CVE 397

Professional Training (Internship)

Name:___Seif Eddin Bassem Mahjoub______

Student ID#:____63949________

Date (September 2020)

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Table of Contents
List of figures:.............................................................................................................................................2
Executive summary:....................................................................................................................................4
Introduction:................................................................................................................................................4
Description of tasks:....................................................................................................................................4
Introduction to civil Engg & Structures in Oil & Gas Industry:...............................................................5
Design of foundation for pinned and fixed base columns......................................................................10
Introduction to civil engineering software.............................................................................................13
Underground pits Analysis and design..................................................................................................14
Retaining wall analysis and design........................................................................................................15
Offshore sleepers analysis and design...................................................................................................19
Introduction to architectural eng. in oil & gas industry..........................................................................20
Fire insulation system in offshore buildings..........................................................................................21
Lessons Learned:.......................................................................................................................................22
Summary and conclusion:.........................................................................................................................22
Recommendations:....................................................................................................................................22

List of figures:
FIG 1: SUCCESSFUL EPC PROJECT CYCLE......................................................................................................5
FIG 2: 3D MODEL OF STRUCTURES IN CIVIL ENGINEERING............................................................................6
FIG 4: PILE CAPS AND PILES USED TO SUPPORT THE PLATFORM IN NPCC YARD..........................................6
FIG 3: NPCC YARD........................................................................................................................................6
FIG 5: SHEET PILES........................................................................................................................................7
FIG 6: SITE PREPARATIONS AND DEMOLITIONS BEFORE CONSTRUCTION.......................................................7
FIG 7: ROADS AND FENCES.............................................................................................................................7
FIG 8: OPEN CHANNEL ..................................................................................................... FIG 9: CULVERT
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FIG 10: TANK FOUNDATION .................................................................... FIG 11: BUND WALLS AND TANK
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FIG 12: VALVE PITS........................................................................................................................................8
FIG 13: HORIZONTAL VESSEL........................................................................................................................9
FIG 14: ELECTRICAL AND INSTRUMENTATION TRENCHES..............................................................................9
FIG 15: SUBSTATION AND CONTROL BUILDING...........................................................................................10
FIG 16: PINNED SUPPORT.............................................................................................................................10
FIG 17:FIXED SUPPORT................................................................................................................................11
FIG 18: CASE 1 BASE PLATE.........................................................................................................................11
FIG 19: CASE 2 BASE PLATE.........................................................................................................................12
FIG 20: RETAINING WALL PARTS.................................................................................................................16

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FIG 21: GRAVITY RETAINING WALL............................................ FIG 22: SEMI GRAVITY RETAINING WALL.
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FIG 23: CANTILEVERED RETAINING WALLS ............................... FIG 24: COUNTERFORT RETAINING WALLS
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FIG 25: WEEP HOLE DRAINAGE MECHANISM................................................................................................17
FIG 26: EARTH PRESSURE DISTRIBUTION.....................................................................................................17
FIG 27: PARTIALLY SUBMERGED SOIL PRESSURE DISTRIBUTION..................................................................18
FIG 28: THE METHOD OF PROPORTIONING TO CHECK FOR STABILITY..........................................................18
FIG 29: BEAM AND SLAB IN SLEEPER...........................................................................................................19
FIG 30: EXTERNAL WALLS AND INTERNAL FALSE CEILING SYSTEMS...........................................................20
FIG 31: FIRE RATING CLASSIFICATIONS IN CONSTRUCTION. THE FIRE INSULATION MATERIALS INCLUDE: 21

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Executive summary:
Doing my internship during the Summer II 2020 semester in National petroleum Construction company, I
got introduced to some new information during the internship time. Doing this internship online, most of
the information i got was theoretical in which we started by having an Introduction to civil Engg &
Structures in Oil & Gas Industry, underground pits, retaining walls, offshore sleepers, and fire insulation
systems. We then had a recap on several topics we took in university through the sophomore and junior
years including Design of foundation for pinned and fixed base column and civil engineering softwares
such as AutoCAD. I learned how important is civil engineering in the petroleum industry and how precise
we should be to provide the safest possible structures specially when handling hazardous and flammable
materials such as gas and petrol. In general the internship was useful, but due to the unfortunate
circumstances of COVID-19 i would have preferred to have my internship in site rather than online since
its very important for engineering student to get involved in real life experiences and handle engineering
aspects in hand.

Introduction:
During this summer i did my internship at NPCC (National Petroleum Construction Company) head
quartered in Abudhabi and established in 1973 by Senaat, It operates in Arabian gulf, South and south
east Asia. Since NPCC is an engineering, procurement and construction company that provides total EPC
solutions to both Offshore and onshore Oil and Gas sector, the company has a lot of relationships with
operating companies, National oil companies, and international oil companies. This internship focused
mainly on structures used in the ga and oil industry, in which several important topics were discussed:

• Introduction to civil Engg & Structures in Oil & Gas Industry.

• Design of foundation for pinned and fixed base columns.

• Introduction to civil engineering software.

• Underground pits Analysis and design.

• Retaining wall analysis and design.

• Offshore sleepers analysis and design.

• Introduction to architectural engg in oil & gas industry.

• Fire insulation system in offshore buildings.

Going through those topics i was able to grasp the ideas easily since i have seen most of the theory
discussed during my classes in university. Taking courses such as construction materials, mechanics of
materials, theory of structures, and steel design helped me a lot in understanding and know how does the
criteria used in ASTM specifications vary from one structure to another, in addition to the importance of
the load resistance on structures. In addition being introduced to autocad, and SAP2000 in university
helped me a lot in getting comfortable while using the programs during the internship.

Description of tasks:
In this internship the topics covered and discussed were mainly related to the structures and materials
used in the oil and gas industry, providing the bet, safest, and most economical foundations for the

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owners and clients. As mentioned before the internship focused on eight main objectives that will be
discussed specifically here.

Introduction to civil Engg & Structures in Oil & Gas Industry:

We first started our internship by getting introduced to the Engineering, procurement, and construction. In
the oil and gas industry there are requirements and a cycle that should be followed to have a successful
EPC project.

Fig 1: Successful EPC project Cycle.

After signing the agreement between the client and the contractor the design and detailed engineering will
start, then the procurement team will look for offers and vendors, then the materials and equipments are
manufactured and shipped into the worksite, the eqipments are then installed and assembled in the
workplace, then the construction and erection of the foundation starts, finally after the construction is
complete there comes the process of testing and inspection and when everything is properly done and
tested the project is hand over within the given time and agreed schedule.

.Since NPCC is an EPC company the projects must go through a project cycle, Starting with the first
stage of a project which is the project tender stage. A civil engineer has to review all tinder documents
and provide tinder invoice to the commercial department, including the preparation of the bill of
materials, purchase requisition for bulk material, man hour estimation, assumption, qualification, and risk
assessment. Major purchase requisition will be floated to vendors to obtain the budgetary cost. If any
engineer or contractor required the invoice to be identified based on tinder requirements then the work
scope will be issued to obtain the quotation. Thereafter comes the part of signing the contract, and finally
the execution stage and detailed design in which regular weekly meeting will be conducted to discuss the
progress and resolve issues. Which summarizes the interface of civil engineering in the project cycle.

Civil engineers mainly works in all areas associated with all onshore oil and gas installation, structural
and design activities such as concrete structures and geotechnical engineering with relevant

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specifications. As civil engineers we provide services that are either fabrication and construction only or
could be related to the EPC as mentioned in the cycle above.

As civil engineers we deliver the following:

- Basis of design for civil and structures.

- Specifications for materials of construction and workmanship.

- Standard drawings for civil during detail engineering stage.

- Construction subcontracts technical scope of work for topography.

- Sire preparation and civil general arrangement drawings.

- Front end engineering design reviews and endorsement.

- Tender estimation inputs.

- Material requisitions and procurement analysis.

- Construction engineering.

- 3D modeling of structures.

Fig 2: 3D model of structures in civil

engineering.

Following are some of the civil structures that were introduced to us during the internship:

1- offshore structure: example of it is the Pile foundation which is a long cylinder that is needed to
support the top side which is a part of the platform which is under construction in the NPCC yard.

Fig 4: Pile caps and piles used to

support the platform in NPCC
yard.

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Fig 3: NPCC yard

2- Sheet plies: are structural sections that can be interconnected to form a continuous sheet pile. Which is
used when construction is taking place in a confined space.

Fig 5: Sheet Piles.

3- Site preparation: Which is the demolition,

construction and renovation work removal and
relocation of utilities including electricity ,gas, steam ,
and sewer water.

Fig 6: Site preparations and demolitions before construction.

4- Roads, paving, fence and gates: Which is one of the main works in civil engineering which are used to
prevent or control the entry or exit of individuals to the project.

Fig 7: Roads and fences.

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5- Under and above ground drainage networks: an example of it is the open channel which acts as a way
to allow a liquid flow within a free surface ,in addition there is the culvert which is placed under a road.

Fig 8: Open Channel Fig 9: Culvert

6- Storage tanks: Which are containers that hold liquids, compressed gasses, or mediums used for the
short or long term storage of heat or cold.

Fig 10: Tank foundation Fig 11: Bund walls and Tank

7- Valve pits: which are structure consists of reinforced concrete blocks that is shaped with or without
cover. Those are used to restrain soil at different levels.

Fig 12: Valve pits

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8- Horizontal vessel: Which mainly include heat exchanger and drums need foundation.

Fig 13: Horizontal Vessel.

9- Electrical and instrumentation trenches: Which is a type

of excavation that is shed in the ground that is generally
deeper than its width which is used to hide utilities such as
cables.

Fig 14: Electrical and instrumentation trenches

10- Substation and Control building: Which is a reinforced concrete building that is constructed to house
the electrical and instrumentation equipment like the HV and LV switch gears.

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Fig 15: Substation and Control building

Design of foundation for pinned and fixed base columns.

Moving into the second topic we discussed the difference between pinned and fixed base columns.

 Pinned support: are supports that are assumed to be free to rotate.

-In practice they are often detailed with four bolts making it more stable when the column is
initially built.
- The plates will have more stiffness and may transfer moment

Fig 16: Pinned Support

 Fixed support: are supports that are assumed to be entirely rigid.

- The fixed support is moment resisting thus causing it to resist any type of movement on the
structure.

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 - Fixed bases have stiffened base plates, those stiffeners may be made from plate or steel
members such as channels.

Fig 17:Fixed Support.

We were also introduced to base plates and their components, in addition on how to perform manual
calculation on base plate design:

The main component of all base plates are the anchor rods, which are used to prevent column from
overturning during construction. It is critical to provide well defined adequate load path when tension and
shear loading will be transferred though anchor rods.

Calculation steps for 2 different cases:

Case 1: The area of concrete of the foundation is four times the area of the base plate:

Fig 18: Case 1 base plate.

- Determine the factored load.

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- Calculate the required plate area (A1) based in the maximum concrete bearing stress.

Fp= 1.7 F'c

- Use the value found in the previous steps to get the dimensions of B and N.

- Find the thickness of the plate by calculating the maximum value of m and n and place them in the
formula.

- Determine the pedestal dimension A2 which is 4BN.

Case 2: The pedestal dimensions known:

Fig 19: Case 2 base plate.

- Determine the factored load.

- Calculate the required plate area (A1) and

take the maximum value amongst them.

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- Use the value found in the previous steps to get the dimensions of B and N.

- Find the thickness of the plate by calculating the maximum value of m and n and place them in the
formula.

Knowing that Anchor rods are concrete embeds or foundation bolts that are embedded in concrete
foundations to support structural steel columns, we were able to design the bolts manually by following
the steps and using the equations provided in the manual from the company as follows:

For anchor rod connections in tension, the design tensile strength of contributing anchor rods is taken as
the smallest of the sum of the steel tensile strengths of the contributing individual anchor rods or the
concrete tensile strength of the anchor group.

The limiting tension on a rod is based on the minimum area along the maximum stressed length of that
rod.

- Get the nominal tensile strength of a fastener:

Introduction to civil engineering software.

After going through the third topic, it showed how important are computer programs in civil engineering.
Civil engineering software's are very important and helpful since it includes a range of tools to help civil
engineers in the design and construction process. Those programs help in all the stages of the project
starting from drafting , documenting, designing, visualizing and analyzing. Those software can perform
variety of complex calculations thus saves time and realize the results. Having previous knowledge about

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some programs used from university i enhanced the information i already have and got into new
programs that i have never used before.

We started with AUTOCAD which is the most important program used for both 2D and 3D
representations. We identified the meaning and capabilities of AUTOCAD which is a computer aided
design that is more accurate than manual drafting and is used for creation, modification and exchange of a
design.CAD software has different capabilities in which it is used to draw accurate 2D drawings such as
foundations and pipe supports, in addition it can also be used to render 3d models to help visualizing all
items at plant.

Getting into the program itself we were introduced to some of the common commands used in which all
the commands could be found on the task bar on the top of the application, but we can use some
command shortcuts to save some time while working. The following are some of the simple commands
used while drawing use the AUTOCAD program.

L: To draw a simple line.

C: to draw a circle.

PL: to draw a polyline.

REC: to draw a rectangle.

ARC: To draw an arc.

SC: to change the scale of the object drawn.

Area: to find the area of an object.

Mline: create or select multiline.

Other important programs used are:

STAADPRO, MAT 3D, MICROSOFT EXCEL.

Underground pits Analysis and design.

Fourth topic discusses underground pits, the most used type is the Reinforced concrete pits which are
mainly composed of reinforced side walls and reinforced base slab, in addition to equipments/ valves and
instruments foundation.

In designing underground pits a list of data is required:

-Coordinates of nodes.

- geometrical properties.

- Support information.

- Material constants.

- Loads and load combinations.

In order to have successful concrete construction we need 10 main specifications:

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 1. Structural concrete strength at 28 days.

2. Yield stress of steel reinforcement bars.

3. Reinforced concrete density.

4. Min cover to reinforcement.

5. Co. of friction between soil and concrete.

6. Allowable soil bearing capacity.

7. Dry density of soil.

8. Co. of earth pressure.

9. Modules of elasticity of concrete.

10. Required loading ( dead, soil, soil surcharge, piping, and E&I).

Finally we got to know simple calculations to design slabs and side walls.

Design the side wall:

1. Calculate pressure at base of wall : at top of GWL, below GWL due to water, below GWL due to
submerged soil.

2. Calculate the maximum bending moment and shear force.

3. Calculate the area of steel required for horizontal and vertical directions.

Design the slab:

1. Calculate net pressure from bottom.

2. Calculate maximum bending moment.

3. Calculate bending moment at center of bottom slab.

4. Calculate area of steel required.

5. Calculate effective depth of slab.

6. Calculate spacing of reinforcement.

Retaining wall analysis and design.

The fifth topic that was discussed during the internship is the retaining walls. We got to know the general
meaning of retaining structures which are built for the purpose of retaining or holding back materials and

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mainly made up from concrete. Going into our main topic retaining walls are soil structure systems that
are mainly used to support earth backfills and holding back a soil mass or other materials. Retaining wall
could be made from concrete blocks, poured concrete, treated timbers, rocks, and boulders.

A retaining wall is made up of several parts:

- Front face

- Rear face

- Stem

- Sloping face

- Vertical face

- Drainage

- Base

Fig 20: Retaining Wall parts.

There are four different types that were discussed:

- Gravity retaining walls

- Semi gravity retaining walls

- Cantilevered retaining walls

- Counterfort retaining walls

Fig 21: Gravity retaining wall. Fig 22: Semi gravity retaining wall.

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Fig 23: Cantilevered retaining walls Fig 24: Counterfort retaining walls

In some cases water drainage must be provided in the retaining walls by using weep holes, because when
the backfill becomes wet due to rainfall the unit weight increases thus increasing the pressure on the
retaining walls and creates unstable conditions

Fig 25: Weep hole drainage mechanism.

Finally when designing the retaining walls we need to do calculations of the earth pressure and partially
submerged soil, and stability of a retaining wall:

Distribution of the earth pressure:

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Fig 26: Earth pressure distribution.

For a partially submerged soil:

Fig 27: partially submerged soil

pressure distribution.

find the pressure from the effective stress using :

then find the total lateral pressure from earth and water:

while u is the lateral pressure from water:

To check the stability of a retaining wall use the following steps and calculations:

Fig 28: The method of proportioning to check for

stability.

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- Check for overturning about its toe:

- Check for sliding failure along its base:

- Check for bearing capacity failure of the base.

- Check for uplift.

- Check for settlement.

Offshore sleepers analysis and design.

Getting introduced to offshore sleepers i got to know that sleepers are reinforced concrete support
anchoring offshore pipeline crossing at seabed, in addition they provide stability and resist sliding
movement of the pipeline and it can support several sizes of pipelines an loads.

Offshore sleepers components:

- Slab

- Beam

- Shoulders

- Lifting anchors

Fig 29: Beam and slab in sleeper.

We then got into the Procedure and specifications needed for designing a concrete offshore sleeper:

- Calculate the bending moment and shear force based on lifting analysis.

- Calculate the bending moment and shear force based on place analysis.

- Calculate steel required using max bending moment and shear force.

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- Calculate reinforcement in beams and slabs .

- Analysis and design of lifting anchors.

The main specifications needed:

1. Lifting analysis
2. Volume of sleeper
3. Self weight of sleeper
4. In place analysis
5. Seabed soil bearing pressure
6. Beam
7. Required steel reinforcement (longitudinally for bending and vertically for shear.
8. Bottom Slab ( transversally for bending and shear)
9. Effective width and depth of sleeper
10. Grade of concrete and grade of steel

Introduction to architectural eng. in oil & gas industry.

We got introduced to some of the implementations of architecture in the gas and oil industry since it is
related widely to civil engineering.

Architectural interfaces happens with several things:

- Piping

- E&I

- Safety

- Structural

The main architectural material and Equipment were briefly explained to us, architectural materials
include: external and internal wall systems in addition to the internal false ceiling system.

Fig 30: external walls and internal false ceiling systems.

Finally the instructor summarized to us the key features of

architecture design:

1. Safety, durability, ease of maintenance and comfort ability

of the rooms.

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 2. The material used shall be new, free of defects and the best quality manufactured by approved
manufacturer.

3. Shall be maintenance free for the operational duty.

4. Considering adequate space to accommodate respective equipment's and materials.

5. All wall system, door, windows, false ceiling, false floor, penetrations should be fire resistant.

Fire insulation system in offshore buildings.

The final topic that we discussed before the internship has ended was the fire insulation system which is
crucial in the gas and oil industry. First we were lectured about the fire classifications:

Class B fires: which are fires in flammable liquids such as oils.

Class A fires: which are fires in normal combustible materials such as wood.

Class H fires: also called as the hydrocarbon fire which is a fire fueled by hydrocarbon compounds.

Fig 31: Fire rating classifications in construction.

The fire insulation materials include:

1- Fire insulation

2- Pins and washers

3 -Wire support mesh.

Finally the steps of installing a fire insulation was

explained:

1. Welding of pins to the plate, the distance between each pin should not be more than 300mm.

2. Painting of the plate with anticorrosion paint to avoid corrosion.

3. Insulation between stiffeners, the joints should be tight and air gaps must be present.

4. Fixing the insulation by fixing the washers on the pins.

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Lessons Learned:
1- The importance of civil engineers in the building structures in the gas and oil industry.

2- Differentiate between pinned and fixed supports.

3- How to manually do calculations to design a base plate.

4- What are the mostly used programs in building structures in addition to the simple commands used in
AUTOCAD.

5- The importance of underground pits and the data required t design it, in addition to the main
specifications we need to have a successful concrete

6- What is a retaining wall , its importance, and main parts.

7- Types of retaining walls and how to calculate the pressure distribution.

8- What are offshore sleepers with their components, and main specifications needed to design it.

9- The importance of architecture in the field of civil engineering.

10- How to choose the fire insulating systems according to the specifications.

Summary and conclusion:

In conclusion this internship was very interesting in which i got to know a lot of information and get
involved with people who are in the industry and gain from their experience as much as possible. I was
introduced to one of the most important industries in the UAE which is the gas and oil industry. Working
there requires a lot of hard work, dedication and precaution. With all the new programs available working
on advanced projects is much easier and faster. I am grateful for having such an opportunity to do my
internship in those hard circumstances although I would have preferred to be in the site, but the trainers
did a great job in delivering the information required in the easiest and most elaborative way.

Recommendations:
I was fortunate to have the internship offered from the university. I think that offering the students an
internship opportunity will help a lot since a lot of students suffer from finding an internship opportunity.
Rather than that everything is perfect.

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