PetroVietnam University
Petroleum Department
------------
INTERNSHIP REPORT
Internship Unit:
Student:
July 2015
Bo Co Thc Tp Sn Xut
THANK YOU
First of all, it is my sincere thank-you to the leadership board of PVEP who has
offered me the production internship from 6th July to 31st July 2015. I want to say a
very thank you to everyone in development production board, who has been help me
alot and especially my internship instructor at PVEP- Doctor Hoang Xuan Vu (PVEP
senior production engineer) who has been very supportive and Mr Tran Van Ban (
PVEP development production board manager in HCM city) , they helped me a lot for
the comprehensive understanding related to production problems, also willing to share
with me his experiences to work as a production engineer which is very helpful to me
in the future. Not only Mr. Vu, but all of the staff at production board of PVEP have
also supported me a lot in having more reading materials in the field, also having an
orientation for my graduation thesis in my final year of university. I have to say that
Ive had a great time here to get experiences as if I am an already production engineer.
It is my truly honor to work in such a professional environment and with such
enthusiastic and friendly people. Besides, I also send my thank-you to Miss Le Hai
Linh my lecturer at Petro Vietnam University, who is in charge of my internship
during the time I had worked at PVEP, Mr Hoang Thinh Nhan-Vice-Dean of
Petroleum Department of PetroVietnam University, who has introduced and made my
internship procedures available. Finally, thank you very much!
Ho Chi Minh City
30th July 2015
Student: Tran Xuan Truong
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PVEP INTRODUCTION
PVEP has been having a long tradition and the key unit of PVN in the oil
exploration and drilling in years. The process of establishment and development of
PVEP has associated with the oil history of Vietnam over the past fifty years.
Originating from companies of Petrovietnam II (PV-II, established in 5/1988) and
Petrovietnam I ( established in 11/1988), PVEP has many times changed its name and
structure to suit with different periods of development. In 1993, PVSC and PVEP were
established through reconstructing PV-II and PV-I, this was an important milestone to
mark one stride of Vietnam oil industry in effectively manage oil drilling and
exploration operations in Vietnam, also participating in both domestic and overseas oil
activities as an oil contractor in order to develop into a real oil company step by step.
The birth of PIDC based on PVSC in 2000 was a historical milestone for the
development of present PVEP with PIDC boosting investment, joining capitals into
domestic projects, getting first successes in controlling crucial exploration projects by
itself along with deploying overseas projects through joint projects with Iraq, Algeria,
Malaysia, Indonesia.
PVEP is established in 4th May 2007 based on the combination of oil exploration
production company and oil investment-development company in order to reunite the
business and production activities in domestic and overseas.
Inheriting the accomplishments and experiences from precursor units, PVEP has
drastically developed and reaped lots of successes in the oil exploration and production
field. In the period of 2007-2012, PVEP exploited more than 40 million tons of oil and
condensate, 36.5 billion m3 of gas, announced the 27 oil explorations and put the new
16 reservoirs into production. The revenue during this period reached over 171.000
billion of Dong, submitting 59.000 billion of Dong for state budgets. Continuing the
role of pioneer unit of PVN in global economic integration, PVEP is now taking part
in tens of projects over 14 countries. By which some reservoirs of Cendor, D30 in
Malaysia and accelerating the production activities in Peru, Algeria,The
accomplishments of PVEP along with PVN has significantly contributed to secure
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national energy security, control the macroeconomics as well as the island sovereignty
of Vietnam.
1. Duties and functions of the boards
The boards have common functions as consultant to help the board of directors and
board member in the management and administration activities of the company
Taking responsibility to resolve work related directly to each department.
Participate in helping to resolve work of other department if relevant or when to be
asked
Support the implementation and monitoring of implementation, the project's operating
subsidiaries or unit members.
Building regulations, workflow process to ensures consistent and in accordance with
the provisions and the general operation of the company. Taking responsibility to
construct the statutes, policies, internal regulations of the company relating to the field
of activity of the board.
Building strategies, short, medium and long-term plans for the company.
Direct manage worker, salary, proposals awards, discipline for staff.
Ensure the principle of democratic concentration for each board, collective stick
construction group reviews, develop the capacity to work of the employee.
Report on activities of the department in time prescribe and irregular reports as the
bridge of the leadership Of the company, annual summary reports on field operations
of the board.
2. The mainly production activities and business of the company
Exploration and exploitation of oil and gas of PVEP currently vibrant take place in
both domestic and abroad. In the country, PVEP exploration activity in some places
include red river base, Phu Khanh base, Cuu Long base, Nam con son base, Malay
Tho Chu base. PVEP are projected in 13 countries of the region have the potential gas
oil in the Middle East, North and Central Africa, Latin America, South-East Asia.
2.1. The exploration
PVEP has built the target exploration strategic both in domestic and aboard according
to the period of 2011-2015. Striving for increase in capacity both at home and abroad
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are 120 million tons of oil and fiend recovery period 2016-2025 and reached 200
reserves increase million tones of friend recovered oil.
2.2. Domestic exploration
The price of oil suddenly falling from 112 USD per barrel in June 2014, down to under
60 USD per barrel (mid-December, 2014), it record lowest level in the past 5 years,
plus the fluctuations in economic both in domestic and foreign countries has directly
impact on PVEP's activities.
In Vietnam, PVEP's business must face the hard difficult due to the tense situation on
the East Coast, some of the main mine are on the momentum of decline production of
small mines, mostly in deep water offshore areas-where always contains risks and
complex geology.
In the region has the potential of oil and gas has been proven to have high potential,
little risk, PVEP involved up to 100% of the shares or holds dominant stakes and direct
executives, especially in the Cuu Long base, Nam con son base, Red river base. In
addition, PVEP continue to study the subjects of traditional African exploration (nonstructural traps), study of the hot new deposits and new resources such as coal, gas,
shale gas ice fire.
2.3. Foreign exploration operations
Along with that is the fierce competition in the international oil and gas operations
makes the expand investment of PVEP met many obstacles. Moreover, the field of
investment in some countries have projects of PVEP continued negative changes.
PVEP actively invests on the principle of economic efficiency in order to offset the
lack of output shortages in the country and contribute to ensuring energy security for
the nation's economy.
In the period of 2015-2020, PVEP will select the potential areas with highly of oil and
gas, favorable political relations and cooperation with other oil and gas companies.
PVEP focuses on investments in the key areas of potential in Southeast Asia, Africa,
the Middle East, the countries of the former Soviet Union and Central/South America.
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3. Production activity
According to the plan signed with PVN, PVEP's reserves increase during the year
2015 from 18 to 23 million tons of oil, the rules produced 5.86 million ( 4.71 million
tonnes of oil and 1.15 billion m3 of gas ), planning to produce three new field and
take signed 1-2 new contracts. However, due to oil price fluctuations, PVEP has
proactively reviewing and adjusting the project to match with the actual situation (cut
off 6 wells in home, three wells in the foreign, reduced investment of 480 million
USD, equivalent to 29%compared to the plan). PVEP also successfully reduced
operating costs, production (OPEX) down on the under 13%.
In the period 2012-2015 the total output of oil and gas extraction is expected on the
conversion 130 million tons and in the period 2016-2025 the total output of oil and gas
exploitation project above 400 million tons.
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INDEX
CHAPTER I: PIPELINES ............................................................................................... 1
1. Pipelines ................................................................................................................... 1
2. Design Factors .......................................................................................................... 1
CHAPTER II: WELLHEAD ........................................................................................... 3
1. Wellhead Equipment ................................................................................................ 3
1.1. Xmas tree ........................................................................................................... 3
1.2. Down Hole Safety Valve ................................................................................... 4
2. Routine Operating Checks and Maintenance ........................................................... 5
3. Developing an Oil Field ........................................................................................... 5
4. Deviated Drilling ...................................................................................................... 6
5. Completing a Well ................................................................................................... 7
CHAPTER III: SEPARATOR ........................................................................................ 9
1. Objective .................................................................................................................. 9
2. Separation ................................................................................................................. 9
3. Flow patterns .......................................................................................................... 10
4. Separator Construction ........................................................................................... 11
5. Principles of separation: ......................................................................................... 12
6. The Separation Process: ......................................................................................... 12
6.1. Physical Separation .......................................................................................... 12
6.2. Flash Separation ............................................................................................... 12
6.3. Inlet Separation ................................................................................................ 12
6.4. Secondary Separation (Quieting Sections) ...................................................... 12
6.5. Residence Time ............................................................................................... 13
7. Separation and stabilisation PFD ........................................................................... 13
7.1. Separation Trains ............................................................................................. 13
7.2. The Ideal Separator .......................................................................................... 13
8. Separation systems ................................................................................................. 14
9. Reservoir to Process Train ..................................................................................... 14
10. Cooling after the final stage of separation: .......................................................... 15
11. Separator Instrumentation .................................................................................... 15
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LIST OF TABLE
Table 6. 1 API Flange Temperature to Pressure Rating..........................................................................31
Table 6. 2 API Flange Test and Working Pressures. ...............................................................................31
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CHAPTER I: PIPELINES
1. Pipelines
Pipelines are the most common way of transporting oil or gas. Pipelines are like any
flow line except that pipelines are
Very long.
As straight as is possible.
Are welded (continuous).
Have no sharp bends.
Are often buried or inaccessible over the majority of their length
Require regular cleaning and inspection.
Are often very cold due to depth of water resulting in condensation and corrosion.
2. Design Factors
The design factors of the pipe line which must be considered are
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Heavy Crudes: Some crude oil with very high pour points or high wax content require
pipelines of special design or treatment to meet following needs such as
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4. Deviated Drilling
Deviated drilling allows a single structure to reach the furthest expanses of the
reservoir
Subsea Completions can also be tied back to the platform from outlying traps,
and secondary reservoirs
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5. Completing a Well
The well completion consists of decreasing diameters of tubing, each one drilled
deeper into the formation and cemented in position.
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3. Flow patterns
The flow in vertical and horizontal separators is similar
A mixture of fluids enters at the side or end of the vessel
Lighter components exit from the top (gas)
Denser (heavier) components exit from the bottom (oil & water)
A three-phase Horizontal Separator uses a weir or stilling pipe to segregate the
heavier components into two streams.
The weir acts as a barrier and holds the water phase behind it
The oil floats on the water and cascades over the weir
The weir acts as an interface (between oil and water) level control
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4. Separator Construction
Separators are made of steel, and built according to rigid engineering specifications
All seams are welded
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Coalescing
Chemical injection
The number of crude oil separation trains and the number of stages (separators of
decreasing pressure! temperature) varies with each installation. The principles of a
two-stage process apply equally to a four-stage process.
7.2. The Ideal Separator
An ideal separator reduces the pressure of thereservoir fluids to near atmospheric
pressure at the discharge of the separator . In practice, this s rarely possible because
the crude mixture would foam uncontrollably (like a champagne bottle opening) and
the best approach is to use multiple stages, which reduce the pressure gradually - in
stages.
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8. Separation systems
Separators are located downstream of the wellhead Xmas tree, choke, and manifolds
They provide the following services
Clean up completions
Test individual wells
The majority of separators offshore are three-phase separators.
The main difference between three and two- phase separation is the weir plate which
separated liquids, and the additional instrumentation needed to control an additional
interlace
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Level Control
Liquids under level control follows the same path regardless of the condition of the gas
compression. Level control is accomplished by use of a level sensor, and a transmitter
acting on one or more control valve
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Centrifugal pumps are generally used for lower pressure, higher volume applications.
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Head is the difference between the suction and the discharge pressure. Net Positive
Suction Head (NPSH) = The required head of fluid to flood the suction inlet and
prevent vapor locking.
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Chapter V: Compresser
1. Objective
Principles of Gas Compression
Method of Gas Compression
Types of Gas Compressor
Problems of Gas Compression
Lubricating System of Compressor
Interstage Cooling System of Compressor
2. Definition
2.1. Gas
Is a matter, which has loosely bound molecules, and these molecules freely occupy
any amount of space
Gases can be compressed into a required volume or density and can be compressed to
a liquid state. Gases flow from higher pressure to lower pressure to find a balanced
state.
2.2. Water Content:
The amount of water contained within the gas usually measured at a certain pressure
and temperature (dew point)
2.3. Dew Point:
Is that temperature when the first drop of liquid condenses from a vapor
Operating Temperature: Required temperature to prevent liquid dropping out or
forming in the gas.
2.4. Cricondenbar:
The maximum pressure at which vapor and liquid may exist in equilibrium
2.5. Compression Ratio:
Compression Ratio (CR) is the ratio between the suction pressure (Absolute) and the
discharge pressure (Absolute) of a compressor.
Absolute Pressure:
Pressure measured by the pressure gauge + approx 15 psi
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Absolute Pressure, the pressure exerted by the atmosphere s not included in the
Gauge reading.
Therefore, atmospheric pressure is added to the gauge reading to convert in to
an Absolute Pressure.
These common conversion values are used to calculate Absolute pressure: psig
(pounds per square inch gauge) = 14.7 psia (pounds per square inch absolute), kPag
(kiloPascals gauge) = 101 KPaa (kilo Pascals absolute). 1 barg (bar gauge) = 0 bara
(bar absolute), 0 bara (bar absolute) = -1 barg (bar gauge)
3. Methods of Compression
A gas compressor is a mechanical device that takes in a gas and increases its pressure
by squeezing a volume of it into a smaller volume. Usually this is done in several
stages. Below is a two-stage compression system.
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By Centrifugal Compressor:
Centrifugal Compressor imparts energy in to gas flow, by increasing the velocity of
the gas then changing the velocity to pressure. These compressors are used where
higher flow rates and volumes of gas is required, but at lower pressures.
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Reciprocating Type :
Connecting Rod
Piston
Crosshead
Cylinder head
Piston Rod
Cylinder
Suction Valves
Discharge
Suction Inlet
Discharge Valve
Packing
Wrist Pin
Crankshaft
5. Double-Acting compressors
Double-Acting compressors compress on both strokes of the piston.When multistage
machines are used, they are frequenUy cooled between the stages.
6. Lubricating System
The purpose of the Lubricating System is to: Create an anti-friction film between
moving surfaces
Reduce metal wear
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7. Interstage Cooling
Interstage cooling is necessary to protect the compressor from damage and to make the
compression process more efficient. Lnterstage cooling principles apply to both types
of compressors, (reciprocating and centrifugal) and has the following advantages:
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Main (Journal) Bearings: Maintain the rotor assembly n its correct position,
especially when load or speed parameters changes.
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Compression Ratio
Volumetric Flow Rate
Pressure & Flow Characteristics of the System
Attached here is a stage table of compressors to give comparative study between the
number of impellers in use, increase in temperature and power consumption.
10. Compressor Controls
The following types of drivers used to drive Compressor
Gas or Steam Turbines
Variable direct voltage Electric Motor
Variable alternating current frequency Electric Motor
Fixed Speed drives
Diesel Engines
Safety Systems and Controls
Compressors are usually controlled locally by Programmable Logic Controller
(PLC) or computer systems.
Critical signals from the Local Control Panels (LCP) are copied to the Central
Control Room displays for appropriate action.
Manual start-up and shut-down procedures must be followed carefully
Built-in protection systems contain, pre-lubricating and post- lubrication cycles
to protect bearings when cooling and heating.
In case where electrical lubricating pumps fail, gravity fed lubrication is
provided for back-up protection of bearings and shafts.
Additionally, the compressors will not start without certain recommended
permissive achieved: for instance lub oil temperature.
Centrifugal Compressor Problems
11. Problems and solution
Two main operating problems : Surge and Stonewall
Surge occurs when the compressor s operated at below its minimum capacity at
particular speed. It undergoes supply starvation and cannot provide sufficient
discharge pressure. The result is that reverse flow occurs. This reverse flow then
increases the discharge pressure and flow resumes forward, dropping the inlet pressure
once more. The cycle repeats rapidly and vibrations increase greatly. If the surge is not
controlled quickly, it can cause extensive damage to the compressor. Refer to
compressor operating curves for the comparative study.
Solution: Antisurge control.
Surge is an unstable operating condition, it is controlled by the recycling gas from the
discharge of the compressor and fed in to suction side of the compressor and this
maintains a minimum flow through the compressor
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The number of the series relates to the maximum working pressure expressed in psi at
a temperature of100F.
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Temp F
API 2000
3000
5000
10000
15000
100
150
200
250
300
350
400
450
2000
1964
1928
1892
1856
1820
1784
1748
3000
2946
2892
2838
2784
2730
2676
2622
5000
4910
4820
4730
4640
4550
4460
4370
10000
9820
9460
9280
9100
8920
8740
8560
15000
14730
14460
14190
13920
13650
13380
13110
For flanges less or equal to 14 diameter, the hydrostatic test pressure is 2 times the
maximum working pressure (MWP).
For flanges of equal or more than 16 diameter the hydrostatic test pressure is 1.5
times the maximum working pressure (MWP).
Table 6. 2 API Flange Test and Working Pressures.
Series API
Max WP psi
2000
3000
5000
2000
3000
5000
4000
6000
10000
3000
4500
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1.3.1. Torque
The use of torque is the most widespread throughout industry. Torque can be achieved
through manual means, such as:
Flogging spanners, torque multipliers, or hydraulic, air or electric powered wrenches.
Torquing is the area where most mistakes are made
1.3.2. Tension
Tensioning Tools are usually hydraulically powered and used for multiple or simultaneous
tightening of bolts.(The bolt is stretched and then the nuts are added). They are more accurate
(if maintained properly) than using torque since friction factors are not involved.
New bolts should be used and not retightened ones.
1.3.3. Heating
Bolt heating is a specialised process and often used by the Power Generation Industry
for tightening turbine-casing studs. The studs have a pre-drilled hole down their centre
into which an electrically powered heating element or wand is introduced.
1.3.4. Differences between Torque and Tension
Torque
2. Flanges
2.1. Type of glanges
Below are typical bolt tightening sequences for flanges. Bolts are numbered in a
clockwise direction. The correct sequence prevents misalignment of the flanges and
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ensures even energisation of the gasket seal across the flange gasket face.
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Correct numbering of bolts should result in all odd numbers on one side of the flange
and even numbers on the other side.
2.2. Flange Bolt Tightening Sequences
Tightening should be carried out in a minimum of four passes.
Passes 1-3 following numbered bolt sequence.
Pass 4 tightening adjacent bolts all round the flange.
If using a Torque Wrench:
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Flat non metallic gasket are used and fitted within the bolts of the flange.
Faces should be clean but do not score the face when cleaning.
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Manual (local)
Pneumatic (remote)
Electro hydraulic (remote)
Chokes are located downstream of the wing valve on a xmas tree and are used
to reduce pressure and absorb pressure differential.
3.4.1. Erosion
3.4.2. Cavitation:
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2. General
The aim of this section is to try and understand what the chemicals are doing and how
they act and interact.
2.1. Solids Deposition
Solids depositions cause hydrate, wax, asphaltines, and scale which results in
equipment plugging, downtime, damage to the equipment and additional costs or
penalties
2.2. Formation Of Emulsions
Emulsions and foam results in high viscosities and separation problems Interfaces
During Operation stages Interface s maintained between
2.3. Solids Deposits
Prevention & Reduction of Solids Deposits are carried out by following methods
3. Control
3.1. Gas Hydrates
Chemical Inhibitors
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Temperature/Pressure
Depressurisation
Chemical Treatment
Completion Design
Fraccing/ Polymers
Separation
Mechanical (Pigging)
Chemical Inhibitors
Mechanical (Pigging, Scraping]
Squeeze treatment
Chemical Inhibitors
Temperature Management
Mechanical (Pigging, Scraping)
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The Graph Shows The Effect Of Adding Methanol In Various Dose Rates.
4. Hydrate Prevention:
Some hydrocarbon components will solidify or liquefy when the pressure and
temperature are reduced. This reduction occurs when the fluid flows from a hot
reservoir to the colder surface. Wax is a very common problem and it coats the insides
of pipes and pressure vessels.
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Wax/paraffin Characteristics:
Ashphaltenes are hard pellets of hydrocarbon material formed when pressure drops.
They appear when reservoir pressure is below bubble point due to change in crude oil
composition they create problems usually in reservoir or well bore (Treated by scraper
intervention, and soaking with solvent benzene I xylene)
Figure 7. 4 Asphaltenes
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Scale is a term loosely applied to the mineral salts which have precipitated from
an aqueous (water) solution and have been deposited on the surfaces of
production pipe work, vessels and other equipment.
Accumulation of such deposits can restrict flows through control valves,
exchangers, flow straighteners, and isolation valves. Scale can also restrict the
performance of metering systems, pumps and rotors.
Sulphate scales are deposited due to incompatibility of waters, e.g. injected
seawater / aquifer water
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CONCLUSION
The one-month internship at the development production board of PVEP has given
me the overview about typical jobs of a production engineer. In which, Ive managed
to delve into fundamental knowledge for a production engineer such as pipelines,
wellhead tools, separator, pumps, compressors system..ect. Although, I am still yet to
practice these jobs in reality. However, its wonderful to have some knowledge
relating to production management as a senior production engineer by which Ive been
taught how to read a production report or a daily production report as well as suggest
solutions to effectively and promptly solve the emergencies. Most importantly, the
instructor gave me orientations for the graduation thesis that is suitable with my
capacity and interest as well as introduced me useful information for job applications
in the future.
As said above, this internship has helped me orientate the graduation thesis in the
next year of 2016. Therefore, I very expect to get supports from leadership board of
PVU for an appropriate internship place in the future so that I could have a successful
graduation internship and thesis , making first premises for successful job applications
and further career development.
Eventually, thank you very much to all who have supported me during this
internship. I tried my bests to complete this report reflecting what I had done and
learned, shortcomings are inevitable though. It will be very helpful to me to have your
sincere remarks and assessments, so that I could have better preparations for the next
one.
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