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Internship at Amilcar Petroleum Operations (APO)
Internship at Amilcar Petroleum Operations (APO)
About
Amilcar Petroleum Operations (APO) is Tunisia’s largest upstream producer of gas. It operates as a non-operated Joint Venture (JV) between ETAP (Entreprise Tunisienne des Activites Petrolieres), the Tunisian national oil company and Shell Tunisia Upstream Limited.
APO is a company created under bylaws (‘les statuts’) dated April 23rd 2014 and commenced operations on May 14th 2014, for the Hasdrubal concession. In 2022 APO expanded also to operate the Miskar concession. Today APO operates two complex systems: offshore platforms, subsea pipelines, and onshore gas plants, together with an LPG terminal.
During my internship at Amilcar Petroleum Operations (APO),
I had the opportunity to familiarize myself with gas treatment processes, maintenance procedures, and electrical network management in the oil and gas industry. This internship allowed me to gain an in-depth understanding of industrial processes, strict safety standards, and control systems used to ensure efficient and secure operations of the facilities.
Skills Acquired:
Technical: Mastery of gas treatment processes, maintenance systems, and electrical networks.
Safety: In-depth knowledge of safety procedures, PPE, and risk management systems.
Analytical: Ability to identify and prioritize maintenance tasks to optimize equipment availability.
Teamwork: Collaboration with technical teams to resolve operational issues and ensure business continuity.
Technical Internship :
1. Gas Treatment
Gas Treatment Processes:
I studied the various stages of gas treatment, including phase separation, condensate stabilization, acid gas extraction (CO₂ and H₂S) via the amine unit, and gas dehydration using molecular sieves.Key Units:
I learned about the operation of treatment units such as the Slug Catcher, condensate stabilization unit, glycol unit, and nitrogen extraction unit.Optimization:
I understood how APO optimizes its processes to maximize the production of marketable gas while meeting the quality standards required by clients like STEG.
2. Industrial Maintenance
Maintenance Philosophy:
I discovered APO’s structured maintenance approach, based on risk identification, intervention planning, and continuous improvement. The use of the CMMS (Computerized Maintenance Management System) to manage equipment and work orders was a key part of my learning.Preventive and Corrective Maintenance:
I participated in PDR (Preventive Daily Review) meetings to prioritize maintenance tasks and ensure equipment reliability.Safety:
I learned the Lockout/Tagout (LOTO) procedures and the importance of Isolation Control Certificates (ICC) to ensure safety during interventions.
3. Electrical Network
Power Generation and Distribution:
I studied the operation of gas turbines (GTG) and emergency diesel generators, as well as their synchronization to ensure a stable power supply.Control Systems:
I observed the use of the Distributed Control System (DCS) to monitor and control plant operations, along with alarm and emergency shutdown systems to protect equipment and personnel.Instrument Calibration:
I assisted in the calibration of temperature sensors and pneumatic transmitters, which are essential for process control.
4. Safety and Environment
Safety Rules:
I was trained on APO’s Life-Saving Rules, which govern high-risk activities to prevent accidents.Personal Protective Equipment (PPE):
I learned to identify and use the appropriate PPE for various risks (flame-resistant clothing, helmets, respiratory protection, etc.).Risk Management:
I participated in Hazard Identification and Risk Assessments (HIRA) and safety audits to identify and mitigate potential hazards.Environmental Protection:
I understood how APO manages environmental risks, including emissions of toxic gases like H₂S, and complies with Tunisian and international standards (ISO 14001).
5. Practical Tasks
Pressure Safety Valve (PSV) Testing:
I participated in the disassembly, inspection, and reassembly of safety valves, following strict procedures to ensure their proper functioning.Installation and Calibration:
I assisted in the installation of new valves and their calibration to verify their set pressure and leak-tightness.
Internship at Amecap Les Ateliers Mécaniques de Précision (Amecap)
Internship at Amecap Les Ateliers Mécaniques de Précision (Amecap)
Amecap
Les ateliers mécaniques de précision, société industrielle créé en 1991, implanté dans la région de Sfax en TUNISIE. Nous sommes spécialisés dans le décolletage de précision sur des tours à came, tours à commande numérique et centre d’usinage. Nous fabriquons une gamme complète d'accessoires pour les installations sanitaires et nous sommes en mesure de répondre à toute demande de sous-traitance de pièces mécaniques et autres de haute précision. Dans une perspective de progrès et de développement international, AMECAP vise à créer un lieu d’échange et de partenariat avec leur clientèle étrangère et locale. AMECAP, s’engage également à apporter une valeur ajoutée à leurs clients en matière de qualité de décolletage et usinage grâce à une récente technologie renouvelée, une approche axée sur l’innovation, la précision et l’efficacité ainsi qu’un travail soigné de nos employés bien qualifiés.
As part of my graduation project, I worked on the study and design of an automated loading system for an eccentric press, in collaboration with the company AMECAP, which specializes in precision mechanical parts manufacturing. The main goal of this project was to improve production efficiency and enhance worker safety by automating the loading and unloading process of parts on the mechanical press used for manufacturing plumbing accessories and valves made of copper alloys.
Expected Results
- Increased Production Efficiency : The automated system reduces cycle times and increases productivity.
- Improved Safety : Automation minimizes the need for manual intervention, reducing the risk of accidents.
- Precision and Reliability : Calculations and simulations ensure the system is robust and capable of operating under industrial conditions.
Key Steps I Took :
Analysis of the Current Situation and Needs Assessment
I began by studying the existing manual process, noting that it suffered from slow production rates and posed risks to workers due to manual intervention. Based on this, I developed a plan aligned with the company’s requirements and objectives.
Automation and Control (Collaboration with My Colleague)
I designed an automated control system using GRAFCET to model the sequence of operations and implemented programmable logic controllers (PLCs) to manage the pneumatic cylinders and sensors. Additionally, I designed the pneumatic circuits using FluidSIM.
Proposed Solutions
After analyzing the situation, I proposed several technical solutions for automating the loading process, evaluating the pros and cons of each. Ultimately, I selected the best solution, which relied on a vibrating bowl feeder (Bol Vibrant), pneumatic cylinders, and guidance systems.
Design and Engineering Analysis
I performed detailed calculations to determine the dimensions of the system's main components, such as pneumatic cylinders, guide rails, and springs. I also conducted stress analysis using SolidWorks for finite element simulation (FEM) to ensure the system could withstand operational stresses.
Electrical Work (Collaboration with My Colleague)
In the electrical part of the project, my colleague and I worked together to design and implement the control system. We selected the Siemens S7-1200 PLC (CPU 1214C) for its compatibility with our system's requirements. We assigned addresses to inputs and outputs, programmed the ladder logic based on the GRAFCET diagrams, and ensured proper wiring of sensors, actuators, and the pneumatic system. This collaboration allowed us to integrate the electrical and pneumatic components seamlessly, ensuring the system's reliability and efficiency.
Technical Documentation
Finally, I prepared a technical file containing detailed drawings of the parts and systems, as well as implementation plans for the automated system.
Theoretical Research
I conducted a literature review on mechanical presses and loading systems, focusing on broaching techniques and feeding/discharge systems. This research helped me better understand the available systems and how to apply them.
Nouvelles imprimeries du sud (NIS)
Nouvelles imprimeries du sud (NIS)
The company Nouvelles Imprimeries du Sud (NIS) was established in 1990 and is located in the Poudrière 2 industrial zone in Sfax. From its inception, the goal set by its founder, was to position NIS among the top manufacturers of compact cardboard packaging for:
Pharmaceuticals
Cosmetics
Industrial sectors
The success of NIS is based on:
Reliability and commitment to quality, deadlines, and quantities.
The ability to respond immediately to exceptional circumstances for clients.
Technical Internship :
July 2022 – December 2022
Applied preventive maintenance practices to mechanical components, ensuring optimal performance and minimizing downtime.
Conducted general observations on the internal functioning of various machines within the production line to identify potential issues and improve efficiency.
Gained expertise in adjusting automated systems (automates) and understanding the different components of the machinery.
Contributed to maintaining smooth operations and enhancing the reliability of the manufacturing process.
Allo friod
Allo friod
La société, active depuis 1985, est spécialisée dans les services liés à la réfrigération et à la climatisation. Elle propose la vente, l'installation et l'entretien de divers équipements, ainsi que la réparation et la maintenance de climatiseurs, réfrigérateurs et congélateurs. De plus, elle est experte dans la conception, le montage, la construction et la maintenance de chambres froides, aussi bien pour des applications industrielles que domestiques. La société met en avant son expertise, des prix compétitifs, un service sérieux et une grande ponctualité, garantissant ainsi des solutions complètes et fiables pour ses clients.
Technical Internship :
Assembling electrical cabinets.
Assembling a refrigeration system.
General inspection of various components and refrigeration systems.
Mastering stick welding.
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