2 Personnel transportation
(By air):
aircraft, chopper, helicopter, main rotor, rotating rear rotor blades, invisible, captain, jet fuel,
heli crew, pilot, ground crew, helicopter dispatcher, passenger, HLO, luggage carrier, fireman, Restricted/forbidden items, flammables,
compressed gases, explosives, magnetized material, radioactive material, oxidizing material, poisons,
noxious or irritating materials, weapons, drug,
lighter, mobile phone, secure, loose item, short pants, slippers, hats, caps, helmets
(Helicopter Operation):
boarding, approach, secure, fasten, seatbelt, take-off, hover, winching, landing, touchdown, disembark, safety net, hand rail, emergency heli. crash, jettison, inflate, emergency tool, crow bar,
belt cutter
(By boat):
supply vessel, stand-by boat, personnel basket,
tag line, flexed, vertigo, rough sea, rolling, pitching
2.2.3 New arrivals
safety orientation/briefing, T card, designated areas, classified areas, zones, safety rules, emergency duties, muster station
2.2.4 Personal protective equipment(PPE)
(Head protection):
helmet, hard hat, cushion, chin strap
(Eye protection):
safety glasses, goggle, spectacle, side shield,
prescription lenses, contact
(Hearing protection):
ear plug, ear muff, decibel, noise reducing rate
(Respiratory protection):
face shield, mask, respirator, filter, smoke hood, escape set, ELSA
(Hand protection):
Insulation, heavy- duty gloves, anti-slippery glove,
dotted glove, chemical glove
(Body protection):
overall, boiler suit, uniform, slicker suit,
chemical resistant suit, apron, fire suit, fireman outfit,
life jacket, work vest, survival suit,
suits for watchman or HLO safety harness,
safety belt, rope access, inertia mechanism
(Foot gear):
safety boot, acid resistant, steel toe, toe cap, steel sole, steel heel, cuff, red wing
2.3.5 Working system
safe work analysis, pre-job meeting, take two
(Permit):
general work permit, hot work permit,
confined space entry permit, cold work permit,
scaffolding, work overboard, pressure testing,
chemical handling, MSDS, radiation, elevated work,
function, restriction, extension, renew, invalid,
suspended, cancel
(Hot work):
lower explosive limit (LEL), upper explosive limit(UEL), fire-watch, spark, splash, welding flash,
slag, fire blanket
(Confined space entry):
discharge, isolation, flushing, purging, inert gas,
ventilation, atmosphere testing, flammable, toxic,
part per million (PPM), oxygen content,
electrical work permit, tag out, lock out, test
2.3.6 Undesirable events
(General):
risk, hazard, near miss, incident, accident,
lost time accident
(Property damage):
loss of production, spill
collision, crash, man over-board, tripping,
falling
(Personnel injury):
sprain, twist, squeeze, burn, scald, abrasion, laceration, cut, entangle, electrical shock,
chemical exposure, poisoning, radiation, multiple injury,
(Process):
reporting, investigation, direct cause, underlying cause,
indirect cause, personal factor, job factor,
root cause, lack of control, hazard identification,
risk analysis
2.3.7 Environment and pollution
spill, boom, retrieving, air borne particle,
dispersant liquid, chemical splash, vapor,
PPM, green house effect, O zone
2.3.8 Health and medical
(Occupational illness):
ergonomic, chronic, acute, infectious, back injury,
respiratory, cancer, cryogenic, hypothermia,
(Medic):
hospital, hospitalize, doctor, medic, medical, ward, clinic, first aid kit, medicine, pill, tablet, capsule, bandage, gauze, scissors, tweezers, stretcher, safety shower, eye wash station,
swelling, cold, flu, bruise, fracture,
bleeding, internal bleeding, internal injury, cramp, dermatitis, infection, pneumonia, hepatitis,
hepatitis A, headache, throw up, vomit, stroke,
rheumatism, arthritis, amputation, disabling, incapacitated,
fatality, unconscious, CPR splice, sterilize
2.3.9 Warning signs
NO SMOKING! NO ENTRY! NO OVERALL!
NO BOOTS! NO RUNNING!
NO HORSE PLAYING! NO OBSTACLE! NO FISHING!
AUTHORIZED PERSONNEL ONLY! STAY CLEAR!
CAUTION HIGH VOLTAGE! CAUTION WET FLOOR!
PPE IS REQUIRED BEYOND THIS POINT!
WATCH YOUR HEAD! WATCH YOUR STEP! STAFF ONLY!
FOR EMERGENCY USE ONLY! KEEP THE DOOR CLOSED!
PRESSURIZED SYSTEM! EMERGENCY EXIT!
EMERGENCY LIGHT! ESCAPE ROUTE! RESCUE ZONE
2.3.10 Emergency response
(Detecting):
smoke detector, heat detector, flame detector,
ultraviolet detector, infrared detector, portable detector
(Alarm):
general alarm, man-over board,
gas / fire alarm, abandon alarm,
intermittent short signal, continuously oscillating,
manual call point
(Emergency organization):
station bill, emergency preparedness, core team,
on scene commander, fire team, initial response team,
first aid team, technical team,
temporary refuge, muster station
(Fire fighting):
fire water pump, emergency fire pump,
fire water main, fire water header, fire monitor,
foam tank, form room, hydrant, fire hose, nozzle,
deluge, sprinkler, water curtain
portable/wheeled/CO2/water/foam extinguisher,
nitrogen cartridge, dual(twin) agent, twin unit,
SCBA, fireman outfit, fire damper
(Life saving):
lifeboat/capsule, helmsman/coxswain/captain,
launching, hatch, sprinkler, compass,
emergency position indicating radio beacon,
search and rescue radar transponder,
radar reflector, paddle, parachute, fishing kit,
bucket, hook, rescue ring, provisions and tools
fast rescue boat, life raft, rope ladder,
life ring/buoy with light, rope shooter
(Evacuation):
distress call, SOS, May Day, global positioning system,
head counting, rescue center
2.2 Reading
2.2.1 Work permit
Work Permit
Permit to work is safety control system to minimize personal injury or damage to property through a written authorization to perform certain work.
Although the permit format and layout may be different, there are in general only three main parts to any permit.
∙ Part (1)--- details the location the work is to be done, equipment identification, description of the work to be performed; company or department doing the work (Instrument-Electrical-Mechanical-Contractor etc), date and time the permit is valid and potential hazards.
∙ Part (2)--- lay down the precautions to be taken and safety requirements (PPE-Isolations, Gas testing and any special precautions etc.)
∙ Part (3)--- contain the details for signature authority/approval, worksite inspection and details on work completion.
The normal signatures required prior to work being approved are, Area Supervisor (Production Operations), Craftsman (Person doing the work), Safety Officer and where necessary the Observer/Fire Watch person.
Work permits will normally come in triplicate, top copy normally White, first copy Blue, and second copy Pink. The top copy (White) goes with the craftsman to the job site, the (Blue) copy placed on the permit display board at the point of issue and the (Pink) copy retained on file in the issue book/log. This procedure may vary from company to company but will remain basically the same.
Each permit should be numbered, normally placed in the top right hand corner.
On work completion, each permit must be signed off and returned to the point of issue. The work area should be left clean and tidy and all tools, machinery, trash etc. removed from site. It is normal policy to keep permits on file for a period of one year.
2.3.2 Scaffolding
Scaffolding
Scaffolding used on any facility shall be constructed in line with recognized standards, materials shall be of good quality, non-flammable construction shall follow the manufacturers and engineering guidelines and scaffolding erection shall only be permitted by a person certified and skilled in this process.
Falling Prevention
Each scaffold shall be designed and constructed so as to ensure that it can withstand the intended load including personnel, materials, tools, lifting equipment and the weight of the scaffold.
All scaffolds in excess of (1.8) meters in height shall have installed, handrails, mid-rails and toe-boards. Where, due to the location of the scaffold, handrails cannot be fitted, all personnel accessing and/or working on the scaffold shall wear safety harnesses (safety belts should not be used) and lanyards. Lanyards shall not be secured to the scaffold; suitable anchor points shall be determined as work progresses. In addition, where it is feasible to do so, safety anchor lines shall be fitted.
Approval
Certification of a scaffold is required before it may be used for working purposes.
2.3.3 Fire prevention
Fire Prevention
Fire prevention measures should be considered prior to all work starting on scaffolds. Attention should be paid to the following:
Welding cutting and grinding at elevated levels will require the use of either fire blankets, wetting down or other non-combustible barriers in order to minimize the fire risk from sparks and/or open flame
Compressed gas cylinders should be located well away from the actual work area where cutting and welding is in progress.
Trailing supply hoses should be safely routed from the compressed cylinders to the point of work
Flammable materials should not be stored on the scaffold platforms, only those materials required for immediate use should be permitted
Matches or lighters shall not be used to ignite gas torches, only approved igniters are permitted
Fire extinguishers shall be provided on location when hot work is performed and at any other time specified on the permit to work
During all work on scaffolding irrespective of its height, personal protective equipment shall be used in line with company Health, Safety and environmental Procedures.
2.3.4 Basic rigging and slinging
Basic Rigging And Slinging
Cranes and other types of lifting equipment are machines that, like any other machine, need to be respected when employees are using them. Lifting equipment of any kind does require regular inspecting, testing and maintenance by skilled personnel in order to ensure its integrity.
Crane Operators, Signalmen and Slingers do require being certified and competent in their individual skills. However, basic rigging and slinging around your work area using Block and Tackle, Winches etc; although requiring similar levels of skill and, carrying similar dangers, do not require the certification of employees for use.
All lifting equipment must carry a current code (normally a color code) indicating that it has been tested and is considered fit for use, any equipment not carrying the current code should not be used. In addition, all slings, chains, hooks and shackles etc should be visually inspected prior to use. Where defects are found and/or any lifting device is suspect, it should not be used but removed from service.
Following a few basic rules will minimize the risk of injury to personnel and/or accidents during any lifting activity. Accidents and injuries caused during lifting operations are rarely as a result of equipment failure but by human error, where employees ignore the basic safety rules, take risks, use the wrong equipment or deliberately take short cuts etc. Hand and foot injuries are probably the most common during lifting operations followed by the striking of a persons head or body against material or equipment.
Safety Hints
∙ Know the weight being lifted and the safe working load of the lifting equipment
∙ Select lifting tackle of adequate strength for the load to be lifted
∙ When using multi-leg slings, ensure they are of sufficient length to avoid a wide angle towards the horizontal, widening the angle reduces the safe working load
∙ Always inspect lifting tackle before use
∙ All end links; rings or shackles must ride freely upon any hook on which they are used
∙ Slings not in use for carrying the load should not be carried on the same hook, as in some instances it can cause the sling carrying the load to ride on the nose of the hook
∙ Ensure the proper pin is used in all shackles
∙ Always try to load evenly all legs of a multi-sling
∙ Do not allow wire ropes to become rusty
∙ Avoid sharp bends and kinking of wire slings
∙ Do not use rope or webbing slings in contact hot metal
∙ Protect slings with wood or other packing when they are placed over sharp edges
∙ Do not drag slings, hooks, or loads along the ground
∙ Always ensure the lifting hook is centrally placed over the load to avoid unnecessary swinging during lifting and fitted with a hook latch
∙ Ensure the load is free before lifting
∙ Ensure you’re your hands are clear of any chains, ropes, slings etc before the load is lifted.
∙ Stand well clear of the load before lifting
∙ Identify all obstructions on the lifting route
∙ Never move a load unless it is safely slung
∙ Always try the load to ensure it is safely slung prior to starting the lifting run
∙ Raise, lower and traverse the load slowly, it is not a race
∙ Never allow the load to travel over the heads of other persons, give a warning prior to lifting
∙ Always attach guy-lines where possible
∙ Never ride on a load or permit anyone else to ride on a load
∙ Always use proper hand signals when moving a load. One person must give the signals only
∙ Stack material safely and securely and allow safe access for its removal and/or use
∙ Ensure the area you are placing the load has adequate foundation
∙ Make provision for the removal of slings
∙ Always use the appropriate PPE, gloves, hardhat, footwear etc
∙ Store lifting equipment correctly
Manually handling equipment can cause injury to personnel unless the proper lifting method is applied. Back injuries are common where employees ignore the basic safe practices; a few simple precautions and the application of common sense will minimize the risk of back injury.
Safety hints
∙ Do I have to make the lift or can it be done by other means--use a trolley, roll it, portable lifting hoist etc
∙ Is the weight too much for me to lift?
∙ Is the article too bulky to lift?
∙ Is the article too high for me to lift?
∙ Can I split the load by unpacking individual pieces?
∙ Can I lift the load if I get assistance?
I must follow the basic rules for lifting—Keep a straight load as close to my body as possible—Maintain good balance—Ensure my route is clear and free of obstructions—Use gloves and other appropriate PPE—Test the weight before lifting—Keep a clear line of vision at all times .
Hand injuries are amongst the more common injuries that personnel sustain therefore, it is essential that the correct hand protection be provided and used. Hand protection is made from several different types of material depending on the specific risk. Such materials may be cotton, leather, rubber, neoprene, reinforced mesh etc. Gloves should not be worn around unguarded rotating tools and equipment such as drills and lathes.
The types of potential hand injury will dictate the type of protection selected, for example:
∙ Leather gauntlet type gloves will be selected where additional protection is required to the forearm for work such as welding or burning
∙ Chemical handling will require the use of specially selected gloves as recommended by the manufacturer for a specific chemical. These gloves are normally of man-made material and will require thorough inspection prior to use to ensure no punctures, tears, or other damage is apparent
∙ Insulated gloves are used where hot or very cold materials are handled or used, these may be of fire resisting material or not.
∙ Electrical work does require special gloves, which must be periodically tested and approved by a certified body for insulation integrity and damage
∙ Many different types of general purpose gloves are used which are normally made from cotton, leather, or a mixture of both depending on the work performed
∙ Barrier type skin creams can be provided for additional protection when handling oil or other liquids that may penetrate through the glove and hence onto the skin
The hand injuries sustained fall into several categories, for example:
∙ Puncture wounds—where an knife or screw driver may slip and enter the skin in a vertical manner
∙ Laceration—opening of the skin by a sharp object such as a knife or glass
∙ Hot and cold burns—skin contact with material that has just been welded or cut or contact with cryogenic material
∙ Abrasions—rubbing the skin against a rough surface taking off the top skin layer
∙ Friction burns—allowing a rope or line to pass through the hands in an uncontrolled way
∙ Amputation—fingers caught in unguarded pulleys or drive belts or presses
∙ Crushing—hands trapped beneath heavy loads or falling objects
∙ Bruising—striking against an object or hitting the hand with tools such as a hammer
∙ Pinching—tight gripping of the skin between two surfaces such as trapping the fingers in a toolbox lid or door
∙ Peeling of the skin—rings getting caught on equipment whilst the hand is in motion tearing the skin of the flesh
2.3.5 Environment Control
Environment Control
In general terms, the average person when referring to the term ‘Pollution’ will allow their thoughts to go immediately to the more commonly advertised areas such as, their living environment. Although of great importance, the environment is only one area where pollution has to be considered.
In this training note, we will look at not only the environment but also the pollution that can occur in the work place and the preventive measures that can be put in place to minimize and or eliminate the risk.
Probably one of the greatest risks within the oil and gas industry is that of a major oil spill on either water or land.
Incidents of this nature would occur only under extreme circumstances such as, a collision at sea, equipment failure and/or emergency conditions.
Under any of these circumstances procedures, systems, equipment and the organization to deal with the situation, are put in place to respond immediately to minimize the damage to the environment.
Control under these situations would come within the scope of a comprehensive OSPAC (Oil Spill Pollution and Control) plan and the participants who support it. However, other forms of pollution that effect the working environments are of equal importance.
The work place is in general a safe place to be; unfortunately, pollution of the working environment is often ignored through the lack of understanding, not only by employees but also by some levels of management within a particular group.
Pollution does come in many forms all of which may have an adverse effect on the work force, their work areas and the general environment.
Typical examples are:
∙ Pollution of the air by particles, vapors, dust/powders, fumes, chemicals and uncontrolled emissions or releases
∙ Inadequate waste management control, storage and disposal
∙ Inadequate storage, handling and use of chemicals and other hazardous materials
∙ Produced water removal, treatment and disposal
∙ Discharges from drilling and other production processes
∙ Noise pollution
∙ The use of dispersants, solvents to clean up and control spills
∙ In all cases, irrespective of the type of pollution it is necessary to pre-plan by:
∙ Identifying the risk
∙ Develop and implement control systems
∙ Provide equipment and resources to minimize the risk
∙ Train employees in the proper use of equipment to include selection, limitations, affects of miss-use, precautions etc
∙ Have in place good preventative maintenance programs, inspection and work procedures
∙ Introduce and maintain a good employee awareness program
∙ Work place pollution/causes
∙ Grit-blasting where inadequate preparations have been made to contain dust particles by sheeting/barriers not being installed, extractors, ducting and collection hoppers not used, unsatisfactory PPE being selected, dirty and clean areas not being provided for de-contamination purposes, poor disposal methods of spent grit, poorly maintained equipment
∙ Asbestos removal and insulation work where inadequate safety measures to seal off areas have not been put in place, material has not been bagged and placed in containers, inadequate marking of waste material, de-contamination and clean areas not set up, unsatisfactory cleaning and checking of the area on work completion
∙ Inadequate preparation and testing of confined spaces leading to the lack of good ventilation, hazardous materials such as toxic materials, chemicals, flammable gases and vapors, fumes from coating/painting-welding, high temperatures, unsatisfactory positioning of machinery allowing exhaust gases to collect and migrate into work areas
∙ Waste management by the lack of good storage areas and proper storage containers, poor segregation of waste, irregular removal, unauthorized disposal methods for domestic waste, chemical waste, hazardous material, inadequate weather protection causing a reaction by either wet conditions or direct sunlight, poor housekeeping
∙ Storage conditions for compressed gases, chemicals, hazardous materials, unventilated areas, poorly maintained storage conditions, weather protection, containers in poor condition, loose caps, valves leaking, wrong type of storage container
∙ Produced water-oily water being discharged without adequate treatment, equipment failures causing high levels and overflow, wash-down if minor spills without adequate containment
∙ Leaks from equipment (Mobile Compressors, Generators etc) through the lack of good maintenance, equipment failure through accidental damage or emergency
∙ Drilling activities where discharges of contaminated water, oil, mud, chemicals may occur accidentally or intentionally during mixing, injecting etc
∙ The incorrect use of dispersants, solvents when cleaning up spills or cleaning down work areas
∙ Battery rooms, charging areas, UPS systems where inadequate ventilation/extraction is installed, poor work practices are used allowing the build up of explosive and harmful atmospheres, poor storage and handling of electrolyte
∙ The above are only some of the key points for consideration when thinking of pollution prevention and deal mainly with the work place. However, each can have a dramatic effect on the general environment where continual disregard of procedures and work practices is the norm.
Major environmental protection is under normal conditions, controlled by sound engineering practices during the design stages of any facility, government and local regulations and good work practices. Each of these areas being incorporated into the company’s environmental policy procedure guides for employees to follow.
Pollution prevention is achieved by:
IDENTIFY THE HAZARD---IMPLEMENT AND ENFORCE THE PRECAUTIONARY MEASURES
2.3 Listening material
2.3.6 Listen to the video on Piper alpha.
2.3.7 Watch helicopter briefing VCD.
2.3.8 Offshore safety orientation
2.3.9 Electrical isolation
2.4 Writing
2.4.1 Under the guidance of instructor, the trainees will practice how to fill in various work permit.
2.4.2 Learn to write Accident /Incident report.
2.4.3 Learn to write Hazards assessment report.
2.5 Assessment and comment
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral(informal) comment, criticism or suggestion will be collected, discussed or analyzed.
3.0 Crude Oil and Gas Production
3.1 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking, reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
3.2 Glossary
3.2.1 Petrol chemistry and physics
(Materials)
acetylene, acetone, additive, asphalt, calcium,
carbon, CO2, CO, H2S, sodium,
chlorine, de-emulsifier, drag reducer,
ethane, glycol, hydrogen, hydrocarbon,
methane, methanol, nitrogen, oxygen, paraffin, propane, scale inhibitor, sulfur, silicon, de-emulsifier, hypochlorite,
(Property)
acid, alkaline, compound, concentration,
state, solid, liquid, vapour, fluid,
steam, weight, specific gravity, volume,
density, solvent, solution, viscosity, flammable,
inert, inertia, volatile, elastic, resilient,
toxic, poisonous, vacuum, neutral, dew point,
freezing point,
(Verbs)
boiling, evaporate, condensate, freeze, compress,
conduction, radiation, convection, radiator,
3.2.2 Symbols and abbreviations
symbol, abbreviation, ISA,
(General)
AP, ESD, PSD, MF, MD,
GD, SD, TD, HS, SDV,
NO, NC
(Pressure)
P, PI, PIC, PCV, PAH,
PAL, PSH, PSL, PSHH, PSLL,
PSV, PR
(Temperature)
T, TI, TIC, TAH,
TAL, TSH, TSL, TE, TW,
TT
(Level)
L, LI, LC, LIC, LV,
LAH, LAL, LSH, LSL
(Flow)
F, FI, FIC, FAH, FAL
FV FSV FE FQI
(Others)
MOV, F/G, HOA, HS,
I/P, MOV, MCC, MSDS, P/I,
PR, RO, TSE, TR, TRC,
VSH, VSL, POB
3.2.3 Well control
wellhead control panel, Christmas tree, master valve,
wing valve, SSV, SCSSV, choke valve, swab valve,
packer, production tubing, annular
3.3.4 Separation
Emulsion, coalescence, BS&W, ratio, water cut,
percentage, ullage, foam, interface turbulent,
turbulence, droplet, vortex, Separation, segregation
separator, bulk separator, treater, slug catcher,
floatation cell, skimmer, hydro-cyclone,
weir, baffle, compartment, chamber,
level gauge, sight glass, vortex breaker, man-way,
3.3.5 Sampling and analysis
laboratory, sample, flask, sampling pump,
purity, probe, benzene, spot, gauging hatch,
spin (spun), hydrometer, heat bath, whirl, graduation,
3.3.6 Secondary recovery
3.3.7 Ancillary and utility
PIG, scraper, pig launcher, pig receiver, air receiver,
scrubber, flare scrubber, high pressure vent scrubber,
low pressure vent scrubber, flare, pilot flare, potable water,
RO unit, heat exchanger, heat medium,
insulation, tube bundle, cooling agent, sump,
sump caisson, pontoon, dehydration, sewage,
3.3.8 Miscellaneous
upstream, downstream, recover, lift, vent,
drain, open drain, closed drain, drainage, bleed, relief, discharge, divert, flare,
flare boom, pilot flame,
3.2 Reading
3.2.1 Introduction
Introduction
An oil field production separator is a pressure vessel in which a mixture of well fluids that are not soluble in each other are separated from one another (Figure 1-1).
Fluid flow from a well can include gas, condensable vapour, water vapour, crude oil, water and solids. When well fluids reach the surface, where pressure is lower than in the reservoir, the capacity of the liquid to hold gas in solution decreases and gas separates out of the oil. Also, the temperature at the surface is lower than the reservoir temperature, therefore well-stream vapors condense and combine with the liquid.
Production separators are used to separate and segregate gas from liquid and one liquid (such as crude oil) from another liquid (such as water).
The main functions of an oil field separator are:
▪ To cause a primary phase separation of gas from liquid.
▪ To continue this process by removing entrained liquids from the gas.
In addition, the separator must have the following characteristics:
Allows sufficient time for the gas to be released from the oil.
Allows sufficient time for the separation of oil and water.
Provides controls that prevent gas escaping with the liquids.
Discharges the separated fluids from the vessel in such a manner that remixing of any of them is impossible.
Note: Non-hydrocarbon components and emulsion in the well-stream cannot be removed in a production separator.
3.2.2 Crude Oil Product Degassing
Crude Oil Product Degassing
A crude oil production separator removes most of the gas from oil; however, even a small quantity of dissolved un-separated gas in the crude oil outlet causes dangerous over-pressure conditions in downstream low pressure equipment such as gun barrels and production flow tanks. To prevent this over-pressure hazard and to reduce the vapour pressure of stored crude oil, the gas boot column removes, or strips, more gas from the separator oil. The gas boot is a simple form of crude oil stabilizer.
3.2.3 Principles Of Operation
Principles Of Operation
The gas boot illustrated in Figure 3-1 is a column inside which are four bubble cap type trays. Crude oil from separation enters at the top of the gas boot and flows downwards across the trays in single-pass flow. On each tray, gas separates from the oil and flows upwards through each bubble cap and leaves the column through the gas outlet The gas is usually routed to a flare for disposal, or it can be compressed and recovered.
Crude oil accumulates in the lower section of the column, where any water settles out. The water leaves the gas boot under level control and is routed to produced water treatment facilities.
The degassed crude oil leaves the column under hydrostatic head pressure and enters a production flow tank.
The function of the bubble caps on each tray (Figure 3-2) is to distribute and disperse the rising gas intimately through the level of oil moving across each tray. The scalloped edge of the bubble cap causes gas bubbles to form. These bubbles have a large surface area and therefore absorb the smaller bubbles in the flowing oil and carry them upwards through the column.
The gas boot operates at very low pressure (slightly above atmospheric) which enables any gas in the oil to separate almost completely. The column gives 2 to 3 minutes of oil residence time.
3.3 Listening
3.3.1 Valve types and operation (34min)(17)
3.3.2 Pumps-Basic types and operation(25min)(19)
3.3.3 Heat exchangers-Operation of shall and tube types(25min)(12)
3.3.4 Pumps-Positive displacement pumps(43min)(22)
3.3.5 Refrigeration systems-Operation(25min)(23)
3.4 Writing
3.4.1 Writing of daily report
3.4.2 Writing of waste discharge report.
3.4.3 Writing of process shutdown report.
3.4.4 Writing of sampling report
3.4.5 Describe the structure and operation procedures of Christmas tree
3.4.6 Write an article to describe the start up procedure
3.5 Assessment and comment
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral (informal) comment, criticism or suggestion will be collected, discussed or analyzed.
4.0 Mechanical Engineering
4.1 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking , reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
4.2 Glossary
4.2.1 Basic hand tools
(General tools)
hammer, hammer drill, hammer wrench,
hammer screw driver, anvil, spanner, wrench, adjustable spanner, socket spanner, pipe wrench,
Stiltson, open ended wrench, combined wrench, chain wrench,
strap wrench, torque wrench, screw driver, slotted screw driver,
negative screw driver, Phillips screw driver,
cross head screw driver, positive screw driver,
pliers, circle clip pliers, long nose pliers,
needle nose pliers, bent nose pliers, Allen key,
Hexagonal spanner, vice, flashlight, jack,
crowbar,
(Measuring tools)
ruler, tape measure, caliper,
Vernier caliper, micrometer, dial indicator,
protractor, feeler gage
(Cutting tools)
cutter, pipe cutter, tubing cutter, hole cutter, cable cutter,
thread cutter, tap, die, saw, hack saw,
senior hack saw, junior hack saw,
pneumatic saw, saw blade, punch, hole puncher,
file, fine file, coarse file, round file, half round file,
flat file, square file, drill, pneumatic drill,
electrical drill, battery drill, drill press, drill bits,
chuck, grinder, grinding wheel, chisel,
knife, jack knife, trim knife, scissors, trammel
4.2.2 Engineering measurement
angular, inch, foot, meter, centimeter,
millimeter, graduation, scale, spindle, thimble,
ratchet-stop, Thimble scale, Barrel scale, limit,
top limit, bottom limit, tolerance, clearance, interference,
transition, dimension, convention,
4.2.3 Engineering Materials and properties
(Metal)
ferrous metal, cast iron, steel, cast steel,
rolled steel, stainless steel, wrought iron,
I beam, H beam, angle steel, channel steel,
galvanized iron, sheet, nonferrous metal,
copper, brass, bronze, Zinc, lead,
lead wire, aluminum, titanium
(Nonmetal)
rubber, glass, glass steel, plastic, asbestos,
asbestos tape, asbestos code, asbestos clay, asbestos gloves, fiber glass, fire clay, lime cement,
rag, Denso tape,
(Others)
PVC, nylon, Teflon, glue, WD-40, anti-seize compound, anti –freeze, rust remover, sulphuric-acid, nitric-acid, soda, graphite
(Mechanical property)
strength, elongation, elastic, elasticity, elastic limit, tensile, Tensile strength, brittle, fragile, brittleness, strength in compression, shear strength in shear, ductility, malleability, fracture, crack, hardness, scratching, wear, toughness, thermal, melt, melting point, grain, wrought, graphite, Babbit, aluminum, corrosive, toxic, non-toxic, electroplating
4.2.4 Lubrication and hydraulic
Lubrication, hydraulics, dampen, contamination,
slide, rub Grease, Lubricant boundary, layer, barrier, slippery, additive, Semi-solid, Ingress,
rust, foam, Detergent, Blend, Servo, Relief valve,
4.2.5 Fastening devices
Fasten, adhesive, thread, left-hand thread,
pitch, bolt, Hexagon, U-bolt, stud,
stud bolt, shear bolt, eye bolt nut, lock nut, washer,
plain washer, spring washer, shake proof washer,
tab, tab washer, screw, setscrew, grub screw,
self-tapping screw, self-drilling screw, round head screw, counter sink screw, flush head screw, cheese head screw, socket head screw, flange, turn buckle, shackle, conjunction, acme, buttress, buttress thread, ISOMC, UNF, UNC, Weld, forge,
rivet, clamp, clip
4.2.6 Gaskets, packing, seals and bearings
gasket, ring, O-ring, cork , compound, packing, impregnate, braid crimp, Chevron, lip,
seal, lip seal, mechanical seal, labyrinth, labyrinth seal, gas seal, bearing, ball bearing,
roller bearing, journal, journal bearing,
thrust, thrust bearing, anti-friction, oil wedge, roller sleeve,
4.2.7 Manual valves
valve, globe, globe valve, butterfly, butterfly valve, choke, ball valve, gate valve, check valve（foot valve，non-return valve）, needle valve, hand wheel, stem, gland, disc, bonnet, spindle, spherical,
4.2.8 Belt drives, shaft coupling and alignment
belt, V-belt, reinforcement, wedge, groove, pulley, sheave, shaft, tension, stretch, co-axial, split, rim, face,
hub, jacking bolt, shim,
4.2.9 Pumps and compressors
pump, hand pump, electrical pump, pneumatic pump, discharge, displacement, head, prime, cavity, centrifugal pump, multistage centrifugal pump, positive displacement pump, reciprocating pump, impeller, impeller vane, blade, suction, cavitations, net positive suction head (NPSH), bubble, trap, implode, particle, pit shaft, wear ring, packing gland, lantern sleeve, stuffing, stuffing box, stream volute, compress, compressor, compression, volumetric, buffer, chamber, gear plunger, single acting, double acting, bladder, pulsation, lobe, sliding vane, mesh, utility, utility air, instrument air dryer, desiccant, muffle, silencer,
5.3.10 Offshore crane
crane, floating crane, crane barge, gantry, turntable, pedestal, boom, hoist,
air motor hoist, auxiliary hoist, wire rope (cable),
harness, bridle main, load, horn, riper, load line, sheave, jib, whip, whip line fast line, overhaul ball, headache ball, lacing, boom lacing lattice, pedestal, swing, static lift, SWL, brake, winch, draw works, drum, cotter, cotter pin, latch, anti-two block,
bird cage, lift arm, lifting appliance, lifting beam, lifting gear, lifting hook, lifting jack, lifting rate, lifting table lifting operation, sling, shackle, abaca rope, nylon rope, rope net, davit, lifeboat davit, davit winch
5.3.11 Internal combustion engines
(General)
Combustion, engine, fuel, diesel fuel, gas fuel, dual fuel, gasoline, kerosene, Jet fuel, fuel tank, dipstick, starter, lubrication, pre-lubrication, post-lubrication, cooling, cooler, coolant, radiator, starter (start motor), speed probe, magnetic pickup,
tachometer, enclosure, compartment, louver, Caterpillar, Detroit engine, Solar Turbines,
(Diesel engine)
cylinder, piston, piston ring, crank, test crank, crankcase, cam, camshaft, stroke, cycle, rocker, flywheel, turbo-charge
connecting rod, push rod, throttle,
(Turbine)
inlet guide vane (IGV), exit guide vane, injector, emission, airfoil blade, burner, restrictor, bore scope
5.3.12 Miscellaneous
abrasive, lever, fulcrum, friction, slide, engage, disengage, tension, clutch
5.4 Reading
5.4.1 Principles Of Operation
Principles Of Operation
The internal combustion engine converts the energy stored in fuel, usually by burning it in a cylinder closed at one end. Inside the cylinder is a piston, free to move up and down.
The fuel ignites in the cylinder and gases are produced which expand rapidly, forcing the piston down the cylinder. The piston is connected to a crank by a connecting rod. As the piston is forced down the cylinder, the crank is rotated by the connecting rod, thus producing motion of the crankshaft.
There are many different types of internal combustion engine, with most falling into two broad categories: spark ignition and compression ignition. A third category is often found at petrochemical installations: the natural gas engine.
The most common types of spark ignition engine are the four-stroke and the two stroke (the four-stroke being the more common of the two).
The most common type of compression ignition engine is the four-stroke, though two stroke engines may occasionally be encountered.
5.4.2 Internal Combustible Engine
Internal Combustible Engine
An engine is a device for converting energy of any type into mechanical energy. Most engines use fuel which is converted to heat which is then converted into mechanical energy. This type of engine is referred to as a heat engine. This module deals with the two main categories of heat engine: the internal combustion engine and the gas turbine engine. The internal combustion engine is further subdivided into spark and compression ignition engines. In an internal combustion engine, the burning of the fuel takes place inside the engine, unlike the gas turbine in which combustion takes place outside the engine.
STRUCTURE
Most combustion engines have similar construction, with pistons, connecting rods and a crankshaft. In four-stroke engines the cylinder head is fitted with valves to allow the air or mixture to enter the cylinder and for the exhaust gas to escape.
Engines can have one cylinder, for example, a motor cycle, or multiple cylinders. These cylinders can be in a straight line or Vee form. In multiple cylinder engines ignition takes place in each cylinder in turn, thus providing a steady and continuous power output.
Fuel for gasoline and gas engines is mixed with air before it is introduced into the cylinder. The correct ratio is between 15 and 17 parts of air to 1 part of fuel. This is done in a carburetor.
Fuel for diesel engines is provided by a metering pump which delivers exact amounts of fuel to each cylinder at the correct moment.
5.4.3 Positive displacement pump
Positive displacement pump
Rotary positive displacement pumps are pumps which use rotary motion. Liquids are moved by trapping a volume of liquid between a set of rotating elements such as a set of gear teeth housed in a casing. As the elements rotate, liquid is sucked into a space between a pair of elements. As the elements continue to rotate, the liquid is trapped between the elements and the pump casing. The liquid is moved around the pump until it is discharged.
Rotary type positive displacement pumps are simpler in construction than reciprocating pumps. They tend to have a low displacement and therefore have to operate at high speeds to achieve reasonably high flow-rates at low pressures.
Centrifugal type pumps are found in most locations. The type of pump used depends upon the location and duty. They may be driven by electric motors, turbines or diesel engines. Pumps not required to transfer larger quantities of oil at higher pressure and/or pump into another pump's suction, are referred to as booster pumps. Types and numbers of pumps vary at each station. This exercise covers centrifugal pump operation in general.
The pumps can be operated in series or in parallel. The usual mode of operation is one or two pumps on line with one standby.
Centrifugal pumps use centrifugal force to move fluids. A simple example of how a centrifugal pump operates is that of a spinning disk (Figure 2-1). If a fluid such as water is slowly poured into the centre of the disk, the fluid is forced outwards. This is exactly how a centrifugal pump operates.
Figure 2-2 shows how this principle is applied to an actual pump. Liquid flows from the pump inlet port into the eye of the impeller which is referred to as the low pressure side of the pump. The rotation of the impeller accelerates the liquid to a point where it is forced to move from the impeller eye through the impeller blades to the outside rim. As the liquid moves from the eye to the rim, it causes a low pressure area in the eye which causes more liquid to flow into the eye. When the liquid reaches the rim, it enters the pump casing where it loses some of its velocity. As the velocity decreases, the pressure increases.
5.4 Listening
5.4.4 Pumps-Centrifugal pumps basics and troubleshooting (40min)(20)
5.4.5 Bearings-Fundamentals (30min)(1)
5.4.6 Compressor-Centrifugal and axial (25min)(5)
5.4.7 Pipes and valves-Safety valves (40min)(16)
5.4.8 Pumps-Multistage centrifugal (40min)(21)
5.5 Writing
4.5.1 Write a piece of article about gears.
4.5.2 Rewrite the reading material 4.3.2
5.6 Assessment and comment
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral(informal) comment, criticism or suggestion will be collected, discussed or analyzed.
6.0 Electrical Engineering
6.1 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking, reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
6.2 Glossary
6.2.1 Electric theory
electricity, electrical, electronics, charge, electron, proton, ion, charge, positive charge, negative charge, energy, power, current,
AC, phase, frequency, DC, magnitude, ampere, mA, microampere, potential, voltage volt, volt, resistance, OhmΩ, Ohm’s law, circuit, circuitry, open circuit, short circuit, close circuit, conductivity, continuity, Watt, kilowatt, horse power, Hertz, semi-conductor, transistor, electromagnetic field, conductor load
6.2.2 Electrical tools
Multi-meter, digital multi-meter(DMM), fluke, analog multi-meter, mega- ohm meter, ampere meter, clip-on ampere meter, wire stripper,
tape, oscilloscope, phase tester, electricity detector
6.2.3 Power generation
generator, AC generator, alternator, DC generator, dynamo rotor, rotate, revolve, revolution, stator, stationary, winding, magnetic field, excitation, PMG, EG, Typhoon generator,
6.2.4 Switchgear and power distribution
switchgear, bus, bus duct, breaker, vacuum breaker, transformer, step up transformer, step down transformer,
PT, CT, MCC, motor starter, synchronize, synchronizer, distribution panel,
6.2.5 Electrical equipment
lamp, rice cooker, microwave oven, blower,
fan, cooling fan, ventilation fan, heater, washing machine, space heater, air conditioner,
HVAC, refrigerant, Freon, radiator, TV, VCR, speaker, motor, armature, synchronous motor, induction motor, step motor,
start motor, ESP, VSD, electrical grill,
dish washer,
6.2.6 Basic electrical parts
(Basic)
fuse, resistor, color coded resistor, capacitor, inductor, diode, triode, switch, relay,
time relay, thermal relay, contactor, contact, coil, transformer, plug, socket
(Cable)
cable, wire, lead, AWG, core, insulation, cable gland, terminator, splicer, cable tray, cable trough, cable conduit, cable trunking, cable tie (Tyrap), hub reducer, junction box,
6.2.7 Battery and UPS
Battery, battery bank, cell, primary cell, secondary cell, pole, polarity, positive, negative, electrode, Lead acid battery, nickel cadmium (Nicad) battery, battery charger, UPS, rectifier, converter, inverter, electrolyte, SCR
6.2.8 Electronics
Electronic, semi-conductor, diode, triode, Thyristor
6.2.9 Miscellaneous
hot, live, rack out, tag-out , black out, energize, de-energize, make, override, short, shock, electrocute, trip, shunt
6.3 Reading
6.3.1 Power Transmission
Power Transmission
With three-phase power, providing the loading of all three phases is equal, ground can be taken as the fourth conductor; only three conductors are then required as shown in Figure 2-1.
If the phase loads are not balanced, the star point at the load end of the transmission line will not be at zero volts; the star point at the generator, however, will be. Since a voltage, difference exists, a current will flow to ground, i.e. there will be a ground leakage current and consequential loss of power as well as potential danger to personnel.
A balanced three-phase transmission requires no more conductors than a single phase supply which would require a ground wire, (live, neutral and ground). This fact, however, depends on ground fault detection protection equipment being installed and on the careful balancing of phase loads. If the load is not suitable for three-phase power (e.g. small motors or lighting and heating), the single-phase loads must be carefully distributed between the phases and must only be operated in such a way as to preserve balanced operation.
In practice, such balancing is only possible where the single phase loads have a high diversity factor, i.e. there are many of them or where whole groups, such as heaters, are either on or off together. Single-phase supply is normal for domestic use when taken from a national generation grid, for instance, but it may not be possible to mix single-phase and three-phase generation and distribution on an industrial plant which generates its own electrical power.
6.4.2 Battery
Battery
(GENERAL)
All batteries can be divided into two types of cell:
▪ Primary cells
▪ Secondary cells
A primary cell produces electrical energy by non-reversible chemical action. This means that once the chemical energy has been used up, the battery is drained and cannot be used again.
A secondary cell produces electrical energy by reversible chemical action. This means that passing a current through it from another source can recharge the cell or cells of the battery.
(PRIMARY CELLS)
There are several types of primary cells available. The most common being the dry Lechanch cell. This type of cell is used in electrical and instrumentation test equipment.
The Lechanch cell shown in Figure 3-1 consists of a zinc case and a central carbon rod surrounded by a mixture of carbon powder and manganese dioxide. The remaining area is packed with ammonium chloride.
The function of the carbon powder and the manganese dioxide is to act as a depolarizer to prevent hydrogen from forming on the carbon rod. The chemical reaction between the ammonium chloride and the zinc case causes an electric current to flow.
(SECONDARY CELLS)
There are many designs and sizes of secondary cell, the most common being the lead-acid cell (see Figure 3-2).
The lead-acid cell consists of two types of lead plates (one is referred to as the positive plate, the other as the negative plate). The battery is made up of a series of positive and negative plates immersed in an electrolyte, which is usually a solution of sulphuric acid and distilled water.
The positive and negative plates are constructed so that they resemble a grid or mesh. The spaces in the negative plate are filled with a lead paste. The spaces in the positive plate are filled with lead peroxide paste.
The lead and the lead peroxide react with the sulphuric acid to form lead sulphate, which produces the electric current. Over a period of time, the cell runs down and both sets of plates become covered with a white deposit of lead sulphate.
When the cell is recharged, the electric current turns the lead sulphate back to lead on the negative plate and back to lead peroxide on the positive plate.
The voltage of the lead acid cell when fully charged is 2 volts. When the cell is discharged, the voltage fails to about 1.8 volts due to the internal resistance of the cell
6.4.3 Induction Motors
Induction Motors
(GENERAL)
Electric motors can be divided into two broad categories depending on the nature of the source used to power them:
Direct current (DC) motors
Alternating current (AC) motors
These categories can be further divided into a number of sub-categories. Figurel.1 shows the relationships between the different types.
(DC MOTORS)
There are three main types of DC motor:
▪ Series
▪ Shunt
▪ Compound
DC motors are not generally encountered in petrochemical production and process applications. They are, however, often used as starter motors for equipment such as diesel generators (series) or as a source of power for equipment such as cranes (compound). For this reason, only the series and compound types are described in this module. DC compound motors can be differential or cumulative; only the cumulative is described in this module.
6.4 Listening
6.4.4 Electrical theory-AC circuit (40min)(11)
6.4.5 Circuit breakers-breakers and switchgear (35+35min)(2) (3)
6.4.6 Electrical motor-Three phase (40min)(10)
6.4.7 Electrical motor-AC motor controllers (30min)(9)
6.5 Writing
6.5.1 Write a piece of article on battery.
6.5.2 Try to write a passage to elaborate on the differences between AC and DC.
6.5.3 5.5.3 Write a short article on motors.
6.6 Assessment and comment
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral (informal) comment, criticism or suggestion will be collected, discussed or analyzed.
7.0 Instrumentation And Control
7.1 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking , reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
7.2 Glossary
7.2.1 Theory
Instrument, instrumentation, automation, control, monitor, limit, adjust, process, sequence, parameter, constant, variable, loop, closed loop, open loop, reliability, linear, linearity, feedback, feed forward, PID, cascade,
7.2.2 Instrumentation tools
(Tubing)
tubing cutter, tubing bender,
(Pressure)
dead weight tester, hydraulic calibrator, pneumatic calibrator, portable pneumatic calibrator(Wallace Box), hydraulic calibrator, signal generator, test gauge
(Temperature)
sand bath, salt bath, heater, thermometer,
(Electrical)
multi-meter, resistance box, wire stripper, cramp, oscilloscope, signal generator, capacitance generator,
(Others)
marker pen, snoopy, hypothetical
7.2.3 Signal and Measurement
(General )
measure, signal, gauge data, digital, analog, electrical, hydraulic, pneumatic, transmitter, error, deviation, discrepancy, compensation, clearance, tolerance, amplify, nominal, size, dimension
(Pressure)
PSI, Pascal, Bar, inch of water column,
Inch of mercury column, pressure gauge, barometer,
pressure transmitter, pressure switch, Bourdon tube, bellow
(Temperature)
temperature gauge, temperature transmitter, temperature switch, RTD, TC, thermal well, thermal control valve, Fahrenheit (℉), Celsius (℃)
(Level element)
level gauge, sight glass, level switch, level transmitter
(Flow)
flow element, flow meter, orifice plate, turbine flow meter, meter, Venturi, Pilot tube
(Others)
vibration, humidity, viscosity, speed, revolution (RPM)
7.2.4 Controller
electrical controller, hydraulic controller, pneumatic controller, PIC, LIC, flapper, nozzle, span, range
7.2.5 Control device
Control valve, actuator, solenoid valve, positioner, stem, seat, plug, trim, packing, SDV, BDV, disc, leak,
pass, ball, sphere, MOV travel,
7.2.6 Tubing and fitting
NPT, NPTF, NPTM, male, female,
NF, NC, pipe, tubing hose, hose clamp, fitting, connector, connector, union, reducer, elbow, nipple , coupling, Tee, cross, ferrule, front ferrule, rear ferrule, Teflon tape, Swagelok,
7.2.7 PLC and DCS
PLC, controller, I/O module, chassis, channel, paralel, serial, adaptor, power supplier, addressing, RS232, LED, scale, instruction, download, upload, online, offline, run,
link, force, force on, force off, ladder, rung, PID, back up, bit, bite, word, enable, disable
7.2.8 F/G detection and protection
LEL, UEL, sensor, detector, gas detector (GD),
smoke detector (SD), ultra violet detector (UV), thermal detector,
thermal detector(TD), flame detector, IR, fusible plug, deluge, sprinkler, Halon,
FM 200, fire alarm, gas alarm, concentration
7.2.9 Miscellaneous
range, span, zero, alignment, misalignment, set-point, rating, offset, magnitude, proportion,
drift, fluctuate, linear, interference, configure, discrete, attenuate, simulator, demonstrator, amplifier,
PSV, rupture disk, module, PCB, figure, barrier, radioactive,
7.3 Reading
7.3.1 Process control
Process control
It is possible to hold a temperature relatively constant using a thermostat. If we take an electrical room heater as an example and set the thermostat at 200C, the thermostat will switch on the heater only when the room temperature is under 200C. The temperature then rises to 200C and the thermostat shuts the heater off. This type of simple control, which is called onoff control, is not always suitable.
We can see that on-off control is not always suitable by considering the driver of a car who wants to ride at 50 km/h. He doesn't control his speed by treading hard on the accelerator and then letting it go. That kind of driving would be very uncomfortable and would not extend the life of his car. An experienced driver pushes the pedal in far enough to allow the speed to remain constant at 50 km/h. Clearly this is not an example of automatic control but it does show that onoff control is not suitable for speed regulation or other applications.
Why is automatic control used?
Let us consider another example:
Assume that for a combustion motor the cooling water leaving the motor must have a constant temperature (say 650C). The operator can open or close the cooling water valve if the measured temperature is above or below 650C (fig. 1).
The temperature can vary for many reasons, e.g. a load change on the engine or a change in the pressure or temperature of the cooling water supply. The causes of the deviation are called disturbances.
The operator must regulate the temperature, this means that he must constantly look at the temperature gauge and, if necessary, alter the valve. If the valve and the temperature gauge are far apart, remote measuring can be used (fig. 2). This is an improvement but the operator still has to watch the gauge constantly and, when necessary, adjust the valve.
If automatic control is used (fig. 3), the operator has only to monitor the machine performance on a regular basis.
7.4.2 The Differential Pressure (D.P) Cell
The Differential Pressure (D.P) Cell
A D.P cell can be used for:
∙ flow measurement.
∙ differential pressure measurement.
∙ level measurement.
∙ under pressure and overpressure measurement.
∙ absolute pressure measurement.
A differential pressure cell measures these values and converts them into pneumatic signals, which are then transmitted to a controller. The main parts of a Differential Pressure Cell are:
a) Flapper/nozzle
b) Booster Relay
c) Feedback System
d) Pressure Sensing Diaphragm and Lever.
7.4.3 Flapper nozzle System
Flapper nozzle System
In a pneumatic transmitter the process measured-value is converted to an air signal. The conversion of the measured value to air pressure is carried out by means of a flapper-nozzle system.
Figure 1
The flapper is a plate that pivots (moves) to close the opening of a nozzle. If the flapper is far away from the nozzle air flows out of the nozzle easily. The nozzle pressure will be almost zero because the hole in the restriction is smaller (about 0.1 mm) than the opening in the nozzle.
If the measured value (process variable) increases, the measuring element pushes the flapper closer to the nozzle. The nozzle pressure therefore increases because the air cannot flow out as easily. If the flapper completely closes off the nozzle the nozzle pressure becomes equal to the supplied air pressure (1.4 bar).
The movement of the flapper converts the measured value into an air pressure, which is then sent or transmitted to a Controller, which is normally situated in the Control Room.
7.4.4 Measurement
Measurement
Instrumentation plays a critical role in the measurement and control of a stable and safe Process Plant operation. Instruments are used to measure and control the condition of process streams as they pass through a Plant.
Instruments are used to measure and control process variables such as:
∙ Temperature
∙ Flow
∙ Level
∙ Pressure
∙ Quality
Automatic instrument control systems are most commonly used to continually monitor these process conditions and correct them, without operator intervention, if there is a deviation from the process value required.
7.5 Listening
6.4.1 Valves-Introduction to actuators (30min)(26)
6.4.2 Valves- Electric and hydraulic actuators (20min)(25)
6.4.3 Pipes and valves-Motor operations (20min)(6)
7.6 Writing
7.6.1 Write an article on process control
7.6.2 Rewrite reading material 6.3.2.
7.6.3 Rewrite reading material 6.3.3.
7.7 Assessment and comment
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral(informal) comment, criticism or suggestion will be collected, discussed or analyzed.
7.0 IT and Telecom
7.1 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking, reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
8.2 Glossary
8.2.1 Computer
computer, laptop, desktop, note book, hardware, main machine, mother board, CPU, Intel, Pentium, memory, ROM, RAM, CD-Rom, monitor, keyboard, printer, HP, modem, peripheral, mouse, sound card, scanner, plotter, software operation system, DOS, windows, MS, MS office, Excel, Word, Access, Power-point, Out look, IE, Auto-Cad, database, compatible, IBM, Dell, Compaq, Legend, Great Wall
8.2.2 Network
network, LAN, internet, server, router, gateway, logon, logoff, download, upload, administrator, operator, TCP/IP, domain,
8.2.3 Telecommunication
(Equipment)
telecom, radio, walkie-talkie, transmitter, receiver, PA, UHF, pager, satellite, antenna, fiber optic, radio, hand-talkie, walkie-talkie, radio call sign, radio silence, radio operator, radio man, radio room, VHF, EPIRB, emergency position indicating radio, beacon, channel hold on, stand by, hold on, hang on, transfer, put through, read, copy, roger, page, ETA, ETD, call sign, HLO, microwave, fiber optic coaxial cable double twisted cable
8.2.4 Phonetic alphabet
A, B, C, D, E,
F, G, H, I, J,
K, L, M, N, O,
P, Q, R, S, T,
U, V, W, X, Y,
Z
8.2.5 Miscellaneous
log on, log off, domain, boot, default, Compatible, configure,
8.3 Reading
8.3.1 Computer
Computer
Computers are very commonly used nowadays in our life. You may find computers everywhere in offices, homes, factories etc., even inside small electronic devices and family electrical appliances. Since being invented in early 1950s in the Pennsylvania University in USA, large computers have played important roles in areas like military, scientific research and weather forecast etc., but another kind of computers named “Personal Computer” (PC) came into being and greatly influenced the whole world.
Generally speaking, computers are made up of hardware and software. Hardware or the electronic components of a PC normally includes following items:
CPU, motherboard, power supplier, memory chips, hard disc display card, sound card, CD-ROM drive, floppy disc drive, network interface card, modem, monitor, keyboard, mouse and speakers. We also have many kind of optional peripheral equipment working together with PC, such as printers, scanners, plotter and digital cameras. In additional to the hardware mentioned above, we still need software to run the PC, just like that we use rules, working procedures, drawings and numerous documents to run a factory. The most important software in a PC is the “Operation System”, or OS for short. Apart from OS, we have other software or “applications” to do a large quantity of jobs, whatever data processing, math calculation, cartoon creating, engineer’s drawing, game playing, You name it, you have it. The relationship between OS and applications just like the relationship between the stage and the performers. The OS provided the platform and managed everything for all the performers and all the activities on the stage.
8.4 Listening
8.4.1 The disk drive industry (10min)
8.4.2 Listen to an article read by the instructor or one of the trainees.
8.5 Writing
8.5.1 Write an article of the composition of a computer and function of each part.
8.6 Assessment and comment
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral(informal) comment, criticism or suggestion will be collected, discussed or analyzed.
9.0 Marine
9.1 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking, reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
9.2 Glossary
9.2.1 Helicopter’s crew list
captain, chief officer/chief mate, second officer/second mate, third officer or third mate, assistant officer, cadet, chief radio officer, radio officer, pump-man, bosun, AB,
able bodied, OS, ordinary seaman, carpenter, chief engineer, first engineer,
second engineer, third engineer, engine cadet, electrician, electrical engineer, fitter, motorman, wiper, doctor, secretary
9.2.2 Location
(A. FWD)
wheel, house, bridge, communication room, heli-deck, D-deck, bedroom, cabinet, office, common office, electric trunk, stairway, navigation instrument room, C-deck, emergency stairway,
cabin, heli-fuel tank unit, emergency generator room,
emergency head quarter, CO2 room, A-deck, store,
bosun store, bonded store, recreation room,
slop chest, corridor, air handling unit room, linen store,
linen chute, sauna room, lobby, entrance corridors,
hydraulic room, electrical space room, staircase, incinerator room, STP room, STP access trunk, landing area, engine room, purifier room, funnel, BOW thruster room
(B. Middle)
HPR, compartment, hydro-acoustic, position reference, chemical store, manifold area,
cat walk, cargo vent riser, deck seal,
PV break,
(C. AFT)
Poop deck, AFT manifold area, AFT machinery fan room, diesel fire pump room, steering gear room, mooring space, paint store, high voltage room, azimuth thruster room, pump room, AFT control house, refuge
9.3.3 Pipe line
cargo line, stripping line, offloading line, COW line, bunker fuel line, bunker water line, drain line, hydraulic line, seawater line, fresh water line, deck wash line, high pressure deck wash line, utility air line, instrument air line, steam line, steam return line, drain line, heli-fuel line, steam line coil, inert gas line, cargo tank, vent line, cargo tank balance line, chemical injection line
9.3.4 Equipment
(A. Navigation)
Navigation, accuracy navigation, navigation beacon, navigation certificate, navigation computer, navigation deck, navigation lamp, navigation mark,
navigation radar, radar antenna, radar map, radar plotting, radio receiver, radar scan, radar view, latitude, longitude, GPS, mast, mast head light, mast step, radar mast
(B. Anchor)
anchor, winch, disc brake, band brake, dog clutch, anchor chain, anchor awash, anchor ball, anchor buoy, anchor cable, anchor clutch, anchor hawse, anchor holding, anchor position, anchor shackle, berth
(C. Mooring)
mooring winch, mooring weight, mooring winch drum, SPM, BTM, mooring head, mooring head pitch bearing, mooring leg, mooring structure, tandem mooring, mooring accessories, mooring area, mooring berth, mooring bitts, mooring boat, mooring by the head and stern, mooring cable, mooring distance, mooring hawser, mooring hook, mooring operation, mooring orders, mooring hole, mooring platform, mooring swivel
(D. Accommodation ladder)
Accommodation ladder winch, gangway, hand-rail, rope ladder, canvas cover, heave, lower,
air motor
(E . COW)
COW machine, crude oil wash machine, 45 degree up,
one hundred degree down, angle indicator, adjust speed, adjust angle, turbine, nozzle, bottom gun, COW master valve, cow valve
(F. Ventilation)
ventilation fan, air driven fan, water driven fan, damper, pneumatic damper, manual damper, louver damper, mesh cover
(G. Steering)
Steering gear, rudder, rudder indicator, tiller, hand-wheel, swash plate
9.3.5 Entering port
call pilot, harbor, port control, ETA, anchorage, entrance buoy, radiogram, maximum draught, entering port, sending rope out, alongside the dock
9.3.6 Cargo work
(A. loading)
loading master, shipping temperature, Fahrenheit, topping off,
(B. offloading)
hose, floating hose, hose connector, blind flange, gasket, hose connecting tool, hose connecting tool box, heave up easy, easy slack, hold it there, deck scupper, scupper plug, fire line,
fire wire, fire line winch, fire extinguisher,
fire hose, air gun, messenger rope, vacuum system,
vacuum tank, vacuum drain tank, vacuum cooling water, vacuum vent header,
oil spill equipment container, oil spill pump, absorbent cotton, absorbent cotton box, traction winch, rope storage tank, hawser winch, bunker hose winch, hose handling winch, chain stopper, rope tensioner, offloading manifold, cargo pump emergency stop button, stripping pump emergency stop button, flushing, pre-heating the offloading line, inflammable cargo, calculation, tank radar,
(C. Metering)
metering station, prover, batch, batching, stream, strainer, filter
(D. Measuring)
MMC, MMC hole, dipping stick, dipping stick, ullage, ullage report, ullage scale, ullage stick, ullage tape, interface
9.3.7 Cargo survey
CIQ, surveyor, CIQ inspector, hatch, hatch cover,
9.3.8 Ballast
eductor, ballast water, bell mouth, ballast cargo, ballast draft, sounding, sounding hole, sounding tape, water paste
9.3.9 Standard wheel order
mid ship, port five, port ten, port fifteen, port twenty,
port twenty-five, hard a port, starboard five, starboard ten, starboard fifteen, starboard twenty, starboard twenty-five, hard a starboard, ease to five, ease to ten, ease to fifteen, ease to twenty, steady, steady as she goes, keep the buoy/mark / beacon on port/ starboard side, report if she does not answer the wheel finished with the wheel
9.4 Reading
9.4.1 Cargo handling equipment
Cargo handling equipment
The various items of machinery and equipment can be found outside of the machinery space . These include desk machinery such as mooring equipment, anchor handling equipment, cargo handling equipment and hatch covers . Other items include lifeboats and liferafts, emergency equipment, watertight doors, stabilizers and bow thrusters . The cargo handling equipment will now be described.
Cargo winches are used with various derrick systems arranged for cargo handling . The unit is rated according to the safe working load to be lifted and usually has a double speed provision. When working at half load .
In the cargo winch, spur reduction gearing transfers the motor drive to the barrel. A warp end may be fitted for operating the derrick topping lift (the wire which adjusts the derrick height). Manually operated band brakes may be fitted and the drive motor will have a brake arranged to fall-safe ,i.e. it will hold the load if power fails or the machine is stopped .
A derrick rig is known as “union purchase’ .one derrick is positioned over the quayside and the other almost vertically over the hold. Topping wires fix the height of the derricks and stays to the deck may be used to prevent fore and aft movement, cargo handling wires run from two winches and join at the hook .A combination of movements from two winches enables lifting, transfer and lowering of the cargo.
Cranes have replaced derricks on many modern ships. Positioned between the holds, often on a platform which can be rotated through 360*, the desk crane provides an immediately operational unit requiring only one man to operate it .
Various type of crane exist for particular duties. In general crane, three separate drives provide the principal movements: a hoisting motor for lifting the load, a luffing motor for raising or lowering the jib, and a slewing motor for rotating the crane . The crane is usually mounted on a pedestal to offer adequate visibility to the operator. For occasional heavy loads, two cranes can be arranged to work together. The operating medium for deck crane motors may be hydraulic or electric.
9.4.2 Mooring equipment
Mooring Equipment
Winches with various arrangements of barrels are the usual mooring equipment used on board ships. It usually consists of a driving motor, a reduction gear, a winch barrel or drum and one or two warp ends. The winch barrel or drum is used for hauling in or letting out the wires or ropes which will fasten the ship to the shore. The warp end is used when moving the ship using ropes or wires fastened to bollards ashore and wrapped around the warp end of the winch.
The motor drive is passed through a spur gear transmission, a clutch and thus to the drum and warp end. A substantial frame supports the assembly and a band brake is used to hold the drum when required. The control arrangements for the drive motor permit forward or reverse rotation together with a selection of speeds during operation.
9.4.3 Loading of ships
Loading of Ships
When then vessel arrives at the port, the cargo is transported to the ship’s side, the derricks are rigged to raise the cargo from the dock and lower it into the hold. In the hold, stevedores stack the cargo carefully. Heavier loads are often lashed and secured to keep them from shifting when the ship rolls and pitches at sea. Wooden frames are built in the hold to keep the cargo in place.
Before loading commences, the terminal operator should have the cargo delivered in advance and located at the correct berth; have clarified the schedule of loading for the various consignments’ provide adequate and correct handling equipment and provide sufficient dock workers, terminal workers and drivers for handling equipment.
To be able to carry out proper planning of the loading operations, it is necessary for the terminal operator to know the time loading or discharging operations can commence. Thus adequate information for shipping agents and port authorities is required.
During loading it is necessary to observe the safety ruled, to observe the planned loading schedule, to ensure correct timing of the cargo for loading, to ensure satisfactory handling of the cargo, to use correct handling equipment and to avoid damage to the cargo. Besides, direct delivery should not be permitted on the apron while loading. After the loading is completed, the operator should check that no cargo has been short shipped.
9.4.4 Discharging cargo
Discharging Cargo
Before discharge commences, the terminal operator should ensure that adequate storage space is available, provide sufficient personnel, provide sufficient and correct handling equipment, and prepare discharging schedule.
Lack of adequate storage space during discharge will reduce productivity, can cause congestion and may also result in damage to the cargo due to, for example, particularly high stacking.
During discharge it is necessary to observe safety rules, to use correct equipment and handling procedures, to avoid damaging the cargo, to provide continuity of work, to observe discharging schedule, to avoid direct discharge and to provide a satisfactory registration and tally. Besides, landed cargo should be moved to storage, lorries and railway wagons should not be permitted on the apron while discharging. After discharge is completed, the operator should check that no cargo has been left behind on board.
9.5 Listening
9.5.1 Listen to relevant articles read by our instructor.
9.6 Writing
9.7 Assessment and comment
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral(informal) comment, criticism or suggestion will be collected, discussed or analyzed.
9.0 Corrosion Control
9.7 Aim and objectives
Aim:
Through the study of the vocabulary listed, the trainees are supposed to have a deeper, more complete or comprehensive understanding or command of these commonly used words in the oil industry. With reading, listening materials, the trainees will learn some relevant knowledge or techniques.
Objectives:
1. Know the meanings, pronunciations, usage of the words listed.
2. Be able to use these words in listening, talking, reading and writing.
3. Through study of the words, the trainees will learn relevant knowledge.
9.8 Glossary
9.8.1 Theory
rust, rusty, corrode, corrosion, corrosive, galvanic corrosion, galvanic chemical corrosion, filiform, filiform corrosion, pitting corrosion,
air bubble pitting, cavition pitting, corrosive pitting,
atmospheric corrosion, atmospheric rusting, mill scale, disintegration, decomposition, oxidation-reduction, crystallization, iron oxides, electrolyte, dissolved ions, hydrogen ion, oxidizing agent, oxidation, reduce, oxidation and reduction reactions, hydroxyl, ferric ion, surface, substrate, galvanized metal solvent, film, ingredients,
9.8.2 Paint
paint, coating, conversion coatings, primer, zinc primer, aromatic polyurethane primer,
chlorinated rubber primer, wax-tape primer, intermediate coat,
topcoat, finish, acetate finish coats, binder, extender, epoxy, epoxy ester, resin, acrylic resin, alkyd resins, vinyl resins, plasticizer, polyamide resin, pigment, titanium barium pigments, extender, extender pigments, hydrolyze, pinholes, vehicle, gloss, spraying, lacquer, varnish, MEK Solvent, chlorinated rubber, vinyl copolymers,
acrylics, methyl cellulose, acrylics & latices, alkyds, bitumastics, plasticizer, esters, polyesters, polyurethanes, polymers, polyethylene, polyvinyl acetate, cross-linking, streak, sandblasting, roller or spray, touchup, titanium dioxide, zinc oxide, zinc sulfide, titanium dioxide, laitance, latex, lacquers, laitance, lead titanate, lithopone, bonding agent, stain, blasting, abrasive blasting, nitrocellulose, nitroparrafins, alkyd, detergent, gloss, streak, ketones, cellosolves, diacetane alcohol, rutile, alphatic, micaceous iron oxide, effloresce, alkyd,
9.8.3 Equipment and tools
(Inspection Tools)
psychrometer, infra-thermometer, electrical dry thickness gauge, wet film thickness gauge, roughness gauge,
(Tools)
UHP Water Blaster (Ultra-High Pressure Water Blaster),
face shield, needle gun, grinder, grinding disk, steel wire cup grinding machine, steel wire cup brush, agitator, blasting hose, bungee straps, copper slag, knot end brush, wire brush, plastic sheeting, roller, air spray gun, airless spray gun,
9.8.4 Miscellaneous
tendency, catalyst, solvent, solution, thick,
thin, rough, even, adhere, adherence, cure, volatile, nonvolatile, VOC, bubble, transparent, translucent, opaque, biodegradation,
fungicides, breakdown, holidays, conversion, anchor, bubble, bubbling, chalk, blushing, chip-and-scrape, bubble, gelation, porous, National Association of Corrosion Engineers (NACE),
SSPC (Steel Structure Painting Codes)
9.9 Reading
9.9.1 Developments in Paint and Coatings
Developments in Paint and Coatings
▪ Completely synthetic resin (1909)
▪ Phenol-formaldehyde: Soluble in oil; modified (in 1920)
▪ Titanium pigments (1918)
▪ Cellulose nitrate and acetate developed for the paint field (1920)
▪ Alkyd resin (1920)
▪ 100% oil soluble phenolic resin developed in 1928
▪ Urea formaldehyde resin developed in 1929
▪ Chlorinate rubber developed in 1930
▪ Vinyl copolymers developed from vinyl chloride; vinyl acetate; vinyl alcohol; and acrylic (1938)
▪ Ethyl cellulose and cellulose acetobutyrate developed in 1938
▪ First vinyl protective coating developed in 1938: five coating system
▪ First inorganic zinc coating developed in 1939
▪ Organic zinc-rich coating started in England in 1940
▪ Sandblasting specified as surface preparation on Naval ships. Vinyl wash primer developed between 1942 to 1945
▪ First self-priming vinyl coating developed and used in 1945
▪ Styronated oils and alkyds developed in 1948
▪ First practical inorganic zinc coating developed and used in U.S.A. Epoxy resins appreared as coating raw materials; amine cured. Polyurethane coating; and coal tar epoxy coatings developed during 1952 –1955.
▪ Epoxy polyamide coatings developed during (1955-1960). First water-base self-curing inorganic zinc coatings.
▪ Self-curing; ethyl silicate base; inorganic zinc coatings used in US (1960-1965)
▪ Single package inorganic zinc coating developed during 1965-1970
▪ Two component aliphatic polyurethane coatings (1970-1975)
▪ Moisture cured polyurethane coating systems used in the US (1975-1980)
▪ Water borne acrylic maintenance coating systems; cardonal based epoxy coatings (1980-1985)
▪ 100% solids epoxies and polyurethanes (1980-1990)
▪ Water borne epoxy coating systems (1985-1990)
▪ Epoxy-novolac tank linings. Polysiloxane coating systems (1990-1995)
10.4.2 Introduction to Paints & coatings
Introduction to Paints & coatings
A coating is a complex material made of a whole series of interacting ingredients such as resins, plasticizers, pigments, extenders, catalysts, fungicides, and solvents. All of these materials are then applied as a thin film of only a few microns or thousandths of an inch. The solvents must evaporate and the nonvolatile portion must deposit a continuous film over the surface. In some cases, this film will react with the surface, with internal curing agents, and with oxygen in the air to become insoluble; or with water in the air to hydrolyze and become insoluble. It must also adhere to the surface and provide an attractive finish that will withstand wind, rain, sun, humidity, cold, heat, oxygen, physical damage, chemicals, biodegradation, and many other physical, chemical, and natural forces.
The variety of materials within a coating and the innumerable conditions under which it must perform thus give rise to hundreds of different types of coatings. Each variation is developed to address differences in material, application, or use. Today’s coating process makes the old “anyone can grab a bucket of paint and a brush” concept obsolete. Coatings are vital to the protection of all types of structures used by society which are, in themselves, becoming more complex and subject to increasingly more corrosive environments. Thus, coatings are becoming so vital to their protection that they should be considered an actual part of the structure and not simply a last-minute detail.
Even more variables are introduced by the drying process. Industrial products finishes have been developed to limit many of the drying variables by controlling the type of application and the speed and temperature at which the coating is cured. Unfortunately, most industrial coatings are applied to structures where the curing of the coating cannot be accurately controlled. This is usually due to variables such as weather, humidity, surface conditions, (rough, smooth, or filled with pinholes), the type of substrate (steel, concrete, wood, plaster, or one of the several nonferrous metals), surface cleanliness, and application techniques, (bushing, rolling, spraying, or the application of a hot-melt). It may also be necessary to deal with a rather wide variety of coatings, which often dry in radically different ways, affecting the final dry film.
Other Coating Terms: Comparisons of various coatings are often made according to composition. The composition of paint is often express by dividing the total weight between the pigment and the vehicle as percentages. In this case, the pigment includes both the hiding and the reinforcing or extender pigments, and also any material used to regulate the gloss of the coating. The vehicle is the complete liquid portion of the paint. Normally, it consists of both nonvolatile matter and volatile materials.
In specifications, the nonvolatile portion of the vehicle is indicated as the vehicle nonvolatile; or more commonly as vehicle solids, binder, or film-former. The volatile portion of the vehicle is the solvent and is usually designated by that name. The sum of the pigments and the vehicle solids is the total nonvolatile or total solids of the coating. This is the part of the coating, which remains on the surface after the coating is applied and after the solvent evaporates. It is the part which makes up the thickness of the coating as indicated by the term mil square feet per gallon, i.e., the amount of total solids in one gallon of coating spread one mil thick over a certain number of square feet. A gallon of coating would cover 1064 square feet one mil tick if the coating were 100% solids. If the coating contained 50% solids, it would then cover 800 mil square feet per gallon. An understanding of these terms is important in comparing coatings received from the same manufacturers, from different plants, or from different manufacturers.
Paints: lacquer, varnish, synthetic paints, Primer: intermediate coats, topcoats, finish, binder, Thinner: Solvent, Evaporation rate, VOC (Volatile Organic Content), waterbased coatings, alcohol, MEK,
10.4.3 Three Types of Coatings
Three Types of Coatings
Thermoplastic coatings or lacquers, dry solely by the evaporation of the solvent (the resin is already in its final form), and there is no chemical or physical change in the nonvolatile portion of the coating that forms the film. In this case, the film-forming process is merely the evaporation of the solvents from the liquid leaving the thermoplastic resins on the surface as a continuous film. This process is not as simple as it sounds, since most coatings are made up of a number of different solvents with different evaporation rates in order to insure that the final film is continuous. If the solvent evaporates too quickly, it may cool the surface of the coating to such an extent that water is condensed on and in the film. This is not an uncommon phenomenon where coatings are applied under high humidity conditions. Blushing is the term that refers to water condensation, which makes the coating turn white. The film that is blushed is generally porous and does not have the same resistant characteristics as the smooth resin film that has properly formed over a surface. Examples of the thermoplastic-type coating are vinyls, acrylics, and chlorinated rubbers.
Conversion Coatings on the other band, dry or react in a whole series of steps. All such coatins undergo a chemical and physical change in the process of film formation. There are several different types of conversion coatings: the oldest and most familiar are paints which have a drying oil and a resinous varnish or resin as the binder. These usually dry more slowly than the thermoplastic coatings and the various drying stages are considerably more complex. These stages ard solvent evaporation, oxidation, thickening or polymerization, and gelation.
Gelation occurs when the polymers reach a size and concentration that forms a continuous network. At this point, although the film is considered dry, it still contains a considerable amount of liquid material and may be somewhat soft. The remaining film continues to cure or dry until the paint becomes hard and ultimately, brittle. These latter changes are accelerated by a sunlight and the heat mixture. When the films reach their ultimate hardness, they generally tend to increase in porosity and lose resistance to moisture and chemicals.
Epoxy: A much more important conversion reaction, from a corrosion standpoint, is catalyst conversion or Cross-linking at ambient temperature. The epoxy coating forms by this process in which the epoxy resin is mixed with an amine just prior to application. The epoxy coating’s drying process consists of solvent evaporation followed by a chemical reaction of the amine and the epoxy resin in such a way that cross-linkage (the joining of two or more molecules of the epoxy resin through a chemical bond with the amine) take place. In this case, the amine actually becomes part of the chemical reaction and is an integral part of the new polymer. It is therefore not a true catalyst. This process is temperature sensitive and can take place in the absence of air. Where cross-linkage takes place, the coating is called thermoset. Thus, it is no longer soluble in its original solvents, nor is it as sensitive to softening by heat.
Another conversion reaction takes place when an epoxy resin reacts with a second resin, e.g., a polyamide resin. Here, the same mechanism as with the amine takes place, only in this case the two resins, the epoxy and the polyamide, react and cross-link to form a solid resin film. The film is therefore somewhat more resilient and elastic than the films formed using the amine epoxy reaction.
Epoxy resins: had a major impact on the protective coating field. These materials reacted in place to form a protective coating which was easier to apply and had good adhesion and acceptable resistance to corrosion. Whereas, the epoxy coatings had excellent durability and chemical resistance (dependent upon the formulation), all of them suffered from the poor resistance to ultraviolet attack on the epoxy resin. This created unacceptable aesthetics in the form of chalking, and loss of gloss and colors. The first attempts to rectify this shortcoming involved the use of vinyl/acrylic topcoats over the intermediate coat of epoxy. While this improved the retention of color and gloss, the period of retention was still not acceptable. With the advent of two-component aliphatic polyurethane topcoats in the later 1960, a major improvement in color and gloss retention become available along with a corollary increase in chemical and solvent resistance f the topcoat compared to vinyl/acrylics.
Polyurethane : While these two component products also form films through a conversion reaction and cross-link into a somewhat chemically resistant film, the main purpose is to improve the finished appearance to which the coating is applied. Polyurethanes form a film through the chemical reaction of either crylic or polyester modified urethane base components with isocryanate reactive converter components. The process, however, is similar to that of epoxy in that nothing of any consequence happens in the way of a chemical reaction until the solvent evaporates from the applied film. At that point, cross-linking proceeds to ultimate hardness according to the resin choice and the ratio of base to converter. This process is not as temperature sensitive as epoxy but is more humidity sensitive during the curing process. Excess humidity at this point can lead to loss of gloss and to cheesy, non-uniform film formation, or wrinkling.
Polyurethane :A third familiar process of film conversion takes place when water from the atmosphere converts the film from a liquid to a solid. This is one of the processes by which the moisture cure polyurethane coatings are formed. In this case, moisture from the air and/or substrate reacts with the polyurethane resins during the initial evaporation stage, cross-linking it and increasing the molecular size of the resin until it becomes solid. The solvent borne inorganic zinc coatings also require moisture from the air whereas the zinc coating also require moisture from the air whereas the water borne inorganic zinc coatings requires carbon dioxide to change the silicate molecule (i.e., sodium, potassium, or ethyl silicate) into a continuous coating by reaction with the zinc pigment.
Some of the other conversion processes require baking or heating, which are not practical where coatings are to be applied to large existing structures or equipment.
The finished product: In the painting or coating process, it is important to distinguish between the liquid coating prior to its application, and the finished product. The final step in the coating formation process occurs only after the coating has been applied and is reacting in place. Thus, the completion of a coating is beyond the control of the original manufacturer so that the quality of the coating depends largely on the care taken during this final step of coating formation. This point must not be overlooked by those with responsibilities form proper coating application and curing.
Coatings are different from almost all other purchases, in that the buyer or the user can tell very little about the quality of the product from its appearance when purchased. The purchaser can only see the can, label, color card, and perhaps a set of application instructions. While the label may show the composition of the coating and may outline various safety procedures to be taken during its application. It offers very little information with regard to the ultimate effectiveness of the product. Two products with essentially the same label analysis can differ greatly in price and in performance. The liquid paint, then, is only of temporary concern to the paint user. The user’s real interest and long-term concern is in the finished surface film after the drying or curing process has been completed.
10.4.4 The Electrochemical Nature of Corrosion
The Electrochemical Nature of Corrosion
Corrosion is the natural process of deterioration of metals and alloys in a corrosive environment. This is a very broad definition, but corrosion occurs in a wide variety of forms, both in pure metals and in alloys. This discussion considers primarily the two most frequently occurring forms of corrosion, general corrosion and pitting. General corrosion is the wasting away of a metal or alloy in a corrosive environment, resulting in an actual decrease in the thickness or size of the original metallic structure. This wasting away occurs relatively uniformly over the surface exposed to the corrosive environment. Pitting is a form of localized corrosion in which a small portion of the metallic structure is corroded at a rate much faster than the bulk of the structure.
Metals such as steel and copper and alloys such as brass and stainless steel appear to be fairly rugged and able to withstand a great deal of physical abuse. This is not true when these metals are surrounded by a corrosive environment. They can be quickly reduced to thin, rusty or oxide-encrusted specimens. To put it another way, these metals always have a tendency to return to their naturally occurring forms.
Metallic elements such as iron, copper, zinc and nickel occur naturally in the form of oxides, sulfides and carbonates. In metal making, this natural process is reversed and the metallic element is separated from its oxide. This requires a great deal of energy, as anyone who has seen a blast furnace can tell you. The resulting metal or alloy is in a high-energy state and, under the right conditions, it will attempt to return to its more natural, lower-energy, reacted state. A detailed corrosion study of a piece of metal is the study of how this happens, the rate at which it happens and what causes it to happen. There are several conditions that must be met before these reactions can occur.
∙ The metal, in this case, iron, must be reactive. It must be inherently unstable in the metallic form, thereby tending to corrode.
∙ The metal must be in contact with an electrolyte. An electrolyte is a solution, usually aqueous, which can conduct electric current and support ionized species.
∙ The electrolyte must contain dissolved species. This can be either dissolved gases, such as oxygen or chlorine, or dissolved ions, such as the hydrogen ion, which acts as an oxidizing agent.
∙ The kinetics of the situation (the rate at which the corrosion reactions can occur) must be rapid enough to be of practical significance.
The first requirement, that the metal must have sufficient reactivity, is exhibited by metals such as iron, copper and steel. They readily corrode under the proper conditions. On the other hand, gold and platinum are more noble metals and do not react readily with their environment. Without the presence of dissolved gases or minerals in an electrolyte, such as water, even highly reactive metals do not corrode. Water contains many types of minerals.
10.5 Listening
10.5.1 Listen to relevant articles read by our instructor.
10.6 Writing
10.7 Assessment and comment:
Assessment:
The trainees will be kindly asked to do a written test or make a presentation using the words they learn.
Review:
The test or the presentation will be reviewed together with the trainees.
Comment:
Written (formal) or oral (informal) comment, criticism or suggestion will be collected, discussed or analyzed.
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