RBOC 5.6 FINAL

REFINERYInstructor Guide

BASIC OPERATOR COURSE

Module 5.6

Describe Collecting Crude Oil and
Product Samples

Training & Development
February 2010

REFINERYTrainee Handbook

BASIC OPERATOR COURSE

Module 5.6

Describe Collecting Crude Oil and
Product Samples

Training & Development
February 2010

© Copyright Saudi Aramco, 2010.
All rights reserved. No portion of this book may be reproduced, by any process

or technique, without the express written consent of Saudi Aramco.

TABLE OF CONTENTS

Unit 5: Describe Operator Maintenance and Sampling

Module 5.6
Describe Collecting Crude Oil and Product Samples

INSTRUCTOR GUIDE

Teaching Plan i
Teaching Plan Addendum ii
Change Record iv
Information Sheets 1
Exercise A 9
Exercise B 22
Test Answer Key 25

February 2010

Unit 5: Describe Operator Maintenance and Sampling TABLE OF CONTENTS

Module 5.6 1
Describe Collecting Crude Oil and Product Samples 9
22
TRAINEE HANDBOOK

Information Sheets
Exercise A
Exercise B

February 2010

TEACHING PLAN

item action aid time

PREPARATION Before class, prepare the classroom. Instructor Guide.
Distribute trainee handbooks. Trainee Handbooks.
Identify and explain the module Information Sheets. 15 min.
INTRODUCTION objectives.


OBJECTIVE State the reasons for collecting crude Information Sheets, 1 hr.
5.6.1 oil and product samples, and the part I.
procedures for identifying them. Exercise A.
Have trainees complete the exercise.

OBJECTIVE Apply the safety precautions and Information Sheets, 1hr.
5.6.2 procedures when collecting crude oil part II.
and product samples. Exercise B.
Have trainees complete the exercise.

REVIEW Review objectives. Information Sheets. 15 min.

WRITTEN TEST Administer the written test. Score and Test Answer Key. 1 hr.
record the results. Test Sheets. 3 hr.
30 min.
Counsel trainees whose performance is
unsatisfactory and provide remedial
training as required.



Estimated time for a class of 8 trainees.


Module 5.6 February 2010 i

TEACHING PLAN ADDENDUM

USING THIS MODULE
In your introduction to the trainees, you should stress the importance of good sampling. The
laboratory tests feedstocks and finished products in order to control quality. If the samples
they test are not representative of the material that has been sampled, then the tests have no
value. Good samples are the most important factor in quality control.
KEY TO EXERCISES

EXERCISE A
1. to identify possible problems with products

2. to control product quality

3. your refinery laboratory

4. form 127

5. form 128

6. check, FST/ID

7. PA. FST/ID, TOP/MID/BOT/AVG.

8. schedule

9. each type of test required

EXERCISE B
1. sample the lower one third of the tank’s contents

2. wear a safety helmet, safety shoes, safety glasses (goggles), safety gloves, and flameproof
clothing

3. ensure that it is explosion proof

ii February 2010 Refinery Basic Operator Course

TEACHING PLAN ADDENDUM

4. stand upwind of the sample point
5. wear a canister type gas mask
6. leave them at the sample deposit station
7. check them on the plant P&ID/PFD
8. flush for a minimum of 30 seconds with the tap fully open
9. flush three times with the bottle/can half full of product
10. Sample the middle and lower levels, and inform the lab that the tank was not full
TEACHING AIDS

Links have been provided to video clips from the WILLIAM LEARNING NETWORK CD-
ROM “Process Sampling–OBTAINING SAMPLES”. These should help the trainees to visualize
the process of sampling.

Module 5.6 February 2010 iii

CHANGE RECORD REASON
First Printing (RTR only)
CHANGE DATE Major Curriculum Revision
September 1993
July 1996 QA Reveiw #OS9818
February 2000 Curriculum Revision
March 2002 Major Curriculum Revision
February 2010

iv February 2010 Refinery Basic Operator Course

Enabling Objectives INFORMATION SHEET

5.6.1 Terminal Objective
Unaided, the trainee will correctly state the reasons Unaided, the trainee will
for collecting crude oil and product samples and the correctly describe the safe
procedures for identifying them. sampling of crude oil
and products according
5.6.2 to refinery schedules and
Unaided, the trainee will correctly apply the operating instructions.
procedures and the safety precautions when
collecting crude oil and product samples.

INTRODUCTION

As a refinery operator, one of your responsibilities
will be to take samples of crude and other products
for testing. In this module you will learn why
samples are taken and how to take them properly
and safely. You will learn about the methods,
equipment, and procedures you use to take and
process vessel and line samples safely. You will learn
how to complete sample tags and how to obtain
vessel and line samples using a sample box and a
sample bottle.

Module 5.6 February 2010 1

INFORMATION SHEET

part i objective 5.6.1

State the Reasons for Collecting Crude Oil
and Product Samples, and the Procedures for
Identifying the Samples

The quality of feedstocks can INTRODUCTION
vary from batch to batch. If the
engineers know the quality of You will take crude oil and product samples from
a batch they can adjust the many different locations in the refinery. You must
process to ensure the quality take the samples in accordance with the plant
of finished products. schedule. There is a sampling schedule posted in the
control room of each refinery plant. In this part of
the module, you will learn the:

o reasons for collecting samples

o procedures for identifying samples

REASONS FOR COLLECTING SAMPLES

You take samples of feedstocks to help determine
the required settings for operational variables such
as temperature or chemical addition.

You will send samples of crude oil for laboratory
testing to find out if they meet specifications.
Depending on results, adjustments can be made to
refining processes to ensure that finished products
meet Saudi Aramco specifications.

You will send samples of finished products to your
refinery laboratory for testing to determine the
composition and quality of the product. Product
samples must meet Saudi Aramco specifications
before they can be shipped to customers.

2 February 2010 Refinery Basic Operator Course

INFORMATION SHEET

You must use sample tags to positively identify
samples so that they can be traced back to their
source.

Now view video clips from WILLIAM LEARNING
NETWORK CD-ROM “Process Sampling–
Obtaining Samples”

Video 010 Video 105
3
Figure 1
WFigilulrieam1s Learning Video Clips V-010 & V-126

Module 5.6
RBOC

procedures for identifying
samples

Sample tags are official Saudi Aramco forms used in
the refinery. Sample tags identify each sample and
indicate the type of test or tests to be done. The
refinery laboratory tests the samples according to
the directions on the sample tags.

Two different sample tags are used for hydrocarbon
samples:

o low flash oil (Saudi Aramco form 127)

o high flash oil (Saudi Aramco form 128)

You will also learn about filling out these tags.

Module 5.6 February 2010

INFORMATION SHEET

Low Flash Oil Sample Tag

Saudi Aramco form 127 is the low
flash oil sample tag. Its color is
yellow.

You fill out the low flash oil sample
tag for the following crude and
refined products that have low flash
points:

o gasoline A-380
o white diesel A-888
o kerosene A-418
o jet fuel A-434
o naphtha A-181/305/310
o crude and crude blends

LFFMiiooggwduurureeFlel22a5s.h6 Oil Sample Tag Refinery Basic Operator Course
RBOC

4 February 2010

INFORMATION SHEET

High Flash Oil Sample Tag

Saudi Aramco form 128 is the high
flash oil sample tag. Its color is white.

You fill out the high flash oil sample
tag for the following products that
have high flash points:

o fuel oil A-960
o asphalts
o water (you will learn about water

or condensate sampling in
module 5.8)

Figure 3 Figure 3
Module 5.6 High Flash Oil Sample Tag
RBOC

Module 5.6 February 2010 5

INFORMATION SHEET

Filling Out The Tags

You attach tags to the sample bottles
with a string. The tags are divided
into two parts by a perforated line.
The tag number is shown on each
part. You must write the sample
information on both parts of each tag.
You mark the bottom part of the tag
to indicate which tests need to be
done: put a check in the box next to
each test that will be done on the
sample. You must not remove the
bottom part of any sample tag. Figure
4 shows a completed low flash oil
sample tag.

Figuurree 44 Refinery Basic Operator Course
CMomduplele5te.6d Tag
RBOC

6 February 2010

Filling In the Top of the Sample Tag INFORMATION SHEET
7
When you take samples, you write the following
information at the top of the tags as shown in
figure 4:

date The date you take the sample.

time The exact time you took the
sample.

stock The type of liquid sampled.

plant/tank The plant and/or vessel
number you took the sample
from.

check Check if you sent the sample
for confirmation of an earlier
test.

pa Check if you need pumping
approval tests for a tank.

fst/id Full shipping test or
identification test. To confirm
previous test results on a tank.

schedule/ Circle one to indicate
unschedule whether the sample was
scheduled by your refinery
instruction or specially
requested.

top, mid, bot, Circle one to indicate the
avg. location in a tank you took
the sample from. A mixed
sample is AVG.

Module 5.6 February 2010

INFORMATION SHEET

Note: If the sample is a check sample, indicate the test
type on the check space of the bottom part of the tag. The
sampler’s badge number should be included.

Filling in the Bottom of the Sample Tag

On the bottom part of the tag, you put check
marks in the box beside each type of test required.

Remember, there are two parts of the sample tag
you need to fill out. At the top of the form, you
record such information as the date and time the
sample was taken, and the location within a tank
the sample was taken from. At the bottom of the
form, you indicate with a check mark the type of
test that needs to be run on the sample. This
information is for the refinery laboratory. Taking
samples involves more than filling out the sample
tags. You must be very careful when you take
samples. You will learn safety precautions to follow
in part III.

SUMMARY

In this part of the module, you have learned why
samples of crude oil and products are collected, and
how they are identified. In part II you will learn
the procedures for taking samples safely. Now do
Exercise A.

8 February 2010 Refinery Basic Operator Course

Exercise A INFORMATION SHEET
9
Directions: Write the answer to the following questions.

1. Why are crude oil feedstocks sampled?



2. Why are samples of finished products sent for
laboratory testing?



3. Where are samples tested?



4. What tag is filled out when gasoline samples
are taken?



5. What tag is filled out when asphalt samples are
taken?



6. What sections of tag are filled when
confirmation of earlier tests are requested?



7. What sections of a sample tag are specifically
for tanks?



Module 5.6 February 2010

INFORMATION SHEET

8. What section of a sample tag is circled when a
sample is scheduled in your refinery
instruction?



9. What is checked on the bottom section of a
sample tag?



10 February 2010 Refinery Basic Operator Course

INFORMATION SHEET

part ii objective 5.6.2

State the Safety Precautions and the Procedures
when Collecting Crude Oil and Product Samples

INTRODUCTION

Although you will be required to collect samples
from different locations (pipelines, automatic
samplers, sample thiefs, etc.) usually you will be
taking tank samples. There are many different types
of tank samples (see figure 5). However, most
refinery samples are taken from taps at the bottom
of tanks that have pipes that connect to the tank's
upper, middle, and lower levels.

GAUGING
HATCH

6"
TOP SAMPLE

UPPER SAMPLE UPPER THIRD

TANK MIDDLE SAMPLE MIDDLE THIRD
CONTENTS
LOWER SAMPLE
OUTLET
BOTTOM WATER SAMPLE LOWER THIRD
Figure 5 BOTTOM SAMPLE WATER
TFiagnukreS5ampling Depths
MRMBooOdduuCllee 55..66 February 2010 11

INFORMATION SHEET

Safety is always the first concern of Saudi Aramco.
In this part of the module you will learn:

o safety precautions you must take when
collecting samples

o procedures for taking tank samples

SAFETY PRECAUTIONS

Safety is very important when you are taking crude
or refined product samples. Always tell your
supervising operator if you are going to collect
samples. Crude and refined products are toxic,
flammable, and skin irritants. To avoid getting hurt,
always follow these safety precautions:

o protect skin and eyes

o keep samples away from any source of ignition

o do not breathe or drink petroleum products

o handle sample containers safely

Protect Skin and Eyes

Always wear the appropriate PPE (Personal
Protective Equipment). PPE includes safety hat,
safety shoes, safety glasses/goggles, work gloves, and
ear plugs in high noise areas.

Now view video clip from WILLIAM LEARNING
NETWORK CD-ROM “Process Sampling–
Obtaining Samples”.

12 February 2010 Refinery Basic Operator Course

INFORMATION SHEET

Video 040

Figure 6
WMFiogiludlruiealem65s.6Learning Video Clip V-040

RBOC

If you get a petroleum product on your skin, you
should wash it with soap and water. Hydrocarbon
causes eye injury if it splashes into your eyes. If any
product gets in your eyes, you must rinse them
immediately with water. Use the special eyewash
stations for this purpose. Learn their locations and
how to use them effectively. Acting quickly and
correctly in an emergency could save you from
serious injury.

Keep Samples Away From Any Source of
Ignition

Petroleum samples are highly flammable. For this
reason keep samples away from anything that could
cause a spark or high temperatures. Never carry a
cigarette lighter in your shirt pocket while taking
samples from a tank or lines. It might fall onto the
ground or floor and make a spark. Smoking is not
permitted except in designated areas outside a plant.
Small lights, portable radios, or cassette players are

Module 5.6 February 2010 13

INFORMATION SHEET

not allowed. All electrical equipment near sampling
points must be explosion-proof.

Do Not Breathe or Drink Petroleum
Products

When taking samples from a vessel, stand upwind
(if possible) to avoid breathing hydrocarbon vapors.

Petroleum products are toxic. They contain high
concentrations of hydrocarbon vapors which are
harmful. Product samples should only be taken and
stored in areas where there is good ventilation.
Sample bottles containing any petroleum product
must be kept tightly sealed with corks or caps.

Petroleum products can harm you if they get into
your eyes, in your mouth, or on your skin.
Petroleum products can cause brain damage,
blindness, or death if swallowed. If you accidentally
swallow any petroleum product, you must get
immediate medical help. You can swallow a
petroleum product by accidentally drinking it,
splashing some on your mouth, or having some on
your hand when you eat.

To reduce the risk of swallowing a product, keep it
in its proper container with a sample tag on it. If
you put some into another container, you must
label that container so everyone knows it contains a
petroleum product.

CAUTION

NEVER put petroleum products into a container that
someone might drink from. For example, do not
use a Pepsi can or a water bottle to hold petroleum
products.

14 February 2010 Refinery Basic Operator Course

INFORMATION SHEET

Occasionally the outside operator might have to
sample floating roof tanks of sour crude oil
containing more than 10 ppm of H2S. This is a
toxic gas that can cause unconsciousness and loss of
life. Normally these tanks are sampled by automatic
sampler. If required to sample a sour crude tank
manually, the outside operator must wear a canister
type gas mask. He must wear the mask before he
passes the landing at the top of the tank stairs, and
not remove it until he returns to the landing.

Now view video clip from WILLIAM LEARNING
NETWORK CD-ROM “Process Sampling–
Obtaining Samples”.

Video 052 Video 162
15
Figure 7
WMFiogilduluriealem75s.6Learning Video Clips V-052 & V-062

RBOC

Handle Sample Containers Safely

Never completely fill sample containers. The sample
liquid level in bottles should not be higher than the
bottle’s shoulder. A vapor space must be left in the
container. This vapor space allows for the expansion
of the liquid sample. A capped and full container
can explode causing a fire, injury, or major incident.

Module 5.6 February 2010

INFORMATION SHEET

A sample deposit station is do not hammer corks into bottles with your hand.
the place where samples The bottle might break or the cork might jam into
are picked up by laboratory the bottle.
personnel.
do not use defective, discolored, or misfitting corks
or caps which do not seal properly. Use only new
corks or caps in order to avoid sample
contamination.

do not put tag strings or anything else under the
cork when stoppering bottles. Tie strings securely to
the neck of the bottle after ensuring the tags are
properly filled out.

do not pick up or carry sample containers by their
tags. The tag might break, or the container may
come loose from the tag, spilling the sample and
possibly causing fire or injury. Use the bottle
carriers.

do not leave samples standing in the sun. The
container and contents may overheat and could
cause a fire or explosion. Keep the sample
containers in the shade as much as possible.

PROCEDUREs FOR TAKING TANK
SAMPLES

Before taking samples the outside operator must
gather all the equipment he needs: sample bottles,
corks, bottle carrier, and cleaning rags. These are
available at the control room or the sample deposit
station.

You must fill out your sample tags in the control
room before going to take samples. Use the sample

16 February 2010 Refinery Basic Operator Course

INFORMATION SHEET

schedule to determine how many samples to take,
and how many tags to fill out.

Now view video clip from WILLIAM LEARNING
NETWORK CD-ROM “Process Sampling –
Obtaining Samples”.

Video 084

Figure 8
WFMigoiludlruiealem85s.6Learning Video Clip V-084

RBOC

After samples have been taken you record them in
the sample book.

The outside operator must deliver the samples to
the sample deposit station for pick-up. Sample
deposit stations are usually located near control
rooms. The sample containers go into a sample
storage box. The laboratory driver or an assigned
operator picks up the samples and transports them
to your refinery laboratory. The laboratory will test
the samples according to your directions on the
sample tags.

Module 5.6 February 2010 17

INFORMATION SHEET

Tanks with side mounted sample taps have draw off
points located on the upper third, the middle, and
the lower third of the tank shell. Block valves are
installed at each sample point and are normally left
open. Piping is installed down from the sample
points to the sample box and drip pan. The pan
and box are equipped with three small sample lines
with block valves, a reservoir large enough to hold
sample line flushes, and a hand pump to return the
contents of the pan to the tank. The sample box
has a cover and must be large enough for the
insertion of a one gallon can. See Figure 9.

Figure 9 Refinery Basic Operator Course
TFMiagopud-ruSelae9m5p.6ling System

RBOC

18 February 2010

INFORMATION SHEET

Table 1 summarizes the procedures for taking tap-
samples.

Procedures for Taking Tap-Samples

Obtain all necessary equipment for sampling.

Fill out the sample tag(s).

Write the sample tag number(s) in the sample book.

Go to the sampling location.

Stand upwind of the sample line and flush the sample bottle.

Note: The sample bottle must be flushed clean by filling it half full three times and then pouring it into the pan.

Check that the sample bleeder tracing stream is in service (if available) then open the sample
bleeder for the upper sample line.

Allow the line to flush until you are satisfied that old product has been flushed from the line.

Note: The lines should be flushed for the following minimum times—lower line 15 seconds, middle line 30 seconds, upper
line 45 seconds. During flushing the lines should be as fully open as possible without splashing. If the valves are only
trickling then the lines will not be flushed. If the valves are open too wide there is a risk of static electricity building up.

Fill the sample bottle 3/4 full (level with the shoulder) with product. See figure 10.
Close the sample bleeder valve.
Cork the sample bottle firmly. See figure 11.

Attach the correct sample tag to the bottle.

Place the sample bottle in the sample box.

Repeat these actions for middle level and lower level taps.

Note: If the tank is not completely full take samples from the middle and lower sections and indicate to the lab that there
was no product in the upper level.

Pump out the oil in the pan back to the storage tank. See figure 12.

Place the sample box in the sample deposit station for pick-up. See figure 13.

Enter sample details in the sampling book.
Table 1

Module 5.6 February 2010 19

INFORMATION SHEET

Figure 10
MFFiiogllduurtehlee150S.6ample Bottle

RBOC

Figure 11 Refinery Basic Operator Course
CMFioogrudkruelet1h51e.6Sample Bottle

RBOC

Figure 12
Pump Out the Oil

20 FebruarFyig2u0r1e01 2
Module 5.6
RBOC

INFORMATION SHEET

Figure 13
PFilgauceret1h3e Sample in the Sample Box

Module 5.6

SRBuOmC mary

In this information sheet, you have learned the
reasons for taking samples, the procedure for filling
out sample tags, and the safety points to consider
when taking crude and refined product samples.
You will learn about collecting LPG samples in
module 5.7.

Module 5.6 February 2010 21

INFORMATION SHEET

EXERCISE B

Directions: Answer the following questions.

1. If you are required to provide a lower tank
sample, you must

.

2. If you need to wear PPE, you must

.

3. Petroleum products are highly flammable. If
you are required to use any electronic
equipment in the plant, you must

.

4. If you are taking a sample from a process plant
in the open, you must

.

5. If you are required to take a sample of a crude
oil containing H2S manually, you must

.

6. If you have taken tank samples and tagged
them correctly you must

.

7. If you are not sure of the location of a process
vessel and its sampling points, you must

.

22 February 2010 Refinery Basic Operator Course

INFORMATION SHEET

8. If you a flushing the middle sample bleeder of
a tp sampler, you must
.

9. If you are flushing a sample bottle/clean, you
must
.

10. If a storage tank is not completely full, you
must

.

Module 5.6 February 2010 23

24 February 2010 Refinery Basic Operator Course

TEST ANSWER KEY

MAXIMUM: 100

OBJECTIVE 5.6.1

Directions: Circle the letter of the correct answer. (10 points)

1. Crude oil and refinery product samples are taken .

a. randomly
b. to keep a historical record of products
c. to ensure that lines and valves are not plugged
d. to help control the quality of refinery products

Directions: For questions 2 and 3 indicate whether you would use a high or low flash sample tag.
(6 points each)

2. For a sample of gasoline, you must use a 3. For a sample of asphalt, you must use a
flash sample tag. flash sample tag.

a. low a. low
b. high b. high
c. color cut c. inspection
d. water testing d. color cut

Directions: For questions 4–7 circle the letter of each correct answer. (9 points each)

4. If a confirmation of an earlier test is required, 5. If pumping approval tests are needed for a

the sample tag box is checked. tank, the sample tag box is checked.

a. PA a. pa

b. check b. check
c. schedule/unschedule c. schedule/unschedule

d. stock d. stock

6. If a mixed sample is taken from a tank, the 7. If sampling is required by refinery instruction,

sample tag is circled. the sample tag is circled.

a. top a. schedule
b. mid b. unschedule
c. bot c. avg
d. avg d. FST/ID

Module 5.6 February 2010 25

TEST ANSWER KEY

OBJECTIVE 5.6.2

Directions: Circle the letter of each correct answer. (9 points each)

8. If you need to take a product sample, you 9. If you are taking a crude or refined product

must . sample, you must .

a. close the sample line a. stand downwind to avoid vapors
b. pour water into the sample bottle b. never carry a cigarette lighter in your shirt
c. completely fill out the sample book
d. protect your skin and eyes pocket
c. completely fill the sample container
d. pour water into the sample container

10. A sample should never be placed in a Pepsi 11. A cork inserted in a sample bottle should be
bottle or other drink container because .
.
a. hammered in tightly to prevent leaks
a. the laboratory will not accept it b. taken from a similar product sample
b. someone might accidentally drink it
c. the soft drink will contaminate the bottle
c. washed thoroughly
sample d. new to avoid product contamination
d. the container will be too small

12. If you are manually sampling a sour crude oil 13. If you have taken good samples and tagged

tank, then you must . them properly, then you must .

a. wear a rubber apron a. deliver them to a laboratory for testing
b. wear wellington boots b. leave them at the sample deposit station
c. put on a canister type gas mask c. take them to the control room
d. put on a face shield d. hand them to your supervising operator

26 February 2010 Refinery Basic Operator Course

TEST ANSWER KEY

14. If you are tap-sampling at a sample box, then 15. If you want to flush sample bottles clean with

you must . product, then you must .

a. stand downwind a. rinse once
b. stand upwind b. rinse twice
c. stand directly in front c. rinse three times
d. stand 5 meters away d. rinse four times

16. If you want to make sure that the bottom line

of a tank tap sampling device is free from old

product, then you must .

a. flush for 15 seconds
b. flush for 35 seconds
c. flush for 45 seconds
d. flush for 60 seconds

Module 5.6 February 2010 27