Welcome
To
To
Mechanical
Mechanical
Maintenance
Maintenance
Mechanical Maintenance
M e c h a n ic a l M a in te n a n c e O r g a n o g r a m
B .C .S h u k la
V P (M )
T .V .S u j i t K .S .K o p p a l k a r
G M (M e c h M a in t) G M ( M .P la n .)
1 nos
H .P .P a i K .S iv a s u b r a m a n i
D G M (M e c h ) H a r is h D a m o d a r
A d a rsh G A
T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s
The Works
Shutdown ARCs
Fabrication
Scaffolding
Insulation
Stress Reliving
Furmaniting
Painting
ARC continued
Fire hydrant Maintenance
Maintenance of Sarpady
ARC for Exchanger Maintenance
ARC for Boiler related jobs
Tank Cleaning
Specialist services:
Like epoxy coating/Foam seal for Floating roof
Refractory jobs
Operation of BDFU
Removal of sand for filters in WWTP
Other ARCs
Other major ARCs
Rotary Maintenance
Bearing
Seals
Lube Oil
Coupling
Belts
Shutdown Maintenance
Routine Maintenance
Includes
Rotary jobs
Jobs with Static Equipment
A sneak preview of our Work Management
Type B Front
Stationary Head
A:One tube Side
B:Two tube side
C:Four tube side
Type C front Stationary
head
A:One Tube side pass
B:Two tube side pass
C:Four tube side pass
Type N
Front stationary head one
tube side pass
Type D
Front Stationary head
Type E shells
Type X shells-cross
flow
Rear head type L,M,N
Seat/Disc
Orifice
Convection
Radiant
Burner Block
Burner Details
Burner repair and Maintenance
Major Jobs In heaters:
Inspection Jobs-Support
work
Spalling/Steam Air Decoking
Burner repair/maintenance
Refractory maintenance
Tube repairs
Support repairs
APH wash/Repairs
Modifications like replace
peep doors
A brief on Refractories
RefractoryJobs
Refractories are made of material with low thermal conductivity
Mainly classified as
Acid
Basic
Neutral
Used as
Brick Type
Dense Type
Insulating Type
Monolithics
Insulating Castable
Dense Castable
Ramming material
Plastics
Globe Valve
Gate Valve
Hig volume/change in
UniDirectional flow
flow when opening or
closing is less
Major Jobs associated with valves
Welding:
Different Welding Processes involved
Arc Welding
Gas welding
Electric Resistance welding
Plasma Transferred Arc Welding
Electron beam Welding
Different Arc Welding Processes
Arc Welding:
An electric arc is established between an
electrode and work piece
Electric arc releases Thermal energy which
heats the joint to be welded
Some of the widely used processes are:
Shielded (manual( Metal Arc Welding
Tungsten inert gas Welding(TIG/GTAW)
Gas Metal Arc Welding (GMAW/MIG/MAG)
Flux Cored Arc welding(FCAW)
Submerged Arc welding(SAW)
Most widely used welding process in
the Refinery
Electrode:
Solid metallic wire-called core wire
Coated with flux
25 to 40 mm left bare at one end for grip
of electrode holder
Striking end-is left exposed to facilitate
arc striking
TIG welding
Tungsten Inert gas Welding:
TIG:Electric Arc Stuck between Work
piece and Non Consummable Tungsten
electrode.
Arc and Weld Zone is protected by an
inert gas(argon/Helium or a mix)
Filler materila is added externally to the
arc in the form of a bare wire
HF(High Freq )Unit generates HF High
Voltage is superimposed on the Weld
Current
Gases are ionised and free element forms
a conducting path between job and
electrode
Therefore no direct contact is necessary
between job and electrode
Tankages
Floating Roof
Fixed Roof
Spheres
Tankages
Inspection jobs
Failures-Repairs
Preventive maintenance
Mixers
Type Of Mixers
Sachony/jet mixers
Painting/prevention of corrosion
Recalibration of Safety valves in spheres
Servicing roof vents/valves/PVRV
Cone Roof Tanks
Floating Roof Tank
Major Jobs in Floating roof tanks
Major jobs
Hydrotest of
Foam tenders
Emergency roof Drain
Steam coils
Service Valves
Major Repair work
Foam Seal
Weather Shield
Bottom plate/test with vacuum box
Tank Pad
Pontoons
Jetty/BDFU/ETP
Jetty
Maintenance jobs with Loading Arms
BDFU:
Rollers and conveyors
Handling Drums
Exchanger maintenance
ETP
Various conveyors/skimmers
Maintenance of storage area-Ponds
Filters
Rotary/reciprocating equipments
ROTARY MAINTENANCE
Major Rotary Maintenace
Pumps
Compressors
Fans
Transmission devices
Turbines
Rotary Maintenance
Rotating machines-1610(Excluding Projects)
Pumps-1076(so we need to discus in greater detail)
Compressors 42
Fans 426
Field maintenance
All rotary<Recip equipments <1 MW
Critical Rotary Group
All rotary /reciprocating machines >1 MW
Machine that Can lead to Plant Shutdown
Condition Monitoring group
Philosophy followed Predictive Maintenance
Pumps Fundamentals
Centrifugal Pumps:
Provide s high s Kinetic Energy and converts To Pressure
discharge!
Fundamentals of Pump
Operations
BEP
Pumps Based on types of impellers
Based on const
Closed:Liquid is
clean/High Pressure
Semi Open:Incl of solids
Open:Mainly slurry appln
Based on Design:
Radial:High Pr Medium
Flow
Mixed:Medium Pr Very High
Flow
Axial:Low Pr High Flow
Centrigugal Pumps-parts maintenance
Criteria
1 Suction
Typical Centrifugal Pump 2 Impeller
3 Discharge
4 stationary Casing
5 Rotating Shaft
3 6 Mechanical Seal in Stuffing Box
7 Gland
8 Radial & Thrust Bearings to Support the Shaft
8 Must be lubricated at all times.
2 4 7
1 5
6
Centri Fugal Pump-Multistage
Pump
Single Stage Double Suction Pump
Multistage
Multistage
Barrel Type
Axially Split
Reactor Charge Pump
Barrel Type
Sundyne Pumps
Low Flow
High Pressure
NPSH avble is low
Mainly used in
Naptha or lighter
ends
Vertical Pumps
Major Jobs:
Impeller
Shaft damages
Bearings
Seals/Gland
replacement
Most Critical sometimes
as its used for handling
slops
A little Deeper into Pumps
Mechanical Seals!!
A continual improvement commitment
of
Mechanical Engineers!!!
Mechanical Seals By Arrangement
Single Multiple
Rotary Stationary
Typical Seal Arrangement and their
leaking places
Gasket hang-up occurs when solids build-up sufficiently to impede gasket movement.
The springs closing force is disrupted and heavy leakage soon develops.
Some types of Seal arrangement
The secondary seal does not have to move along the shaft or sleeve to
maintain face contact
API Plan 11
ANSI Plan 7311
API plans
Recirculation from Seal Chamber to Suction
Single Inside Seal
API Plan 13
ANSI Plan 7313
Api plans
Bypass Flush through Heat Exchanger
Single Inside Seal
API Plan 21
ANSI Plan 7321
Api Plans
Recirculation through Heat Exchanger
Single Inside Seal
with Pumping Ring
API Plan 23
ANSI Plan 7323
Api plans
External Flush
Single Inside Seal
Close
Clearance
Throat
Restriction
API Plan 32
ANSI Plan 7332
Api Plans
Flush and Quench
Single Inside Seal
API Plan 52
ANSI Plan 7352
Positive Displacement Pumps
Major Jobs Associated with
screw pumps:
Replacement of screws
Bearings
Timing gears
Preventive maintenance
Metering pumps
Metering Pumps
1-Suction
2-pressurise to discharge
pressure
3-Valve opens-ideal case no
pressure loss
4-gas trapped in clearance
volume expands
Types of compressors
Single-Acting
suction
side
delivery
side
drive cylinder
Double-Acting
suction side
end
head end
crank
drive cylinder
To understand Double acting
General Arrangement
Cylinder
Distance Piece
Frame/Crank
Case
Major Parts
Unloading cylinder Suction duct
Unloader Valve cover
Piston
Piston rings
Cylinder head
Crank shaft
For Further clarification
Crank Shaft Connecting Rod
Major Elements
Piston Rings
Seal the compression chamber
between the piston and the liner
Rider Rings
Support the weight of the piston and
half of the rod weight,
but should not seal gas pressure.
Packings
Double Double
Acting Distance Crosshead Crankcase
Cylinder Piece
Task and Types of Wiper Packings
Double Double
Acting Distance
Cylinder Piece Crosshead Crankcase
Main Pressure Packing
Seals the inboard compression chamber to distance piece
in the area of the piston rod. Can be lube or non lube.
Pressure range from vacuum to 3000 bar.
O-Rings Piston rod
Cups or Containers
Flange
Purge
inlet
Tie rods
Ring sets
Flange bolts
and nuts Cooling Design example
Intermediate Packing
Intermediate Packings seal the first distance piece
to the second distance piece in the area of the piston rod.
Usually they are not lubricated and not water cooled.
Flange bolts
and nuts Piston rod
Cups or
Containers
Purge (plugged)
Tie rods
Design example
Function of Pressure Packings
Seal gas or oil
in compression chamber
in intermediate piece
lateral
axial
piston rod
Function of Pressure Packings
garter springs
seal rings
piston rod
to distance
Nitrogen piece vent Nitrogen Dangerous
gas
Piston movement
rod
Crank oil
Crankcase
side
Distance oil
piece side
Barrel
Axial Split
High volume Medium High volume High Pressure
pressure
Major Jobs so far on Centrifugal
Compressors
Seal replacement
Bearing replacement
Lube Oil
Turbines
Bearings replacement
Lube Oil changes
Major Overhaul done in STG5 in 2004
LP side blades repaired
Labys were replaced
Turbine blades were repaired
Inspection of HP/LP controlled extractions
Hydraulic Setup
Maintenance of Governors
Over speed test
Most used Transmissions systems
Coupling
Major Jobs associated with couplings
Person Item
Arun H R Gaskets(Exchanger )
Satish.S Shafts
Mahesh Seals
Arun Kulkarni Bearings
Sunil K Impellers/Pump
assembly
Our Commitment to Quality
ISO 9001 what we are looking into?
Quality Objective:
Failure without Notice less than 5% of installed rotary equipments
No repetitive failures
Continual Improvement:
Improve Seal Life
Present average:5 yrs
Standarised on only two vendors
Troubleshoot intensely on failures
Improve Bearing Life
Present average:5 yrs
All bearing failures undergo Analysis
Best in the refineries across India
Standardized Bearings
Life Force of any moving part
Lubrications
Help us to Help You!!!
Maintenance Planning
Civil Maintenance
Raw Water Pumping Station
Computation & control of Revenue & Capital Budgets
Contractors bill certification
Allocation of centralised services such as Insulation,
Scaffolding & On line sealing
Shutdown Planning
Co-ordination with other depts.
Insurance claims
Monthly Reports
Brief on Raw Water Station
Located in Sarpady
The pumping station consists
weir across a river
3 jack well high lift pumps
2 centrifugal low lift pumps
2 no.s DGs
Fire water system.
Major Jobs in Raw Water Station
Maintenance of Diesel Engine
Maintenance of Pumps
Workshop
Classification
Machine Shop
Availabile equipments
Lathes
Milling machine
Drilling Machine
Fabrication
Avaliable Facility
Heavy Equipments/Transport facility
Cranes
Hydras
Fork Lifts
Tool Room
Work shop will be dealt in detail by Satish