Project Report
On
In
AT
GAIL (INDIA) LIMITED,
PATA,AURAIYA (U.P.)
Submitted By:
Aakash Mehta
U.I.E.T,Panjab University,Chd
Roll NO. UE129001
INDEX
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TOPIC
Acknowledgement
GAIL(Inida) Ltd, At Glance
Introduction
Fire and Safety
Sealing System
Gland Packing
Mechanical Seal
Mechanical Seal v/s Gland Packing
Classification of Mechanical Seal
Seal Arrangement
Selecting a Mechanical Seal
Failure of Mechanical Seal
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I owe a great many thanks to a great many people who helped and supported me during
the Project work.
Firstly, I would like to thank training department and especially Mr. P.K. Jain(CM training) for
providing me the opportunity as a vocational trainee in such a huge plant, equipped with
modern technology.
I express my sincere gratitude to Mr. Ajay Tripathi (DGM Mech),under whom I competed my
training program. I owe a sincere thanks to my mentor Mr. Dulal Gain(Sr. Manager) who helped
and supported me during my course of training.
I am also thankful to all the officers, supervisors and staff members for their cooperative and
helpful support for they spent their precious time with me to explain various objectives.
I also feel honored to be a part of GAIL India Ltd. that gave me the vast knowledge about cracker
unit and its different parts. It was a very nice and knowledgeable experienced for me to be a
part of GAIL India Lid. for this while. This experience is surely going to help me in the future.
Aakash Mehta
U.I.E.T, Panjab University,
Chandigarh
13,000 km of OFC network offering highly dependable bandwidth for telecom service
providers.
Joint venture companies in Delhi, Mumbai, Hyderabad, Kanpur, Agra, Lucknow, Bhopal
and Pune, for supplying piped natural gas (PNG) to households and commercial users,
and compressed natural gas (CNG) to transport sector.
Participating stake in the Dahej LNG terminal and the upcoming Kochi LNG Terminal in
Kerala.
GAIL has successfully commissioned LNG terminal at Dabhol in January13.
Established presence in the CNG and City Gas sectors in Egypt through equity
participation in 3 Egyptian companies: Fayum Gas Company SAE, Shell CNG SAE and
National Gas Company SAE.
INTRODUCTION
GAIL (India) Limited, PATA Petrochemical Complex is located in District Auraiya in Uttar Pradesh.
It is based on natural gas as feedstock from GAILs HVJ pipeline, which has been set up in
accordance with GAILs mission to maximize the value addition from each fraction of natural
gas.
The Plant consists of five major units i.e.
i) Gas Processing Unit (GPU)
ii) Gas Cracker Unit (GCU)
iii) High Density Poly-ethylene(HDPE)
iv) Linear Low Density Poly-ethylene (LLDPE) and LPG unit.
v) Integrated Offsite Processing(IOP)unit
HDPE and LLDPE are used by plastic processors to manufacture a large variety of products for
industrial, agricultural and domestic uses. The Plant also has an LPG recovery plant.
NAME OF UNIT
PRODUCT
CAPACITY (MTPA)
LICENSOR
GSU
SWEET GAS
12.66 MMSCMD
TFE(FRANCE)
GPU
C2/C3
3,97,000
EIL
LPG RECOVERY
LPG
2,58,250
EIL
GCU
ETHYLENE
4,46,000
HDPE
HDPE
2,00,000
MITSUI, JAPAN
LLDPE
LLDPE/HDPE
2,10,000
NOVACOR, CANADA
TENE-1
BUTENE-1
10,000
IFP, FRANCE
33444, 31444
Fire tetrahedron:
Principals of Extinguishing Fires Cool the fuel below its ignition point.
Remove the oxygen supply.
Separate the fuel from the oxygen.
Water
Foams
Inert gases
Chemical powders
Halons
Classes of fire:
5 classes of fire:
Class A- Paper, wood, textiles and rubbish. Water is used as extinguishing media, which
provides cooling effect.
Class B- Liquids, such as, alcohol, oil, grease, diesel, paints, etc. Dry Chemical Powder (DCP)
or Aqueous Film Forming Foam (AFFF) are used as extinguishing media. They cut the oxygen
supply.
Class C- Gas fire, like fire in LPG, LNG. Water can be used or DCP can be used for extinguishing
the fire.
Class D- Occur in certain metals like magnesium, sodium, potassium, titanium or zirconium.
Special DCP is used for extinguishing purpose.
Class E- Electrical fire CO2 or DCP can be used. Foam or water should never be used for
extinguishing electrical fire.
fire or provide exposure protection to prevent domino effects. It includes agents like water
sprays, foam and DCP. It includes:
Hydrocarbon detection system like LEL or gas detectors.
Fire alarm system like automatic fire and alarm system, manually operated fire alarm
system, emergency sirens or pagers.
Fixed fire protection system like:
Water based fixed fire fighting systems like fire water network, deluge valve, hydrants,
monitors etc.
Non water based fixed fire fighting system like CO2, environment friendly clean agent
flooding systems, DCP system etc.
Deluge sprinkler system: Its main purpose is to keep vessels and structural steel cool by
application of water via sprinklers to the entire fire area.
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2. Passive Fire Protection System- They are designed and installed at the time the plant is built
and remain passively in place until needed. For e.g. insulating material or fireproofing that is
applied to steel structural members and equipment supports in the plant.
Types of Siren:
Depending on the severity of fire, there are 3 types of siren1. For small fire- No siren.
2. For large fire- Siren is blown 3 times for a total time period of 2 minutes. Each siren is blown
for 30 seconds continuously and after a gap of 15 seconds, siren is blown again for 30
seconds.
3. For disaster- Siren is blown for a total time interval of 2 minutes. Each siren is blown for 30
seconds at an interval of 30 seconds.
Whenever there is any disaster or fire, first report about the incident to the fire and safety
department or the areas control room. Tell about your identity, location of disaster or fire
and the type of emergency. Then move to the nearest ASSEMBLY POINT.
Assembly Point:
Assembly point signifies the areas of safety where persons should assemble in the event of an
emergency or fire.
1. GLAND PACKING SEALS These seals are not 100% leak proof Therefore, these types
of sealing systems are used where handling fluid is non-hazardous and low cost like water.
2. MECHANICAL SEALS These seals are being widely used in process industries and almost
100% leak proof.
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Ensure that all the old packing is removed and the stuffing box is clean and free from
foreign matter.
Always re-pack with new packing.
Choose packings recommended for the fluid to be contained.
Select correct size of packing to fit the stuffing box dimensions.
Wrap packing on the shaft and cut into rings of correct size.
Fit each packing individually by tapping or with split sleeves.
Stagger joints in consecutive packing rings.
Fit gland follower and check that the shaft rotates freely.
Tighten gland nuts evenly with spanner until the packing "drags" when turning the shaft
by hand.
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The following recommendations are general for the selection of suitable dimension:
Shaft Ranges
Width of packing
16 to 28 mm dia.
8 mm
30 to 46 mm dia.
10 mm
50 to 75 mm dia.
12.5 mm
75 to 120 mm dia.
16 mm
19 mm
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2) Mechanical Seal
A mechanical seal is a device that helps join systems or mechanisms together by preventing
leakage (e.g. in a plumbing system), containing pressure, or excluding contamination. The
effectiveness of a seal is dependent on adhesion in the case of sealants and compression in the
case of gaskets.
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SEAL ASSEMBLY
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Mechanical Seal
Multiple Seal
Single Seal
Inside Seal
OutSide Seal
Double Face to Back
Tandem
M
Staged
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SEAL ARRANGEMENTS
Seal arrangements can broadly classified as
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Tandem arrangement
Back to back arrangement
TANDEM ARRANGEMENTS
When two seals are arranged facing in the same direction then the mechanical seals
arrangement is called Tandem seal arrangement.
In tandem mechanical seals the outer seal is flushed with compatible fluid at lower
pressure then stuffing box pressure.
Inner mechanical seal always take higher pressure.
As per API 610 the outer seals must be able to with stand full pressure as well in the event
of inner mechanical seal failure.
This arrangement is used for very high pressure application as well as a safety for some
dangerous or cry genie fluids.
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This arrangement is also used for abrasive media and media that contain substances in
solution which crystallize and deposit cause wear of sealing faces and reduce seal life.
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Temperature
The elastomeric parts of the seal must be able to withstand the temperature of the
medium around the seal. This might be different from the temperature of the pumped medium.
If the temperature is above the boiling point of the pumped medium, lubrication is poor. This
must be considered when selecting seal design and materials. Sealing pressure The sealing
pressure is the pressure around the seal. For high pressures, a balanced seal should be used.
Shaft speed of rotation
If the speed of rotation is low, shaft seals with hard/hard material pairings might
produce noise because the lubricating film in the seal gap is extremely thin. At speeds
above 15 m/sec, a balanced seal with a rotating seat must be used to reduce seal
unbalance.
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CAUSES OF FAILURE
High Temperature
Too much heat in the system may present some of the same evidence as chemical attack.
As the temperature rises the o-ring seal may soften. As the temperature continues to rise
beyond the orings temperature limit, the rubber seal will harden and maybe crack. You must
know the temperature limits (upper and lower) and the chemicals they are compatible with.
Pressure
Pressure is actually linked with the temperature and the tolerance. The pressure that an
o-ring can seal is a function of the temperature of the application and the tolerance (extrusion
gap) of the containment groove. You can seal 100 tons of pressure if you can control the
extrusion gap and the temperature
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