B.Tech Presentationon

Vocational Training at BHARAT PETROLEUM CARPORATION LIMITED,MUMBAI

byVAIBHAV KUMAR ARYA

(2012UME1448)

Dr. G.D. Agarwal

Associate Professor

Dept. of Mech. Engg.

MNIT , Jaipur

Dr. Gopal AgrawalAssociate ProfessorDept. of Mech. Engg.MNIT , Jaipur

Supervisor Mr. K. Pradeep

Asst. Manager, Machine shop BPCL Refinery, Mumbai

DEPARTMENT OF MECHANICAL ENGINEERINGMALAVIYA NATIONAL INSTITUTE OF TECHNOLOGY, JAIPUR

• Bharat Petroleum Corporation Limited (BPCL) is an Indian state-controlled oil and gas company headquartered in Mumbai, Maharashtra.

• BPCL has been ranked 242th in the Fortune Global 500 rankings of the world's biggest corporations for the year 2014.

• Bharat Petroleum operates the following refineries:

• Mumbai Refinery : It has a capacity of 12 million metric tonnes per year.

• Kochi Refineries : It has a capacity of 9.5 million metric tonnes per year.

• Bina Refinery : It has a capacity of 6 million metric tonnes per year. This refinery is operated by Bharat Oman Refineries Limited, a joint venture between Bharat Petroleum and Oman Oil Company.

• Numaligarh Refinery : It has a capacity of 3 million metric tonnes per year.

About The Company

• In 1889 during vast industrial development, an important player in the South Asian market was the Burmah Oil Company.

• In 1928, Asiatic Petroleum Company (India) started cooperation with Burma oil company. This alliance led to the formation of Burmah-Shell Oil Storage and Distributing Company of India Limited.

• Bharat Petroleum Corporation ( BPCL) was established in 1952.

• On 24 January 1976, the Burmah Shell was taken over by the Government of India to form Bharat Refineries Limited. On 1 August 1977, it was renamed Bharat Petroleum Corporation Limited. It was also the first refinery to process newly found indigenous crude Bombay High.

Company History

Centrifugal Pumps• Purpose of a Centrifugal Pump is to convert

energy of a prime mover (an electric motor or turbine) first into velocity or kinetic energy and then into pressure energy of a fluid that is being pumped.

• The energy changes occur by virtue of two main parts of the pump, the impeller and the volute or diffuser.

• The impeller is the rotating part that converts driver energy into the kinetic energy. The volute or diffuser is the stationary part that converts the K.E into pressure energy.

A Typical Centrifugal Pump

CENTRIFUGAL PUMP

Main ComponentsCentrifugal Pumps are made of hundreds of parts no matter how big or tiny. However, there are some major parts which are designed to perform specific tasks.

• Impeller: Centrifugal Pumps use impeller as the primary source for their pumping action. Its function is to increase the pressure of the liquid.

• Casing: The casing contains the liquid and acts as a pressure containment vessel that directs the flow of liquid and out of the centrifugal pump.

• Shaft: The main function of the shaft in a centrifugal pump is to transmit the input power from the driver to the impeller.

• Seal: Centrifugal Pumps can be provided with packing rings or mechanical seals which helps prevent the leakage of the pumped liquid into the surroundings.

• Bearing: The function of the bearing is to support the weight of the shaft assembly, to carry hydraulic loads acting on the shaft, and to keep the pump aligned to the shaft of the driver.

• Coupling: The function of couplings is to connect the pump shaft and the driver shaft, and to transmit the input power from the driver to the pump.

Impeller

A Fully Shrouded Impeller

A Pump using multiple impellers one after another One impeller from the 4 used in

the previous image

Impeller

A Semi-Shrouded Impeller A Screw-type Impeller A Double Suction Impeller

Casing

Inside of a normal pump casing A sump pump casing

Shaft

Shaft

The Long Shaft of A Sump Pump

Seal

The sleeve which is attached on the shaft

The rotary face attached to the flange

The Rotary Face

Seal Assembly

The Bellow being set The assembly is covered with a flange

The Stationary face being mounted

Seal Inspection

Another pair of faces is mounted to make it a double

seal

Setup to check the amount of pressure the seal can handle When the water starts coming out, the

max pressure has been reached

Bearing

A Ball BearingRoller Bearing

A Roller Bearing with a slightly different cage

Bearing

Broken Bearing Cage Bearing Nomenclature

Coupling

A shaft with a Lovejoy Jaw Coupling

The other part of the Love Jaw Coupling

A shaft with a keyway

A Key

CASE STUDY ON ‘20 P 05 A’ PUMP -A SINGLE STAGE OVERHUNG CENTRIFUGAL

PUMP

The pump was reported at machine shop for maintenance & to troubleshoot & problem present from FCCU unit.

SPECIFICATIONTYPE SINGLE STAGE CENTRIFUGAL PUMP

EQUIPMENT NO. 20 P 05 A

DEPARTMENT FCCU (Fluid catalyst & cracking unit)

MODEL NO. CPK-EM65-315 Se

COUPLING MAKE UNIQUE

RPM 2950

PUMP FLOW 55.2 m³/hr

PUMP WORKING TEMPERATURE 250 ˚C

MECHANICAL SEAL MAKE FLOWSERVE

PUMP AXIAL BEARING TYPE SKF 7311 BECBJ

PUMP RADIAL BEARING TYPE SKF 311 EC

LUBRICATION OIL TURBOL 68

HEAD 8m

COMPONENTS• Impeller• Impeller wearing• Impeller locknut• Casing• Stuffing box• Shaft• Coupling• Throat bush• Bearing housing• Thrust bearing• Radial bearing• Mechanical seal • Spacer• Deflector/Isolater • Oil ring (Splasher )• Bearing housing back cover

PROBLEM ENCOUNTERED WITH 20 P 05 A : MECHANICAL SEAL LEAKAGE FOR OVER HAULING

DISMANTLING THE PUMPCoupling grub screw were loosen.Coupling/ hydraulic puller was tried to loosen coupling but it wasn’t enough so coupling was heated to

increase its diameter so that it could easily loosen from shaft.

GRUB SCREW

COUPLING

COUPLING REMOVED

All bolts of stuffing box were removed as it was seized so sudden hydraulic pressure was imparted at suction which provided required momentum to separate casing from remaining assembly.

REMOVED CASING

REMOVED ASSEMBLY

Impeller locknut was removed through anticlockwise rotation as it was clockwise fastened in the direction of rotation of impeller to make sure it didn’t come out during operation.

Impeller (closed type) was pulled out straight aligned away from pump.

Impeller

Impeller locknut

WEARING

Impeller locknut was screwed & through crane assembly was placed vertical. Impeller locknut was again removed. spacer along with shaft & bearing housing was pulled out of stuffing box & mechanical seal assembly

straight aligned using crane.

Stuffing box

Mechanical

seal

Spacer /

distance piece

Shaft

Bearing housing

All four bolts were removed from mechanical seal & seal was removed form stuffing box & kept with proper care at table.

Impeller locknut was again tightened.

Mechanical single seal with bellow as compression unit

Rotary face

Stationary face

Stuffing box

O rings

Spacer was pulled out of bearing housing.Now bearing housing needed to be dismantle most tedious job of all..

Spacer/ distance

pieceBreather (upper

portion)

Bearing housing

Oil drain

Shaft

BACK COVER

Bearing housing back cover was removed followed by isolator.Roller (radial) bearing inner ring was pushed out of bearing housing.

Shaft

isolater

Bearing housing

back cover of

NDU side

Gasket

Inner ring of roller bearing

Bearing housing

Shaft

DU back plate of bearing housing was removed then shaft along with bearings was taken out of bearing housing .

Roller bearing was removed from shaft .

Roller bearing

BACK TO BACK ball bearing

Bearing locknut

Star washer

Isolator

Both ball back to back ball bearing ,isolator, bearing lock nut, star washer was loosened from shaft.

Shaft

Ball bearing

Isolator

Back cover(DU Side)

Back cover(NDU Side)

CLEANING Cleaning is mainly done with :1. Kerosene mixed with oil as it could harm the skin of hand if only kerosene is used.2. Small & big blades.3. Wire brush.4. Polish paper.5. Compressed air for cleaning as well as for drying cleaned parts.

Small blade

Kerosene & oil mix.

Polish paper

Generally following sequence during cleaning is maintained:• Shaft coupling impeller volute casing bearing housing spacer Stuffing box bearing cover remaining small parts

Compressed air

Cleaning operation

INSPECTIONAfter dismantling, a visual inspection & a through check for dimensions were done using micrometers & Vernier calipers. A check list is made along with that other supplementary dimensions are also checked. These include coupling internal diameter (ID) , bearing (ID) , bearing outer diameter (OD) & the clearances with respect to the bearing housing, front & back side wearing OD along with respect to the casing & stuffing box respectively & impeller diameter . An overall check for the bearings, mechanical seal, impeller, hub, spacer, coupling type impeller lock nut, coupling & impeller key, bearing housing & oil rings & Splasher was performed. A trueness check is performed to check the trueness of the shaft & the impeller.Balancing of rotor done after assembly trueness of the rotor.The rotor consists of shaft with impeller, coupling & other rotating parts on the shaft.

PROBLEMS OBSERVED :• The existing mechanical seal (single seal) was hydro tested at 5 kg/cm² & a leak was

found in the seal bellow.

• Rings & gaskets needed to be replaced.

• Stationary face, rotary face & compression unit were replaced.

• Non Driving end deflector was broken

• Mechanical sleeve was worn off so needed to be replaced.

CHECK LIST The existing mechanical seal was hydro tested at 5 kg/cm² & a leak was found in the seal bellow.

ASSEMBLY OF PUMP:1. Insert the Radial & axial bearings by heating them in Induction heater to obtain proper

fit. Temperature of induction heater is 110 C. Bearings are in back to back arrangement.

2. Tighten the axial bearing with the help of bearing locknut & locknut washer.3. Fix the mechanical seal on the stuffing box.4. Mount the bearing housing on the shaft.5. Put on the Bearing cover carrying the oil isolator.6. Then insert the deflector plate.7. Now mount the shaft assembly on the stuffing box & mechanical seal part.8. Now insert the impeller fitted with wearing on the shaft along with the stuffing box.9. Insert the Impeller locknut & key & put locknut cover.10. Now mount the assembly on the casing to obtain full assembled feed pump.

TESTING:Testing is done to check the proper functioning of the pump so that it will not fail on the site after installation. It is very important part of maintenance because, if the pump fails after installation, then it increases the cost in terms of the cost of components required for maintenance & also in terms of manpower required to do the job again.Pump was assembled & seal was tested at 5 kg/cm².It was found there was no leakage.The pump after assembly was rotated for freeness of the rotor in the pump , the pump was inspected for any uneven or lose tightening of bolts.After all visual inspection the pump was made ready for dispatch.

DISPATCH:The pump was dispatched from the machine shop area to the “FCCU UNIT”.

REFRENCES :- • en.wikipedia.org• www.skf.com• www.pumpsandsystems.com• www.advantageengineering.com• www.centrifugal-pump.org• www.pumpfundamentals.com• www.compressionjobs.com