Project Report on Study of Process Pumps by-Sachin

8/14/2019 Project Report on Study of Process Pumps by-Sachin

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Project -R ep ort

On

Proc es s Pump s

Prepared Under: - A.K.Mishra & Dinesh Mishra

Prep ared B y:-

Sac hin


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INDIAN OIL CORPORATION LIMITED

(PIPELINES - DIVISION)

MATHURA-JALANDHAR PIPELINE

DELHI INSTALLATION

P.O. BIJWASAN, NEW DELHI-110061

AN OVE RVIEW

OF THE

ORGANIS ATION


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CONTENTS

1.Route Map Of Mathura-JalandharPipeline(MJPL)

2.Introduction

3.Business Overview

4.Operations

5.Process Pumps

6.MJPL At Glance


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INTRODUCTION

Mathur a-Jalandhar pipe line plays a importantrole by way of transporting petroleum products inbulk to cater the requirements of northern-westernparts of the country (i.e. parts of U.P, Delhi, Punjab,Haryana, Himachal Pradesh, J&K) that includesdefence Aviation needs.

MJPL has always strived hard toachieve it's objective in line with corporate missionand to contribute to it's business growth. A strongcohesive and committed team of MJPL is responsiblefor achieving new benchmarks.

The main factor contributing to attain the operational andother objective are:-

1. Effective planning and close monitoring of operations.2. Compilance of ISO-900:2000 Quality procedures.3. Condition based maintenance of Critical Equipments to

achieve zero-breakdown and 100% availability of equipments.

4. Focus on profitability and quality.

5. Effective Co-ordination with Mathura refinery andPanipat refinery for achieving segment wise capacityutilization.

6. Establishing statistical process control to verify theadequacy of personally from time to time.

7. Monitoring Energy Consumption.8. Monitoring controllable cost, Through-Put, Pipeline Loss

etc.


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The Bu siness Overvie w

Ind ian Oil Corpo ration Limited , which is a conglomerate in IndianPetroleum Industry; engaged in wide ranging downstream activities such

as import of crude oil, transportation and refining of crude oil,transportation and marketing of petroleum products including specializedlubricants and greases. Indian Oil Corporation Ltd. is currently India'slargest company by sales with a turnover of Rs. 220, 77 9 cr ore (US $51billion), the highest-ever for an Indian company, and profits of Rs.74 99 crore (US $1.73 billion) for fiscal 2006. Indian Oil is also thehighest ranked Indian company in the prestigious Fortune 'Global 500'listing, having moved up 18 p laces to the 135 th position this yearbased on fiscal 2006 performance. It is also the 20 th largest pet roleumcompan y in the world .

Mathur a - Jalandhar Pi pel ine (MJ PL) is a unit of Pipelines Division of Public Sector Company MJPL has been accredited with ISO-9 00 1: 20 00certification for maintaining quality systems and ISO -14 00 1: 200 4 forits environmental management system.

MJPL was construc ted durin g early eight ies and came intoope ration in 19 82 . It was basically constructed for catering to thepetroleum needs of consumers in North and northwest part of India

including strategic defense installations in the region. The unitheadquarters of MJPL is located at Bijwasan, New Delhi. In the year 2000Sonepat-Meerut & 2003 Kurushetra-Roorkee-Najibabad & Mathura-Tundlabranch pipelines were also added to meet the ever-increasing demand of petroleum products in these areas including providing larger flexibility inthe operation.

This product pipeline is engaged in transportation of petroleum productsviz. HSD (High Speed Diesel), SKO (Superior Kerosene Oil), MS (MotorSpirit or Petrol), ATF (Aviation Turbine Fuel) from Indian Oils MathuraRefinery and delivering these products at various locations such as De lhi(B ijw asan), Ambala , Jalandhar , Meerut, Tundla (Agr a), Roork eeand Na ji babad to the tanks of Marketing Division, who subsequentlymarket these products. Transportation of products is achieved throughunderground high-pressure pipeline by pumping from Mathura andboosting operation at Bijwasan & Ambala. Mathura is the originatingstation. Stations at Bijwasan & Ambala are meant for receipt of product as


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well as boosting. Jalandhar, Meerut, Tundla, Roorkee and Najibabad areused only for receipt of products. General information of MJPL is as givenbelow: -

Sections Mathura- Delhi

Delhi- Ambala

Ambala-Jalandhar

Sonepat-Meerut

Kurukshetra Roorkee -Najibabad

Mathura-Tundla

Commissioned on

April1982

August1982

December 1982

November 2000

December 2003

February 2003

Length inKM

147 214 165 70 167 58

Pipe Size 16 14 12.75 10.75 10.75 16 Pipe WallThickness

0.281 0.281 0.250 0.219 0.219 0.250

Pipe Grade API5LX46

API5LX46

API5LX46

API5LX46

API5LX46 API5LX46

MOV (inNos.)

2 4 3 1 2 1

HOV (inNos.)

4 5 6 3 4 1

CV (inNos.)

0 3 3 0 0 0

C. P.Stations

10 10 6 3 6 3

RepeaterStns.

5 5 4 1 4 1

SubmergedX-ing

5 13 5 3 13 8

Line

Capacity inMTPA

3.7 2.2 1.35 0.56 0.89 1.2

MAOP(Kg/Cm 2)

73.83 84.39 82.44 85.79 84.00 72.78

The pumping of products at the stated locations is carried out byoperating high capacity centrifugal pumps driven by heavy-duty HTflameproof motors (6.6 K.V.).


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After commissioning of Panipat Refinery as well as Kandla-BhatindaProduct Pipeline (which was subsequently converted into Crude pipeline),Mathura-Jalandhar Pipeline was hooked up with Panipat Refinery as wellas Kandla-Bhatinda Pipeline at Panipat and thereby making it possible to

transport petroleum products from Panipat Refinery also to Ambala & Jalandhar Stations. Hence, at present Mathur a-Jalandhar Pipe line isha ving fl exi bi lit y to tr ansport the products of Mathur a Refinery& Panipat Refinery . Further, in order to cater to rising demand of ATFin Delhi, presently we have designed simultaneous receipt facilities atDelhi station, by which we are able to take delivery of productsimultaneously from Mathura & from Panipat Refineries.MJPL through continuous efforts will continue to cater to the petroleumneeds of Northern India in an eco-friendly and cost effective way for yearsand years to come.

The total manpower of MJPL including all the stations is 119 having 59officers & 60 staff people. These are posted at all the locations vizMathura, Bijwasan(Delhi), Meerut, Roorkee, Tundla & Najibabad. Asalready said, we are a sub unit of Pipelines Division of Indian OilCorporation Limited. The overall manpower of Indian Oil , as on June 30,2007, is 31724. Thus we constitute 0.38% of total manpower of Indian oil.However, in fiscal terms, we have been contributing with our might toachieve excellent financial results. For the year 2006-07, profit (beforetax) per employee for whol e cor por at ion was 33.0 5 Lacs;howev er we succeede d in giving profi t (bef ore tax)/empl oyee

of 68 .2 9 Lacs.


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Oper ations :- 80% of the refined petroleum productsproduced at

Mathura refinery viz superior kerosene, motorsspirit, High speed diesel and aviation turbine fuel arepumped through this pipeline. Balance 20% of the products

are transported from Mathura refinery through rail and road.The sequence of product pumping is arranged in such

a manner that SKO is used in between any two products sothat interface can be cut into adjoining product and SKO isdelivered without contamination.

Pumping operations are controlled by dispatch atBijwasan and other local dispatches are at Mathura, Ambalaand Jalandhar. Products are pumped from the tank atMathura refinery and after pumping the required quantity fromthe tanks to the pipeline these are handed over back torefinery. Similarly at Delhi, Ambala and Jalandhar the tanksare taken over from marketing division for delivering theproduct. The quantity of products taken over from marketingdivision for delivering the products. The quantity of producttaken over and handed over is determined by checking theopening and the closing dip of tank. These are counterchecked by the flow meter readings a installed at station.

At each station electronic control panels have beeninstalled to facilitate effective and smooth operation of pumping and delivering system. It monitors parameter of pumping and delivery of the station.

Mathura - for pumpingDelhi - for pumping and delivery

Ambala - for pumping and deliveryJalandhar- for delivery

For the safety of pipeline auto controls employinglatest instrumentation technology have been incorporated inthis pipeline. Safety of the pipeline has been given utmostimportance for smooth operation. The auto-tripping of thestation against low suction pressure, high discharge pressurehas been built in the control panel. The main line pump andother equipment have also been protected against high levelof vibration, high temperature, low lube-oil pressure and othercritical parameters.


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PROCES S PUMPS

Gener al Descri ption :- Specially designed vertical single or multi-stage

centrifungle process pumps with squareparting line and manufactured in high grade material and offers theadvantage of reduced floor requirement with overall dimension reduced tothe prime moves diameter a very simple evection layout. Manuf actured in two t ypes:-1.VM T ype :- For pumping from sumps and tanks the lower end of thepump is

submerged in liquid.2.VMB Type :- Construction is the same but the pump is fitted in a barrelwith

suction pipe connection brought to the level of installation.

Pump Consist s Of :-

1.Stage Casing :- It houses the diffuses and impeller, it ave metal tometal contact which avoids any deformation due to joints and gaskets andassemble with the help of the bolts.The number of casing varies accordingto the head of to be developed by the pump.

2.I mpe lle r :- There are single suction totally enclosed and dynamically

balanced. These have individual tapes fit, which prevent shaftsagging.


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7. Pump S haft : - Shaft sizes are selected to give adequate rigidity. It isguided by sleeve bearings at the ends which are lubricated by the pumpedliquid.

8.T rans mission shaft :- According to the depth of the sump or tank oneor move transmission shafts are fitted in between pump shaft and headshaft ,which allows the pump to be lowered w.r.t the mounting plane.

9. Head S haft : - It connects motor shaft to the pump shaft /transmission

Shaft. Thus bearing and mechanical seal/packing withsleeve is mounted on this.

2. INS TALL ATI ON :-Installation of the pump set is the essential operation

on which proper working and life of pump depends. Before any installationaccording to overall dimension of pump it is necessary to check:-a).The easy accessibility of the set after installation.b).The clearance required for its easy assembly and dismantling.c).Construction of the pit or sump.d).The foundation (plane) to which the set is to be firmly fixed.


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CON STRUCTION OF THE PIT OR SUMP

The construction of sump plays a very important role onoperation of the pump. It is an important as the selection of the pump.The following factors must be taken into account before construction of the sump:-1. Submergence of the pump.2. Distance between the pump and the walls.3. Safe clearance height of the pump in relation to the bottom.4. Distance between pump sets when several pumps and fitted in thesame pit.5. Feeding of the pit and flow rate.

The most critical point in the proper submergence which will ensure the

maximum life of the pump by placing it in the operation condition forwhich it has been designed .The submergence depends upon the liquid tobe pumped and it's temperature as well as pressure. In all cases it shouldbe given for minimum liquid level, so that the impeller of the first stage isclearly below this level.

ANCHOR BL OC K:-The anchor block must have proper dimension so thatit can suitably take the weight of the pump set as well as stressesproduced by piping etc.

CONCR ETION: -Concrete should be poured in such a way that passagefor the pump as well as the anchor holes are left at adequate place. A thickness of 4 to 5 cms. Should also be reserved at the upper part of theblock for the cement should be rough in order to provide better adhesionto the cement grout.

INS TALL ATI ON OF PU MP SE T:-

1. Wait until the concrete is completely set.2. On each side place the anchor holes and steel wedges whose thickness

should correspond to that of the cement slab finish.3. Slide the anchor bolts into the holes of the anchor block.4. Position the nut and screw down the nuts on the anchor bolts.5. The wedging should both place the set at the desired height and also

Provide perfect leveling for it's anchor plates.6. After this check, pour the cement grout in the block holes and left it

set. Then tight the anchor bolts down.


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FINIS HING OF F OU NDA TI ON SL AB: -It should becarried out with cement and fine sand. It is not advisable to use cementwhich sets quickly as it cracks and breaks off easily.

1. The set being finally blocked on the foundations , grout the cementbetween the foundation and anchoring block. Use a fluid cemnt grout .2. It is recommended that the foundations be left to harden for severaldays before proceeding to put the pump set into operation.

PIPING CONN ECT ION :-

1. There operations should be done taking care to fit accurately thea. Delivery and suction nozzles w.r.t the corresponding pipeb. Connection so that no strain is caused on the pump.

2. It no recommended that piping is supported independently of thepump.

3. While tightening the flauge bolts check the alingment andparallelism of the coupling faces with the dial gauge. The dialgauge should give the same reading as obtained previously.

3. STARTING UP:-

1. Check: -

a) Proper grade of clean grease is used to lubricate the bearing.b) Any external circuit of flushing, quenching and cooling an

activated.c) Pump alingment is not disturbed by due to abnormal external

forceson the nozzle by pipe fittings.

d) The direction of rotation before connecting the 2 halves of thecoupling, ensure proper direction on motor.

4. CHECK -P OIN TS:-

1. S uct ion T roub le: -1. Pump not primed.2. Sump or barrel not filled with liquid.3. Suction lift too high.4. Insufficient margin between suction and vapour

pressure.5. Excessive amount of air or gas in liquid.


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6. Air leaks into suction line.7. Air pocket in suction line.8. Foot value suction pipe size too small.

9. Foot value partly dogged.10. Inlet of suction pipe insufficiently submerged.

2. System Trou bles:-11. Speed too low.12. Speed too high.13. Total head of system higher than design head of

pump.14. Specific gravity of liquid different from specified.15. Total head of system lower than pump design head.16. Viscosity of liquid differs from that for which design.17. Operation at very low capacity.

3. Me chanica l T roub les:-

18. Foreign matter in impeller.19. Mis-alingment.20. Foundation not rigid.21. Shaft bend.22. Rotating part rubbing on stationary part.23. Bearing worn.24. Wear ring worn.

25. Casing gasket 'o' ring defective permitting internalLeakage.

26. Shaft or shaft sleeve worn or scored at the packing.27. Packing improperly installed.28. Rotor out of balance resulting in vibration.29. Gland too tight resulting in no flow of liquid to

lubricate packing.30. Failure to provide cooling liquid to water cooled

stuffing boxes.31. Dirt or girt in sealing liquid, leading to scoring of shaft

sleeve.32. Excessive grease in antifriction - bearing housing or

lack of cooling.33. Lack of lubrication.34. Improper installation of antifriction bearings.35. Dirt getting into bearings.36. Rusting of bearing due to water getting into housing.


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5. MAINT ANEN CE :-Repacking the stuffing Box/Discharge Elbow.

1. Change the packing when the cover comes up against thebox/discharge elbow.

2. Remove the old packing completely and thoroughly clean the stuffingbox elbow.

3. Inspect the sleeve.4. Select the proper packing of the same quality as original.5. Rings should be properly sized.6. Insert each packing ring separately and pushing it squarely into packing

box elbow.7. Successive rings of the packing should be rotated so that joints are

staggered at 120 or 180.

8. Replace the cover and lightly hand tighter.9. Start the pump and allow leakage through packing at the rate of 80 to100 drops/minute.

10. Tighten the gland nut gradually till the leakage rate is reduce to 8 to10 drops/minute.

11. Replacing and adjusting of stuffing boxes/discharge elbow should onlybe done by experienced person.

Mechanica l Seal: - These seals are correctly adjusted in the factoryand

virtually no maintenance is required.

Bearing : -1. Only bearing grade lithium base EP-2 grease to be used. Never use pink grease.2. Pack moderately to avoid over heating of bearings.3. Change grease after first 100 hrs. of operation and check after every500 hrs. of operation.

6. DIS MAN TLING :-

1. Bef ore Dismantlin g-close the pump isolation values.-drain the barrel in case of VMB pumps.-if necessary disconnect the auxiliary pipes.-take out the motor with motor side coupling


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bolt and then motor stool(501)-if required disconnect the piping.

7. RE-ASSEMBLY:-Pay special attention to following points:

1. Before Re assembling:- All components should be cleaned thoroughly and all mounting

surfaces should be checked for defects so that the original settingcan be restored smoothly.

If bearing is showing traces of scaling on the balls and journals itshould be changed. Slight wear is permissible if the journals areperfect.

Any defective seal must be changed. The shaft should be checked on centers or 2.Vee supports.

Maximum out of concentricity must not exceed 0.05mm.

2. Re-Assembly of first stage impeller.3. Re-Assembly of the lower bearing.4. Fitting of 1st stage casing.5. Fitting of 2nd and subsequent stage casing.6. Re-Assembly of intermediate bearing (if applicable).7. Re-Assembly of upper bearing.8. Re-Assembly of transmission assembly.9. Re-Assembly of discharge elbow.10. Refitting the packing.11. Refitting of mechanical seal.12. Re-Assembly of bearing housing.

8. AD JUS TME NT O F TH E R OTATING AS SEM BLYOF T HE PU MP :-

Insert cylindrical pin into adjusting nut. Assemble coupling pump half with coupling key on the head shaft. Unscrew the adjusting nut to lower down the rotor till one of the

the impellers touches stage casing. Tighten the adjusting nut about 2/3 turns such that rotor assembly

is lifted up by about 1mm. to bring the impellers approximately atthe centre of the diffusers.Insert cylindrical pin into the nearesthole of the coupling.


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9. CHEC KINGO F TH E COU PLING :- Before motorassembly

it is absolutely essentialto check the concentricity and parallelism of the coupling tolerances of which are given below:-For pump: -

coupling half O.D concentricity 06 concentricity of motor location diameter 02 parallelism of bearing housing face 02

For motor: - coupling half O.D concentricity 06 concentricity of motor location diameter 02 parallelism of bearing housing face 02

If the values obtained on comparator are more than the

values given below. It is advised to inspect the materials carefully fordamage and carry out necessary repairs.

After the motor has been assembled check alingment of coupling plates with the dial gauge. Maximum difference allowed between

the 2 halves is 0.03 mm.

10. SPARE P ARTS : - We recommend the user to have followingspare parts:-

1. Thrust bearing2. Aset of packing/mechanical seal.

To order spare parts please indicate : -1. BPC S/O no.2. Pump type3. Part no. with descriptions according to sectional drg no.4. Section drg. number.


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MJPL A t Gla nce

Mathura- Delhi- Ambala-Delhi Ambala Jalandhar

Commissioned On 27/04/1982 6/8/1982 9/12/1982Length(KM) 147 214 165

Outer Dia. 16" 14" 12.75"Wall Thickness .281" .281" .250'

Grade API 5L*46 API5L*46 API 5L*46

No. Of ValvesMOV 2 4 3HOV 5 7 6No. Of CP Station 10 9 6No.Of Repeators 3 4 3No. Of Bridge Crossing no 3 1No. Of SubmergedCrossing 5 10 3Length Capacity InMTPA 3.7 2.2 1.35

Documents

Project Report on Study of Process Pumps by-Sachin