II

List of Content

Acknowledgements --------------------------------------------------------------------------------- II

List of Content -------------------------------------------------------------------------------------- III

List of Figures --------------------------------------------------------------------------------------- V

CHAPTER 1: 1.1 INTRODUCTION ------------------------------------------------------------ 1

CHAPTER 2 : 2.1 INTRODUCTION (About Company) ---------------------------------- 2

2.2 Company Products ------------------------------------------------------------------------------- 3
2.3 Safety ---------------------------------------------------------------------------------------------- 3
2.3.1 Emergency Procedure ------------------------------------------------------------------------- 3
2.3.2 Laboratory Safety Tips ------------------------------------------------------------------------ 3
2.3.3 Laboratory Rules For Technicians ----------------------------------------------------------- 4
2.3.4 Personal Protective Equipment (PPE) ------------------------------------------------------- 4

CHAPTER 3: -Training Work-------------------------------------------------------------------- 5

3.1 Training Work ------------------------------------------------------------------------------------- 5

3.1.1 Blending Plant ----------------------------------------------------------------------------------- 5
3.2 Tests Performed In Oil Laboratory ------------------------------------------------------------- 5
3.2.1 Determination Of Additive Elements (ICP) ------------------------------------------------- 6
3.2.2 Density Test -------------------------------------------------------------------------------------- 7
3.2.3 Kinetic Viscosity Test -------------------------------------------------------------------------- 8
3.2.4 Pour Point Test ---------------------------------------------------------------------------------- 9
3.2.5 Foaming Test ------------------------------------------------------------------------------------ 11
3.3 Grease Laboratory -------------------------------------------------------------------------------- 12
3.4 Test Performed In Grease Laboratory ---------------------------------------------------------- 13
3.4.1 Dropping Point Test ---------------------------------------------------------------------------- 13
3.4.2 Oxidation Stability Test ------------------------------------------------------------------------ 15
3.4.3 Wear Preventive Test --------------------------------------------------------------------------- 16

CHAPTER4: 4.1 Conclusion -----------------------------------------------------------------------18

III
 List of Figures

Fig. (3.1): Digital Density Meter ------------------------------------------------------------ 8

Fig. (3.2): Viscometer ------------------------------------------------------------------------- 9

Fig. (3.3): Pour Point Apparatus ----------------------------------------------------------- 10

Fig. (3.4): Foaming Apparatus -------------------------------------------------------------- 12

Fig. (3.5): Dropping Point Apparatus ----------------------------------------------------- 14

Fig. (3.6): Grease Cup ------------------------------------------------------------------------ 14

Fig. (3.7): Oxidation Stability Apparatus ------------------------------------------------- 16

V
Summary:

My coop training was in Alhamrani Fuchs Petroleum at Yanbu industrial from 12\2\2017 and for
fourteen weeks as a chemical technician in the lab. At the beginning of my training, the company gave
us a program about the safety and our department. The program help us to complete our training in safe
and correct way. In FUCHs there are two labs, the big and the main laboratory for testing oils and the
other laboratory is for testing greases. I worked in the main lab which is for oil for ten weeks and for the
remaining four weeks in greases lab. We did lots of tests in the oil lab such as ICP, TBN, foaming,
viscosity, pour point and the color test. Also many tests was done in the grease lab like Dropping Point
and Oxidation Stability.
CHAPTER 1

1.1 Introduction

I have done my coop training at Alhamrani Fuchs Petroleum Saudi Arabia limited company. It
manufactures oils, greases and specialty products with high international standards for hundreds of uses.
Alhamrani Fuchs Petroleum Saudi Arabia limited has two laboratories, one for blending oils and doing
testes for all samples of the products and it is the main lab. The other lab for blending greases and doing
testes for all samples of products. Most of my training work was in oils lab. Also I worked in greases
lab. I was done all required tests of any sample of company products and report the result of the sample.
Alhamrani Fuchs gave me a good experience in industrial work. Chapter three of my report will
consider more details about the work that was done in oils lab and greases lab.

1
CHAPTER 2

2.1 Introduction about Company

In 1995, Alhamrani group started their activity in the field of oils and greases. Then in 1995, Alhamrani
group entered into a joint venture with Fuchs Petrolub AG (Germany) which is the worlds largest
independent producer and distributor of high standard oils and lubricants. By this union Alhamrani
Fuchs-Petroleum Saudi Arabia Ltd was formed. Alhamrani lube blending plant in industrial Yanbu,
constructed in 1988. It is the largest of its kind across the Middle East and Africa and the factory area is
100,000 square meters. It manufactures a complete range of premium lubricants, greases and specialty
products of the highest international standards for hundreds of uses like motor oils and other vehicles,
machinery, mining companies, construction equipment and agriculture.

Once this processing powerhouse might have been consolidated with those artfulness and ability about
German building Furthermore development, an enduring framework about benefits reshaped that
market. For its large portions extensions crosswise over those kingdom and successful conveyance network,
Alhamrani-Fuchs set itself up similarly as to bring a geological advantage. It will be this geological point that
helped in its strength for service, which incorporates bringing consumers requests, manufacturing items,
delivering them to consumers' doorsteps, and implementing highly effective after-sales services and preventive
maintenance programs that remain unrivaled. With a tenor done innovation, Alhamrani-Fuchs developed its
benefits of the improvement of an all-enveloping One-Stop auto mind focal point over 1998. Radiating with
certainty concerning illustration the initial about its kind, it gives just unparalleled auto services,

Anyhow exceptionally customize auto vehicles administrations that need aid conveyed previously. In 2012, this
One-Stop organize with 100 centers over Saudi Arabia. To grantee impeccable standards of service are met, a
great deal of emphasis is placed on human resources. Efforts to develop the skills and competency of our
workforce is a continuous process. Through various training programs where workers are sent abroad, combined
with the local training centers like the one at Yanbu branch, experience and technical of each worker contributes
to the successive development of the corporation as a whole. Alhamrani-Fuchs consciously and progressively
works to raise the local standards of professional aptitude by hiring and training Saudis to reach their maximal
potential, while simultaneously meeting and exceeding government objectives and requirements. Laboratories of
FUCHS Company have good apparatus that are used in order to get the best result to improve the quality of the
final products. Also, it has good employees were they are following the instructions and safety rules carefully. My

2
training supervisor in FUCHS Eng. Azhar Aiqbal. He is the lab manager and this is his phone number
0556145619.

2.2 Company Products

Engine Oil: for gasoline engine like (SUPER GT 20W-50), and diesel engine like (TITAN 2TS
and TITANPOWER100 SAE 40).
Industrial Products (like hydraulic oil, gear oil and turbine oil).
Transmission Oil (like TITANATF3000s).
Grease (such as RENOLITMP).
Special Products (such as engine coolant and brake fluid).
Marine Oil (like TITAN MCO).
2.3 Safety:
Safety means avoiding danger or working without injury or damage by following the safety instruction
to perform work safely. The workers or trainers should have knowledge about safety instructions that
can make the work done smoothly without any accidents that may affect the company or the workers
themselves. The most important part in safety is human health, so every employee should be careful.
Also each company must have medical clinic for emergency accidents so it can give first aid.

2.3.1 Emergency Procedures

For all the employees, There are two procedures should be known. Which is the procedure before
accident happens and when reporting the emergency. Before the accident happen, employees must:
Know the location of the fire extinguisher and first aid kit.
Know the emergency escape way and where they must be if there was an accident (assembly
point).
When the emergency is reporting the employee call the security and tell them some information such as:
The employee must identify himself.
The employee must tell the security about the exact location of the accident.
The employee must report the injuries and damages which happened to the equipment clearly.

2.3.2 Laboratory safety tips

1. The worker must wear his PPE (Personal Protective Equipment).
2. The worker should follow all instructions and systems when he doing experiments or tests.

3
 3. The lab should contain safety requirements such as fire extinguishers, eye washer, first aid kits
and safety exits.
4. Keep the environment inside the laboratory healthy and clean.
5. Store chemicals in a safe place and according to their specifications.

2.3.3 Laboratory Rules for Technicians:

1. Lab coat should be worn inside the lab all the time.
2. Gloves are required to work with chemical solutions.
3. Avoid to pipette, or absorbs chemicals.
4. Eating or smoking are not allowed in the lab.
5. Dont work alone inside the lab.
6. The location of the fire extinguisher and first aid kit should be reachable for employees.
7. Report damaged equipment and injuries to the supervisor.
8. Working area must be safe, and efficient by cleaning it.

2.3.4 Personal Protective Equipment (PPE)

Employees must wear PPE depend on the work they perform and the working area, which is used to
protect the worker body such as:
Eye protection: like safety goggles which is used to protect the worker eyes when dealing with
chemicals.
Ear protection: ear plugs or ear muffs can be used to protect the worker ears when working in
high level noise.
Hand protection: worker should wear rubber gloves when working with caustic and acid, and
other type of gloves can be used depending on the nature of the work.
Foot protection: safety shoes can be used to protect the workers foot from falling objects.

4
CHAPTER 3

3.1 Training Work

There are two laboratories in FUCHS Company used to assist the units in the plant by analyzing daily
samples that come from the units in order to get high quality products for customers. These two
laboratories are the blending laboratory and grease laboratory.

3.1.1 Blending Plant

Products and Uses:

Engine oil: for gasoline engine and diesel engine.
Marine oil: for moderated speed engine.
Transmission oil: for automatic transmission in commercial motor vehicles.
Industrial products: such as Thermisol QB, Reno line B and Cassida fluid.

Raw Material:
In FUCHS Company the raw materials that are used for production of lubricants are:

Base oil: it is processed from crude oil and it has specific characteristic. It contains long chain
of carbon atom between 18 to 40; it has a boiling point between 287 C to 565 C. It has some
types such as 100 SN which is get from Lubref Company from Jeddah, and 500 SN, 150 SN,
150 BS which is get from Lubref Company in Yanbu.
Synthetic oil: like Electrol-iunin habited insulations oil delivered from India, YU-Base
delivered from Singapore, and NESTA oil from Belgium.
Additives: are chemical compounds that improve the lubricant performance of base oil and
for each formulation the company use different additives for each specific application. These
some examples of additives that added to the base oil to get the requirement properties HCO
lithium and lime.

3.2 Tests Performed In Oil Laboratory:

The oil lab doing some tests on the samples that gets from the vessels in the units to check the quality of
the samples either final products or ongoing processes to prove it or to tell if there is any changing in the

5
process. In order to do test to bring any sample to reach to a good quality and efficiency this procedure
must be followed:
Bring the bottle to the sample point in the unit.
Fill the bottle up with the sample.
Let it to pour at least for 3 minutes.
Let the sample overflow in the bottle by fill it again and then take it off carefully.
Close the valve of the vessel very well.

3.2.1 Determination of Additive Elements in Lubricating Oils by Inductively Coupled Plasma

Atomic Emission Spectrometry (ICP):
Scope:
This experiment used to determinate the amount of metals that found in the oil. The apparatus gives the
percentage of these metals: barium, calcium, copper, boron, magnesium, molybdenum, phosphorus,
sulfur and zinc in unused lubricating oils.

Apparatus:

This experiment contains:

Inductively Coupled Plasma Atomic Emission Spectrometer (ICP).

Analytical Balance.
Peristaltic pump.
Solvent Dispenser.
Specimen Solution Containers.
Vortexer.
Ultrasonic Homogenizer.
Procedure:

Make the stander one.

Do calibration with stander one (put the hole in the beaker of stander one then press calibration
after that chose stander one).
Make stander two.

6
 Do calibration with standard two (put the hole in the beaker of stander two then press calibration
after that chose standard two).
Make the sample. .
Put the hole into sample then chose sample and press start.
White until the equipment shows the result for you on the screen.

3.2.2 Density Standard Test Method by Using Digital Density Meter:

Scope:
The density define as mass per unit volume. Density test is used in many industries such as
pharmaceutical industry and chemical industry like crude oil industry. Also it is used in food
and beverages industries. Digital Density Meter test is used only with liquid sample, and it is
carried out under these cases: total vapor pressure under 100000 pa and viscosity under 15000
mm2/s at the test temperature.
Apparatus:
This experiment contains of:
Oscillating U-tube: To calculate density by measuring the change in
Oscillating frequency.
Injection nozzle.
Syringe.
500 ml Bottle.
Digital Screen: to show results.
Procedure:
By using syringe inject 1 or 2 ml of sample through injection nozzle.
In the sample tube check if there are any air bubbles
Remove air bubbles if it is present.
Wait for the density meter until it reached to steady state.
Record the results of the apparatus: density, relative density, temperature and the API
gravity.

7
 Fig. 3.1 Digital Density Meter

3.2.3 Kinematic Viscosity Standard Test Method by Using Viscometer:

Scope:
The measurement of liquid resistance is the kinematic viscosity it calculated by dividing the
dynamic viscosity over density. This test find out how long time does the sample take it to flow
through glass capillary viscometer. Kinematic Viscosity Standard Test Method is used to
calculate the Kinematic Viscosity for both transparent and opaque crude oil product.
Apparatus:
Viscometer is the name of apparatus that used to measure the viscosity. It contains of:
Viscometer: rough glass capillary viscometer used to calculate the viscosity of
transparent liquid.
Controlled Temperature bath: to control the temperature of transparent liquid where
the viscometer placed inside it.
Holder: used to hold the viscometer.
Thermometer: device used to measure the temperature.
Stop Watch: to measure the time that the liquid take it to travel through the
viscometer
Procedure:
Set the temperature of the bath to the specific temperature of the test.
Put the thermometer inside the bath.
In the capillary U-tube pour the oil sample.

8
 By using the suction, pull the sample to the starting position.
At the same time start the stop watch and remove the suction to allow the sample to
flow back under the gravity.
Record the results of the time and temperature. Oil samples with high viscosity take
more time than oil samples with low viscosity to flow.

Fig. 3.2 Viscometer

3.2.4 Pour Points of Petroleum Products

Scope:

The temperature of a liquid at which it becomes semi solid and loses it is flow characteristics is called
the pour point. In a crude oil, a high pour point means a high paraffin content. An indication of the
minimum temperature of its value of certain requests is the pour point of the oil sample.

Apparatus:

Test Jar: a cylindrical transparent glass.

Thermometers: used to measure the temperature.
Cork: to close the test jar.
Jacket: is a metal with cylindrical shape.
Disk: Inside the jacket.
Gasket: Around the outside of the test jar.
Bath.

9
Procedure:

1. Into the test jar pour the sample up to the required level.
2. In the test jar put the cork and thermometer.
3. Make sure that thermometer is below the surface of sample.
4. Around the test tube put ring gasket.
5. Put the test jar inside the bath maintained at 0C.
6. When the temperature of sample reached to 9C check if there is movement of the sample
replace the test jar again to the bath.
7. Check the movement of the sample every 3C lower.
8. If the sample still flow, transfer it to a cooling bath maintained at -20C.
9. If the sample is not flow report the degree of the rest.

Fig. 3.3 Pour Point Apparatus

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3.2.5 Standard Test for Foaming Characteristics of lubricating Oil
Scope:
Foam is the result of the air bubbles that occurs on the liquid surface. There are lots of reasons that can
made foam like contamination of water, solids or fluid with the grease, and mechanical problems. If the
foam is formed in oil, the temperature of that oil will become very hard to control because the foam will
acts as an insulator. When the foam formed in lubricant oil that will make the oil lose some of its
lubricating properties like: oxidation, cavitation and the failure. To avoid this problem anti-foam
additives can be added to foam tendency like silicone. At this test the temperature should be between 24
C and 93.3 C to determine the physical characteristics of the foam of lubricating oil.

Apparatus:

This instrument used to find out the foam at room temperature and at high temperature. This experiment
contains of:

Graduated cylinder.
Liquid Bath.
Stop Watch.
Rubber Stopper.
Air Supplier.
Air Inlet Tube.
Thermometer.
Gas Diffuser.

Procedure:

In the beaker put 200 ml of lubricating sample.

Heat in a range between 46 C and 52 C. Then cool it until the temperature reach to room
temperature.
Adjust the bath at room temperature (24C).
Move the sample from the beaker to the graduated cylinder.
Place the gas diffuser in the cylinder.
Place the air inlet tube in the cylinder

11
 Put the cylinder in the bath.
Wait until the sample temperature reach to the bath temperature.
At a range between 89 to 99 ml/min, connect the air source and wait for five minutes.
After five minutes remove the airflow.
Read and record the volume of the foam.
Leaving the cylinder for 10 minutes then measure the volume of foam again. If the volume of
the foam is 0 ml before the ends of the 10 minutes, the test is finish and the stability of foam
can be taken as 0 ml.

Fig. 3.4 Foaming Apparatus

3.3 Grease Laboratory

Grease lab have different products with different grades. The grade started from zero to three each
product has different grade from the other. These some examples for products: open gear lubricants
(OGL), extreme pressure grease (EPG), multi-purpose gear (MPG), calcium grease and lithium
complex.

Raw Material

Hydrogenated castor oil (HCO) which is came from India.

Lithium hydroxide: which is came from Belgium.
Hydrated lime: which is manufacturing here in Saudi Arabia.

12
 Additives such as (anti-rust, anti-corrosion, anti-wear) some of these additives manufacturing
in Saudi Arabia and some came from another countries.

3.4 Tests Performed In Grease Laboratory

3.4.1 Dropping Point Standard Test for Lubricating Grease

Scope:
The value of temperature when the grease changed or became liquid at specific temperature is
called dropping point. This test is used to determine the temperature of the grease when it is
change to liquid. If the grease contain synthetic thickener it does not change to liquid.
Apparatus:
Grease Cup.
Test Tube.
Two Thermometers.
Oil Bath.
Procedure:
In the cup put the sample of grease until it is become full.
Put the rod above the cup.
Press the rod down.
Put the thermometer and the stopper into the test tube.
In the oil bath put the test tube where the level of the oil bath is lower than the edge
of the tube.
In the oil bath put the second thermometer where the upper edge of the thermometer
is above the level of the bath.
Start heat and stir the oil bath with the range of 4 to 7 C/min.
Decrease the rate of heating in the oil bath, if the bath temperature reaches to a value
below the expected dropping point.
Take the reading of temperatures from two thermometer when the first drop from the
cup recorded. Finally, take their average that will be the dropping point of the grease
sample.

13
Fig 3.5 Dropping Point Apparatus

Fig. 3.6 Grease Cup

14
3.4.2 Oxidation Stability Test of Lubrication Greases by Using Oxygen Pressure Vessel
Scope:
Oxidation stability is a chemical reaction that occurs between lubricating grease or oil. With
high temperature the reaction will increase this lead to the increase of wear and sluggish
operation. Oxidation stability test at specific conditions will determine the resistance of
lubricating grease to the oxidation when it is placed in a closed oxygen atmosphere.
Apparatus:
Oxidation stability test consists of:
Oxidation pressure vessel.
Pressure gauge.
Sample dish.
Dish holder
Oil bath.
Thermometer.
Procedure:
In five different sample dishes place four g of the grease sample to be tested, each
one of these five dishes must be contained four g.
At the bottom of dish holder insert the sample dishes.
Put the dish holder in the pressure vessel then close the vessel very well.
To remove the air make the pressure equal to 100 psi by adding oxygen to the vessel.
Then remove the oxygen from the vessel and repeat the step many times.
Before starting the test keep the vessel beside for 12 hours to check if there is any
leak in the vessel or not.
Check the pressure if it is drop that mean there is leak in the vessel.
Make sure there is no leak in the vessel then place the vessel in the oil bath where the
temperature of the bath is equal to 99 C.
If the pressure increase remove oxygen from the vessel until the pressure become 100
psi. Maintain it for the next two hours after that record pressure.
Leave the vessel in the oil bath until the identified time of the test is completed.

15
 Fig. 3.7 Oxidation Stability Apparatus

3.4.3 Wear Preventive Characteristics Test of Lubricating Grease

Scope:
Wear is occurs between surfaces when they inter-react together. Anti-wear used to avoid or to prevent
wear between surfaces. This test use four-ball method to find out the relative wear preventive properties
in the grease when it applied on steel surfaces.
Apparatus:
Four Ball Wear Tester.
Microscope.
Stop watch.
Procedure:
In the ball cup put enough amount of the grease sample to cover the space between the three
balls that will be placed in the ball cup.
Lock the cup nut after inserting the three balls inside the ball cup.
Put the fourth ball in the chuck. Then insert it in the apparatus. After that tighten the nut very
well.
Fill the ball cup with the grease sample and cover all the four balls.
Set the temperature in the range between 73C and 77C. Then Insert the cup in the tester.
Start the turbine at 1230 rpm and the stop watch when the temperature reach the test
temperature and wait for 60 minutes.
After that switch off the heater and turbine. Then take off the ball cup from the tester.

16