b Pcl Report

7/25/2019 b Pcl Report

1/33

CERTIFICATE

This is to certify that Rajesh Ramesh, 3rd year, B.E(Hons.) Mechanical Engineering, fromBITS ilani !! Birla "oa #am$%s, has s%ccessf%lly com$leted t&o &ee's of Inlant training atB#!R %nder the g%idance of Mr."o$%, #hief Manager Maintenance and here*y s%*mitting

the com$leted Inlant training re$ort.

Mr. "o$%Sr Manager MaintenanceB#!R


2/33

ACKNOWLEDGEMENT

I &o%ld li'e to e+$ress my gratit%de to B#!ochi Refineries td, for giing me theo$$ort%nity to cond%ct an in de$th st%dy of their refining $rocesses, the maintenance &or'scarried o%t o%t, and the machinery %sed for the $rime f%nction of the entire refinery.

I e+tend my sincere gratit%de to my g%ide Mr."o$%, and all the other em$loyees andtechnicians for their coo$eration, al%a*le s%ggestions, s%$$ort and 'ind adices d%ring theentire co%rse of my In$lant training

COMPANY PROFILE

The agreement for the constr%ction of !ochi Refineries &as e+ec%ted on -th /$ril 0123.


3/33

*y the of India, etrole%m #om$any of S/ and the *rothers of #alc%tta. !ochi Refineries &asformally registered on 2th Se$tem*er 0123 at Erma'%lam

hili$s etrole%m International #or$oration &as the $rime contractor for the constr%ction of therefinery. They entr%sted the &or' to acific rocon td. #onstr%ction &or' started in March

124, and the first %nit came on stream -1 months later. The refinery first commenced on -3(MMT/). Se$tem*er 0122 and had a design ca$acity of -.5 million metric tons $er ann%m It&as then increased to 3.3 MMT/ in 013 after &hich $rod%ction of li6%efied $etrole%m gas(") and /iation T%r*ine 7%el (/T7) started

Refining ca$acity &as f%rther increased to 4.5 MMT/ in 8oem*er 0194 &hen a fl%id catalystcrac'ing %nit (7:#) of one MMT/ ca$acity &as added. The refining ca$acity &as aincreased to MMT/ along &ith a ream$ of 7## to 0.4 MMT/. / s%lf%ri;ation %nit.5 &as installed as a $art of this $roject to minimi;e s%lf%r dio+ide emission. The refineryenteredthe $etrochemical sector in 0191 &hen aromatic $rod%ction facilities &ith a design ca$acity of

9,-


4/33

PROCESS UNITS#=0 B:#!

Hydrodes%lf%ri;ation %nit (8H=s. Reformer %nit, !erosene Hydrodes%lf%ri;ation %nit(!H=s) is*rea'er %nit.


5/33

#R=E =ISTI/TI:8 8IT

In this %nit, the cr%de oil is fractional into ario%s *oiling range steams s%chas na$htha, 'eroserie, diesel etc. cr%de from the storage tan' is $%m$ed to the %nit $assed to a

$reheat train sent to a of desalters. desalted cr%de is sent to another $reheat train and fed to$refractionated col%mn in &hich light na$htha (8) is se$arated as oerheated steam. The 8contains ", &hich is recoered in the " recoery %nit. The flashed cr%de from the *ottomof $refractionated is $%m$ed thro%gh $reheat train heated on charge heaters fed to the maincr%de fractionators.The distilled $rod%cts dra&n from different sections.Heay na$htha, 'erosene 0. 'erosene - and diesel *ase are the side $rod%cts dra&n from thecol%mn.The remaining cr%de (red%ced cr%de oil from the *ottom col%mn is ro%ted to 7B in7##

" RE#:ER@ 8IT

8a$htha is sta*ili;ed *y recoering the " com$onents in this %nit, 8 from the $refractionated col%mn is fed to sta*ili;er col%mn after eating " is ac6%ired as the oerheat$rod%ct and it is sent to an amine treating $lant.

8/HTH/ SITTER 8IT

The main f%nction of this %nit is to $rod%ce 2


6/33

mineral t%r$entine oil (MT:) and des%lf%ri;ation of $f- steam from #=0 for *lendingIn diesel $ool.

ISBRE/!ER 8IT

ac%%m resid%e o*tained from im$orted cr%de in the ac%%m %nit (7) has high iscosity. Thisiscosity is red%ced in the is*rea'er %nit. is*rea'ing is *asically a mild thermal crac'ing$rocess &herein long chain hydrocar*on molec%les in heay feed are *ro'en into smallermolec%les haing lo&er iscosity,there*y leading to a red%ction in elocity. This res%lts inconsering al%a*le distilled $rod%cts.

#=- :#!

#r%de from the storage is $reheated, mi+ed &ith stri$$ed &ater, desalted, again $reheated ands$lit into t&o for $reheating. It is finally heated and flashed into atmos$heric col%mn.

/tmos$heric col%mn oerheated a$or is $assed thro%gh the acc%m%lator and oerheated

steamis sent to the na$htha sta*ili;er.

8/HTH/ ST/BIICER

In this %nit, %nsterili;ed na$htha is sent to #= or to /8DH/8 storage.

8/HTH/ #/STI# >/SHA

It remoes H-S and merca$tan from sta*ili;ed na$htha.It is done *y se$arating hydrocar*onsand ca%stic $hases from a mi+t%re of na$htha and ca%stics

" /MI8E TRE/TI8" 8IT

It is designed to remoe H-S from ". This isdone *y $assingfeed thro%gh amine a*sor$tion col%mn and then $rocessing in a regenerator. " froma*sor$tion col%mn is sent to &ash and then to storage thro%gh a sand filterdr%m, and then to storage thro%gh a sand filter.

/##M =ISTI/TI:8 8IT

In this %nit, ": feed from 7## is $rod%ced. Hot R#: is com*ined dieselslo$e oil is collected in hot &ell ac%%m diesel along #=?s gas oil is sent to$ool.


7/33

S7R RE#:ER@ 8IT

It remoes H-S from refinery f%el gas *y conening it into elemental s%lf%r.

/R:M/TI# RE#:ER@ 8ITA

/romatics s%ch as *en;ene and tol%ene are e+tracted from reformate %sing s%lfolane as solenttility system for the s%$$ly of $lant air, instr%ment air, cooling &ater is a $art of /R.

7I=ICE= #/T/@TI# #R/#!I8" 8IT (7##)

7## conerts atmos$heric resid%e coming from #=0 into distillates, motor s$irit and ".There are many $rocess %nits %nder 7##.

7EE= RE/R/TI:8 8IT.

The $%r$ose of the feed $re$aration%nit is to ma'e feed of re6%ired 6%ality to *e $rocessedIn 7##. In this %nit. R#: is distilled %nder ac%%m into fo%r different %nits mainly ac%%m=iesel :il (=:), ight ac%%m "as oil (":), Heay ac%%m "as oil (H"o andac%%m Resid%e (R)

MAINTENANCE

Maintenance is defined as a of actiities $errormed on all $lants and machineries to maintainthe $rime conditions of a $lant and for the smooth r%nning for the achieement of organi;ationalo*jecties.


8/33

:*jecties of maintenance

To 'ee$ facilities and e6%i$ments in the *est o$erating conditions.To o$erate facilities and e6%i$ments to the o$tim%m $ercentage of time.

To o*tain minim%m o$eration cost.To ens%re ma+im%m safety to o$erating $ersonal.To $reent $rod%ction loss d%e to malf%nction ofthe e6%i$ments.To $roide ma+im%m aaila*ility of e6%i$ments.

Basics of maintenanceA

It is to *e managed in a manner &hich shall commens%rate &ith im$ortance.Maintenance &or' sho%ld *e controlled at its so%rce.E+ce$t in emergencies, maintenance jo*s m%st *e $lanned *efore the &or' starts.E+istence of a fle+i*le $olicy to %se e+ternal reso%rces to coer $ea' &or' re6%irements

E+istence of a training $rogram to teach ne& s'ills and to %$grade e+isting s'illsE+istence of a data*ase on the history and condition of each e6%i$ment and facilities.

Ty$es maintenance

Brea'do&n maintenancereentie maintenanceredictie maintenanceSh%tdo&n maintenance

BRE/!=:>8 M/I8TE8/8#EA

Brea'do&n maintenance is the maintenance $erformed on e6%i$ment that has *ro'en do&nandis %sa*le. It is *ased on *rea'do&n maintenance trigger. It may *e either $lanned reactie%n$lanned. /n e+am$le of $lanned maintenance is r%ntofail%re maintenance and reactiemaintenance. Brea'do&n maintenance can *e more costly than $reentie maintenance.

REE8TIE M/I8TE8/8#EA

reentie maintenance is the maintenance that is reg%larly $erformed on a $iece of e6%i$mentto loosen the li'elihood of it failing, reentie maintenance is$erformed &hile the e6%i$ment is still &or'ing, so that it does not *rea' do&n %ne+$ectedly.


9/33

reentie maintenance $lanned that any re6%ired reso%rces are aaila*le. The maintenanceis sched%led *ased on a is so &ith a time *asedtime or %sage trigger, / ty$ical e+am$le of an asset year, *eforeentie maintenance sched%le is an air conditioner &hich is sericed eerys%mmer. /n e+am$le for asset maintenance &ith a %sage *ased $reentie maintenance

sched%le is a motor ehicle &hich might *e sched%led serice eery 0


10/33

incl%de increased e6%i$ment lifetime, increased $lant safety, fe&er accidents &ith negatie im$act

on enironment, and o$timi;ed s$are $arts handling.

SHT=:>8 M/I8TE8/8#E

Sh%tdo&n maintenance is the maintenance $erformed &hen a machine or a $iece of e6%i$mentis t%rned off and o%t of serice.

ST/TI# EFIME8TS

HE/T EG#H/8"ER

/ heat e+changer is a deice %sed to transfer heat *et&een one or more fl%ids. The fl%ids may*e se$arated *y a solid &all to $reent mi+ing or they may *e in direct contact.They are &idely%sed in s$ace heating, refrigeration, air conditioning, $o&er stations, chemical $lants,$etrochemical $lants, $etrole%m refineries, nat%ralgas $rocessing, and se&age treatment.

STR/I"HT TBE HE/T EG#H/8"ER TBE HE/T EG#H/8"ER

Boiler

/ bi!eris a closedesselin &hich &ateror other fl%idis heated. The fl%id does not necessarily *oil.(In 8orth /merica, the term f%rnace is normally %sed if the $%r$ose is not to act%ally *oil the fl%id.)

The heated or a$ori;ed fl%id e+its the *oiler for %se in ario%s $rocesses or heating a$$lications,0

-incl%ding &ater heating,central heating, *oiler*ased $o&er generation, coo'ing, and sanitation.

The so%rce of heat for a *oiler iscom*%stionof any of seeral f%els,s%ch as &ood,coal, oil, ornat%ral gas. Electric steam *oilers%seresistanceor immersionty$eheating elements.8%clearfissionis also %sed as a heat so%rce for generating steam, either directly (B>R) or, in most cases, ins$ecialised heat e+changerscalled steam generators (>R). Heat recoery steam generators(HRS"s) %se the heat rejected from other $rocesses s%ch as gas t%r*ine.

Boilers can *e classified intoHaystac'7ire T%*e>ater T%*e7lash

03)/ES

/ ale is a deice that reg%lates or controls the no& of a fl%id *y
https://en.wikipedia.org/wiki/Pressure_vesselhttps://en.wikipedia.org/wiki/Pressure_vesselhttps://en.wikipedia.org/wiki/Pressure_vesselhttps://en.wikipedia.org/wiki/Waterhttps://en.wikipedia.org/wiki/Fluidhttps://en.wikipedia.org/wiki/Boilinghttps://en.wikipedia.org/wiki/Boilinghttps://en.wikipedia.org/wiki/Furnacehttps://en.wikipedia.org/wiki/Boiler#cite_note-1https://en.wikipedia.org/wiki/Boiler#cite_note-2https://en.wikipedia.org/wiki/Boiler_(water_heating)https://en.wikipedia.org/wiki/Boiler_(water_heating)https://en.wikipedia.org/wiki/Central_heatinghttps://en.wikipedia.org/wiki/Boiler_(power_generation)https://en.wikipedia.org/wiki/Cookinghttps://en.wikipedia.org/wiki/Sanitationhttps://en.wikipedia.org/wiki/Combustionhttps://en.wikipedia.org/wiki/Combustionhttps://en.wikipedia.org/wiki/Combustionhttps://en.wikipedia.org/wiki/Fuelhttps://en.wikipedia.org/wiki/Fuelhttps://en.wikipedia.org/wiki/Woodhttps://en.wikipedia.org/wiki/Woodhttps://en.wikipedia.org/wiki/Coalhttps://en.wikipedia.org/wiki/Petroleumhttps://en.wikipedia.org/wiki/Natural_gashttps://en.wikipedia.org/wiki/Electric_steam_boilerhttps://en.wikipedia.org/wiki/Electrical_resistancehttps://en.wikipedia.org/wiki/Electrical_resistancehttps://en.wikipedia.org/wiki/Immersion_heaterhttps://en.wikipedia.org/wiki/Nuclear_fissionhttps://en.wikipedia.org/wiki/Nuclear_fissionhttps://en.wikipedia.org/wiki/Nuclear_fissionhttps://en.wikipedia.org/wiki/Steamhttps://en.wikipedia.org/wiki/Heat_exchangerhttps://en.wikipedia.org/wiki/Heat_recovery_steam_generatorhttps://en.wikipedia.org/wiki/Heat_recovery_steam_generatorhttps://en.wikipedia.org/wiki/Gas_turbinehttps://en.wikipedia.org/wiki/Pressure_vesselhttps://en.wikipedia.org/wiki/Waterhttps://en.wikipedia.org/wiki/Fluidhttps://en.wikipedia.org/wiki/Boilinghttps://en.wikipedia.org/wiki/Furnacehttps://en.wikipedia.org/wiki/Boiler#cite_note-1https://en.wikipedia.org/wiki/Boiler#cite_note-2https://en.wikipedia.org/wiki/Boiler_(water_heating)https://en.wikipedia.org/wiki/Central_heatinghttps://en.wikipedia.org/wiki/Boiler_(power_generation)https://en.wikipedia.org/wiki/Cookinghttps://en.wikipedia.org/wiki/Sanitationhttps://en.wikipedia.org/wiki/Combustionhttps://en.wikipedia.org/wiki/Fuelhttps://en.wikipedia.org/wiki/Woodhttps://en.wikipedia.org/wiki/Coalhttps://en.wikipedia.org/wiki/Petroleumhttps://en.wikipedia.org/wiki/Natural_gashttps://en.wikipedia.org/wiki/Electric_steam_boilerhttps://en.wikipedia.org/wiki/Electrical_resistancehttps://en.wikipedia.org/wiki/Immersion_heaterhttps://en.wikipedia.org/wiki/Nuclear_fissionhttps://en.wikipedia.org/wiki/Nuclear_fissionhttps://en.wikipedia.org/wiki/Steamhttps://en.wikipedia.org/wiki/Heat_exchangerhttps://en.wikipedia.org/wiki/Heat_recovery_steam_generatorhttps://en.wikipedia.org/wiki/Gas_turbine


11/33

closing, or $artially o*stnacting ario%s $assage&ays, technically fittings,aies are*%t are %s%ally disc%ssed as a se$arate category. In an o$en ale, fl%id no&s in adirection from high $ress%re to lo&er $ress%re.

ales hae many %ses incl%ding controlling &ater for irrigation, ind%strial %ses forcontrolling $rocesses, residential %ses s%ch as onoff and dish and

clothes &ashers and ta$s in the home. Een aerosols hae a tiny ale *%ilt in. ales

are %sed in the military and trans$ort sectors.

Ty$es of alesA

Hydra%lic

ne%matic

Man%al

Solenoid

Motor

#om$onents of a ale

The main $arts of the most %s%al ty$e of ale are the *ody and the *onnet. These t&o

$arts form the casing that holds the fl%id going thro%gh the ale.

B:=@A

The ale?s *ody is the o%ter casing of most or all the ale that contains the internal

$arts or trim. The *onnet is the $art of the encasing thro%gh &hich the steam $asses

and that forms a g%ide and seal for the steam.

B:88ETA

/ *onnet acts as a coer on the ale *ody. It is commonly semi$emanently scre&ed

into the ale *ody or *olted onto it. =%ring man%fact%re of the ale, the integral

$arts are $%t into the *ody and then the *onnet is attached to hold eerything together


12/33

inside. To access intemal $arts of a ale, a %ser &o%ld ta'e off *onnet, %s%ally for

maintenance. Many ales do not hae *onnets. Many *all ales also do not hae

*onnets since the *ody is $%t together in a different style, s%ch as *eing scre&ed

together at the middle of the ale *ody.

:RT

orts are $assage&ays that allo& fl%id to $ass thro%gh the ale. orts are o*str%cted

*y the ale mem*er or disc to control flo&. ales most commonly hae - $orts, *%tother com$onents hae as many as -


13/33

0.4) ST:R/"E T/8!SA

The Storage Tan's are %sed to store the $rod%cts. Most of the tan's are designed and

*%ilt to the /merican etrole%m Instit%te 25< (/I 25


14/33

and concrete.

In the earlier days, $i$ing designs &ere created *y =rafting, Technical dra&ing and

Engineering dra&ing, *%t today is created *y designers &ho hae leaned #/=

(#om$%ter /ided =esign) and #om$%ter /ided =ra&ing soft&are.i$ing has many ind%strial a$$lications, &hich are cr%cial for moing ra& and semi

$rocessed fl%ids for refining into more %sef%l $rod%cts. Some of the more e+oticmaterials of constr%ction are Inconel, Titani%m, #hromemoly and ario%s other steelalloys

R:T/R@ EFIME8TS

-.0 /IR #:MRESS:R

/n /ir #om$ressor is a deice that conerts $o&er (%sing electric motor, diesel, or

gasoline etc) into $otential energy stored in $ress%ri;ed air (i e com$ressed airy. By one of

seeral methods, an air com$ressor forces more and more air into a storage tan', th%s increasing

the $ress%re. >hen the tan' $ress%re reaches an %$$er limit the air com$ressor sh%ts om. The

com$ressed air is then held in the tan' %ntil its %se. Then energy contained in the com$ressed air

can *e %sed for a ariety of a$$lications, %tili;ing the 'inetic energy of the air it is released and

the tan' de$ress%ri;es. >hen tan' $ress%re reaches its lo&er limit, the air com$resses t%rns on

again and re$ress%ri;es the tan'.

There are three ty$es of/ir #om$ressors

Reci$rocating

Rotary #entrif%gal

Rotary scre&

Reci$rocating /ir #om$ressor

/ Reci$rocating /ir #om$ressor or iston #om$ressor, is a $ositiedis$lacement


15/33

com$ressor that %ses $istons drien *y a cran'shaft to delier gases at high $ress%re.

The inta'e gas enters the s%ction manifold, then flo&s into the com$ression cylinder &here it

gets com$ressed *y a $iston drien in a reci$rocating motion ia a cran'shaft and is then

discharged. /$$lications incl%de oil refineries, gas $i$elines, chemical $lants, nat%ral gas

$rocessing $lants and refrigeration $lants

In the ionic li6%id $iston com$ressor, many seals and *earings &ere remoed in the design as the

ionic li6%id does not mi+ &ith the gas. The serice life &as int%rn increased 0< times longer

than a reg%lar dia$hragm com$ressor &ith red%ced maintenance d%ring %se, energy costs are

red%ced *y as m%ch as -


16/33

action. %m$s can *e classified into three major gro%$s according to the method they %se to

moe the fl%id direct lift $%m$s and dis$lacement $%m$s.

%m$s o$erate *y a mechanism according to its design (Rotary or Reci$rocating) and cons%me

energy to $erform mechanical &or' *y moing the fl%id. %m$s o$erate ia manenergyso%rces incl%ding man%al o$eration, electricity or &ind $o&er. They also come in many si;e,

from microsco$ic (%sed in medical a$$lications) to a$$lications in large ind%stries

The main ty$es of $%m$ %sed in !ochi Refinery are

#entrif%gal %m$

machinery. %m$s are a s%*class of dynamic a+isymmetric &or' a*sor*ing t%r*oRotational #entrif%gal %m$s are %sed to trans$ort fl%ids *y the conersion of!inetic energy into Hydrodynamic eneof fl%id Thecomes from an electric motor. The fl%id enters the $%m$ im$eller along or near to its

rotational a+is and is accelerated *y the im$eller, flo&ing radially o%t&ard into a diff%ser

or ol%te cham*er (casing) &here it e+its.

T@ES :7 IMEER


17/33

:E8 IMEER

:$en im$ellers do not hae a front or a rear shro%dK this allo&s de*ris that might fo%l the im$eller to *edragged along *y the im$eller, r%**ing against the front and rear stationary &ear $lates, grinding do&nthe $artic%late to a small eno%gh si;e to $ass thro%gh the im$eller. This &or's &ell &ith soft $artic%lates*%t generally ca%ses too m%ch a*rasion on *oth the im$eller and the &ear $lates if the $artic%late is ahard com$o%nd com$ared to the im$eller material. /nother disadantage for this style of im$eller is theneed for the im$eller anes to *e fairly thic'. They m%st hae the mechanical strength to s%$$ortthemseles %nder the stress of $%m$ing the li6%id. This added thic'ness and res%lts in a decrease in theflo& area. /dditionally the clearances, at the front and rear of the *lade &here the h%* and the shro%ds&o%ld *e on a closed im$eller, res%lt in a lea'age in the im$eller. This lea'age is ery de$endent on theclearances *et&een the im$eller and the &ear $lates. /s the $%m$ &ears oer time these clearancesincrease and f%rther increase the lea'age losses degrading the $%m$s efficiency and often the flo& andhead leels. /n adantage of this style of im$eller is that they deelo$ almost no a+ial hydra%lic thr%stloads d%e to the lac' of shro%ds. They are also easy to man%fact%re d%e to the lac' of cores &hich ma'esthem less e+$ensie.

#losed Im$eller


18/33

/lso called enclosed im$ellers hae a shro%d and a h%* s%rfaced attached. The s%rfaces hae seeraladantages. L They eliminate the lea'age losses across the anes. They $roide strength and sta*ility tothe ane allo&ing the ane thic'ness to *e red%ced and increasing the flo& area thro%gh the im$eller. Thet&o shro%ds also $roide and a+ial thr%st *alancing s%rface from &hich the $ress%re differential can *e*alanced. The o*io%s disadantage to this form of im$eller is that if the de*ris that enters the anes andis too large to $ass thro%gh the im$eller it *ecomes st%c' and m%st *e remoed *y hand. This is oftenreferred to as deragging in the &aste &ater ind%stry. It re6%ires the disassem*ly of the $%m$ &hich istime cons%ming and costly.

Semi O"en Im"e!!er#

These im$ellers hae only one shro%d on either the front or the *ac' of the im$eller. They hae some ofthe adantages of each of the other styles, and their o&n set of dra&*ac's. Thinner *lading and red%cedlea'age losses *eca%se the fl%id has only one lea'age $ath oer the *lade ma'e them more efficient thanf%lly o$en im$eller designs. The one face of the im$eller *eing o$en allo&s them to $ass $artic%late that&o%ld clog many closed im$ellers. Their major disadantage is the fact that they hae only one shro%dthat fl%id $ress%re *%ilds %$on. The differential $ress%re across the im$eller can ca%se e+treme a+ialthr%st loads $%tting e+cessie stress on the *earings or re6%iring thr%st *alancing techni6%es thatincrease lea'age losses or $o&er cons%m$tion lo&ering the $%m$s oerall efficiency.

ositie =is$lacement %m$

/ $ositie dis$lacement $%m$ ma'es a fl%id moe *y tra$$ing a fi+ed amo%nt and forcing(dis$lacing) that tra$$ed ol%me into the discharge $i$e.

/ Reci$rocating $%m$ is a class of ositiedis$lacement $%m$ &incl%des the$iston, $%m$ and dia$hragm $%m$. It is often %sed &here a relatiely small6%antity of li6%id is *e handled and &here deliery $ress%re is 6%ite large. Inreci$rocating $%m$s, the cham*er in &hich the li6%id is tra$$ed, is stationary cylinderthat contains the $iston or $l%nger.

a

=ia$hragm %m$

/ dia"$ra%m "&m"(also 'no&n as a Membrane "&m") is a$ositie dis$lacement $%m$that %sesa com*ination of the reci$rocating action of ar%**er,thermo$lasticor teflondia$hragmand s%ita*leales on either side of the dia$hragm (chec' ale, *%tterfly ales, fla$ ales, or any other form ofsh%toff ales) to $%m$ afl%id.
https://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttps://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttps://en.wikipedia.org/wiki/Rubberhttps://en.wikipedia.org/wiki/Rubberhttps://en.wikipedia.org/wiki/Thermoplastichttps://en.wikipedia.org/wiki/Polytetrafluoroethylenehttps://en.wikipedia.org/wiki/Diaphragm_(mechanics)https://en.wikipedia.org/wiki/Diaphragm_(mechanics)https://en.wikipedia.org/wiki/Check_valvehttps://en.wikipedia.org/wiki/Fluidhttps://en.wikipedia.org/wiki/Fluidhttps://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttps://en.wikipedia.org/wiki/Rubberhttps://en.wikipedia.org/wiki/Thermoplastichttps://en.wikipedia.org/wiki/Polytetrafluoroethylenehttps://en.wikipedia.org/wiki/Diaphragm_(mechanics)https://en.wikipedia.org/wiki/Check_valvehttps://en.wikipedia.org/wiki/Fluid


19/33

ane %m$

/ rtar' vane "&m"is a $ositiedis$lacement $%m$that consists of anes mo%nted to arotorthatrotates inside of a caity. In some cases these anes can hae aria*le length andDor *e tensioned

to maintain contact &ith the &alls as the $%m$ rotates.

-.3) TRBI8E

/ Steam T%r*ine is rotary mechanical deice that e+tracts energy from fl%id flo& and

conerts it into %sef%l &or'. / t%r*ine is a t%r*o machine &ith at least one moing $art

called a rotor assem*ly, &hich is a shaft or a dr%m &ith *lades attached. Moing fl%idacts on the *lades so that they moe and im$act rotational energy to rotor.

Ty$es of T%r*ines %sed in !R

Steam t%r*ines

"as t%r*ines

Steam t%r*ine

/ Steam T%r*ine is %sed to generate electricity in thermal $o&er $lants s%ch as $lants

%sing coal, f%el oil or n%clear f%el. They generate electricity, &hich then $o&ers n electric

motor connected to the mechanical load.

/ "as T%r*ine is also called a com*%stion t%r*ine. It has an %$stream rotatingcom$ressor co%$led to a do&nstream t%r*ine, and a com*%stion cham*er in *et&een.

The *asic o$eration a "as T%r*ine is similar to that of the steam $o&er $lant, e+ce$tthat air is %sed instead of&ater. 7resh atmos$heric air flo&s thro%gh a com$ressor that*rings it higher $ress%re. Energy is added *y s$raying f%el into the air and igniting it so

the com*%stion generates a high tem$erat%re flo&. The high tem$erat%re $ress%rehighgas enters a t%r*ine, &here it e+$ands do&n to e+ha%st $ress%re, $rod%cing a shaft &or'
https://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttps://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttps://en.wikipedia.org/wiki/Rotor_(turbine)https://en.wikipedia.org/wiki/Rotor_(turbine)https://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttps://en.wikipedia.org/wiki/Rotor_(turbine)


20/33

o%t$%t in the $rocess. The t%r*ine shaft &or' is %sed to drie the com$ressor and other

deices s%ch as electric generator that may *e co%$led to the shaft. The energy that is not

%sed for shaft &or' comes o%t in the e+ha%st gases, so these hae either high tem$erat%re

or high elocity. The $%r$ose of the gas is to determine the design so that the mostdesira*le energy form ma+imi;ed. "as T%r*ines are %sed to $o&er aircrafts, trains,

shi$s, electric generators and tan's.

=etails of the main t&o "as T%r*ines %sed in B#!R

0. "T0

o&er o%t$%t o*tained A01 M>

7%el %sedA !ero - and R8"

Ma'e BHE"E

RM 5


21/33

8%m*er of stages 3

7rame 5

T%r*ine e+ha%st tem$ 59


22/33

Seals

/n end *ace mec$anica! #ea!, also referred to as a mec$anica! *ace #ea!*%t %s%ally sim$ly asa mec$anica! #ea!, is a ty$e of seal%tilised in rotating e6%i$ment, s%ch as $%m$s,mi+ers, *lo&ers,andcom$ressors.

>hen a $%m$ o$erates, the li6%id co%ld lea' o%t of the $%m$ *et&een the rotating shaft and thestationary $%m$ casing. Since the shaft rotates, $reenting this lea'age can *e diffic%lt./n end face mechanical seal %ses *oth rigid and fle+i*le elements that maintain contact at a sealinginterface and slide on each other, allo&ing a rotating element to $ass thro%gh a sealed case. Theelements are *oth hydra%lically and mechanically loaded &ith a s$ring or other deice to maintaincontact.

=o%*le Mechanical Seals

Thermosy$hon essels can *e %sed to $roide a so%rce of clean, ress%ri;ed *arrier fl%id to

=o%*le mechanical seals in *ac' to *ac'

The Barrier fl%id enters the Thermosy$hon essel, &here it is cooled *y &ater circ%latingthro%gh cooling coil to *ring do&n the tem$erat%re of *arrier fl%id and *ac' to the seal cham*er.

IBR/TI:8 /8/@SIS

Reg%lar machine i*ration monitoring is a costeffectie method of $redictiemaintenance to e+tend machine serice life and $reent %n$lanned sh%tdo&ns.

>e can $erform reg%lar i*ration analysis of $lant e6%i$ment as $art of a$redictie maintenance $rogramme, or as $art of a Root #a%se /nalysis sericeto determine the ca%se of a machine $ro*lem. #onditions that can *e detected*efore they ca%se machine *rea'do&n areA

Misalignment :%tof*alance
https://en.wikipedia.org/wiki/Seal_(mechanical)https://en.wikipedia.org/wiki/Pumphttps://en.wikipedia.org/wiki/Pumphttps://en.wikipedia.org/wiki/Industrial_mixerhttps://en.wikipedia.org/wiki/Centrifugal_fanhttps://en.wikipedia.org/wiki/Gas_compressorhttps://en.wikipedia.org/wiki/Gas_compressorhttps://en.wikipedia.org/wiki/Seal_(mechanical)https://en.wikipedia.org/wiki/Pumphttps://en.wikipedia.org/wiki/Industrial_mixerhttps://en.wikipedia.org/wiki/Centrifugal_fanhttps://en.wikipedia.org/wiki/Gas_compressor


23/33

Mechanical looseness oor l%*rication

Bent shafts Motor c%rrent fa%lts Bearing damage

The major ste$s inoled in this method inoles

=etection

/nalysis

>ae

S$ectr%m

Ra& =ata

#orrection

%*e :il /nalysis

rinci$le root ca%ses of e6%i$ment fail%re incl%de %nseen corrosion,contaminants, im$ro$er l%*rication and machine &ear. The S$ectro 5-


24/33

Triector :il /naly;er is a m%ltif%nction instr%ment that detects l%*ricant related$ro*lems and ena*les onsite analysis of machinery oils and l%*ricants. It$roides clear indications of metal &ear, l%*ricant chemistry and contamination.The system is coered *y the /STM =402 standard $ractice that ens%res %sers

can achiee re$eata*le res%lts follo&ing standard o$erating g%idelines. rimarya$$lications incl%de l%*ricants for rotating machinery s%ch as $%m$s, motors,com$ressors, gear*o+es, air handlers, t%r*ines, feed $%m$s, dries,transmissions, and hydra%lic systems.


25/33

The S$ectro 5-


26/33

E+cessie loads %s%ally ca%se $remat%re fatig%e. Tight fits, *rinelling and im$ro$er $reloadingcan also *ring a*o%t early fatig%e fail%re.The sol%tion is to red%ce the load or redesign %sing a *earing &ith greater ca$acity.

:erheating

Sym$toms are discoloration of the rings, *alls, and cages from gold to *l%e.Tem$erat%re in e+cess of 4


27/33

Tr%e Brinelling

Brinelling occ%rs &hen loads e+ceed the elastic limit of the ring material.

Brinell mar's sho& as indentations in the race&ays &hich increase *earing i*ration (noise).

/ny static oerload or seere im$act can ca%se *rinelling.


28/33

7alse Brinelling

7alse *rinelling elli$tical &ear mar's in an a+ial direction at each *all $osition &ith a *rightfinish and shar$ demarcation, often s%rro%nded *y a ring of *ro&n de*ris indicates e+cessiee+ternal i*ration.#orrect *y isolating *earings from e+ternal i*ration, and %sing greasescontaining anti&ear addities.

8ormal 7atig%e 7ail%re

7atig%e fail%re %s%ally referred to as s$alling is a fract%re of the r%nning s%rfaces ands%*se6%ent remoal of small discrete $articles of material. S$alling can occ%r on the inner ring,

o%ter ring, or *alls. This ty$e of fail%re is $rogressie and once initiated &ill s$read as a res%lt off%rther o$eration. It &ill al&ays *e accom$anied *y a mar'ed increase in i*ration. The remedyis to re$lace the *earing or consider redesigning to %se a *earing haing a greater calc%latedfatig%e life.


29/33

Reerse oading

/ng%lar contact *earings are designed to acce$t an a+ial load in one direction only. N >henloaded in the o$$osite direction, the elli$tical contact area on the o%ter ring is tr%ncated *y thelo& sho%lder on that side of the o%ter ring. N The res%lt is e+cessie stress and an increase intem$erat%re, follo&ed *y increased i*ration and early fail%re. N #orrectie action is to sim$lyinstall the *earing correctly.


30/33

#ontamination

#ontamination is one of the leading ca%ses of *earing fail%re. #ontamination sym$toms aredenting of the *earing race&ays and *alls res%lting in high i*ration and &ear. #lean &or'areas, tools, fi+t%res, and hands hel$ red%ce contamination fail%res. !ee$ grinding o$erations

a&ay from *earing assem*ly areas and 'ee$ *earings in their original $ac'aging %ntil yo% areready to install them.

%*ricant 7ail%re

=iscolored (*l%eD*ro&n) *all trac's and *alls are sym$toms of l%*ricant fail%re. E+cessie &earof *alls, ring, and cages &ill follo&, res%lting in oerheating and s%*se6%ent catastro$hic fail%re.Ball *earings de$end on the contin%o%s $resence of a ery thin millionths of an inch film ofl%*ricant *et&een *alls and races, and *et&een the cage, *earing rings, and *alls. 7ail%res arety$ically ca%sed *y restricted l%*ricant flo& or e+cessie tem$erat%res that degrade thel%*ricantOs $ro$erties.


31/33

#orrosion

RedD*ro&n areas on *alls, race&ay, cages, or *ands of *all *earings are sym$toms ofcorrosion. N This condition res%lts from e+$osing *earings to corrosie fl%ids or a corrosieatmos$here. N In e+treme cases, corrosion can initiate early fatig%e fail%res. N #orrect *ydierting corrosie fl%ids a&ay from *earing areas and %se integrally sealed *earings &heneer$ossi*le.

Misalignment

N Misalignment can *e detected on the race&ay of the nonrotating ring *y a *all &ear $ath thatis not $arallel to the race&ays edges. N If misalignment e+ceeds


32/33

sho%lders and *earing seatsK %se of single $ointt%rned or gro%nd threads on non hardenedshafts and gro%nd threads only on hardened shaftsK and %sing $recision grade loc'n%ts.

oose 7its

N oose fits can ca%se relatie motion *et&een mating $arts. If the relatie motion *et&eenmating $arts is slight *%t contin%o%s, fretting occ%rs. N 7retting is the generation of fine metal$articles &hich o+idi;e, leaing a distinctie *ro&n color. This material is a*rasie and &illaggraate the looseness. If the looseness is eno%gh to allo& considera*le moement of theinner or o%ter ring, the mo%nting s%rfaces (*ore, o%ter diameters, faces) &ill &ear and heat,ca%sing noise and r%no%t $ro*lems.

Tight 7its/ heay *all &ear $ath in the *ottom of the race&ay aro%nd the entire circ%mference of theinner ring and o%ter ring indicates a tight fit. N >here interference fits e+ceed the radialclearance at o$erating tem$erat%re, the *alls &ill *ecome e+cessiely loaded. This &ill res%lt ina ra$id tem$erat%re rise accom$anied *y high tor6%e. N #ontin%ed o$eration can lead to ra$id&ear and fatig%e. N #orrectie action incl%des a decrease in total interference.


33/33

b Pcl Report

Documents

Transcript of b Pcl Report