rotating 1
DESCRIPTION
rotatingTRANSCRIPT
Rotary Equipment in Refinery
Large population of Rotating equipment – Heart of Refinery Total : 2075
Compressors: Centrifugal compressor : Integrally geared compressor Reciprocating compressors Diaphragm compressors. Screw compressors
Turbines: Steam turbines. Gas Turbines Expansion Turbine
Blowers
Fin fan
Centrifugal Pumps
Dozing pumps Centrifuges, Extruder.
Area wise fin fan
DHDT 44 SRU 54 VGO 44
MS Block 52 DCU 66
HGU 10
CDU 38 FCCU 20
328
Reciprocating compressor
DHDT 2 VGO 4 MS Block 14
HGU 4 CPP 1
25
Centrifugal compressors
DHDT 1 SRU 3 VGO 1
MS Block 2 DCU 1
IAC 5
FCCU 2 CPP 5
ETP 1 PPU 2
23
Screw compressor
PPU 3 MS Block- 3
6
Integrally geared centrifugal compressors : 11
HMEL Criticality Matrix
Area Super critical Critical Semi critical Essential Total CDU 46 58 48 152
DCU 1 53 65 44 163 SRU 48 76 28 152
CT and IAC 1 8 15 22 46
DHDT 1 32 52 24 109
ETP 47 80 53 180
FCCU 2 58 62 28 150 CPP 4 29 43 75 151 HGU 5 19 20 18 62
LPG Treater 9 22 10 41 RODM 29 66 44 139
RWTP 16 35 33 84 VGO 1 31 66 26 124
Offsite 52 98 45 195 MS Block 3 74 74 66 217 PPU 1 109 0 0 110
Total 19 660 832 564 2075
Rotating Equipment Organization
AGM Rotating equipment
Managers -Rotating equipment Regular maintenance
AM Workshop – Rotary equipment, Mechanical seal refurbishing, Oil Analysis, Balancing
AM-Condition monitoring
Manager- Reliability Rotary
AM- Spares & Services
Why Rotating Equipment are most critical & heart of Refinery ?
• Has big population and varies type. • Had complicated instrumentation and control ( microprocessor based) • Logics , PLC based with lot of safety integrated , • Turbomachines have speed governing with integrated compressor control. • Handles Hydrocarbon, Hydrogen.. • Has single line major turbomachines • Has dual mechanical seals ( API seals) • Hot pumps : ( temp. 360 degrees C, congealing fluid, needs proper warm up).
• Slurry pump in FCCU, Column bottom pumps • Fractionator bottom pumps in VGO. • DCU coke charge pumps. • VR pumps in CDU.
• Needs high reliability and availability • What went wrong- RCA of failures . • What can go wrong - FMEA • Low MTTR • High MTBF
• Has dual Dry gas seals in centrifugal compressors.
Some special features :
Maintenance Philosophy
Minimize unplanned / breakdown jobs/ repeated failures,
move with improvements & maximize the life of
components & system.
• Preventive maintenance
• Predictive maintenance
• Emergency maintenance
• Corrective maintenance
June 4, 2014
Copyright © HPCL-Mittal Energy Ltd.
Predictive / Preventive Maintenance
Preventive maintenance: •preventive maintence , based on: OEM recommendations, Behavior pattern of similar machines at other sites. Mainly for equipments having stand-by. Reciprocating machines have time based maintenance.
•Other single stream machines in planned turnaround: Minor or major overhauls.
•SAP has PM module, generate the work notifications and maintenance orders, capture histories , maintenance planning, work scheduling, .
Predictive maintenance:
•Predictive maintenance, attempts to evaluate the condition of equipment by performing periodic or continuous (online) monitoring of equipment.
•Utilizes technologies such as vibration analysis, sound level measurements, ultrasound, oil analysis, Motor Current Analysis and other specific online tests.
June 4, 2014
Copyright © HPCL-Mittal Energy Ltd.
ONLINE CONDITION MONITORING (GE SYSTEM-1)
Machine Data Monitoring & Management System (MMS): To continuously monitor and display parameters like vibrations, bearing temperature, winding temperatures etc. for 37 critical rotary machines across the GGSR Refinery.
Alarms are generated when conditions exceed preconfigured alarm limits and these alarms are used to automatically shut down the machine thru ESD/PLC.
The System 1 software in combination with the System 1 Rulepaks provide output for diagnosis or analysis of all the 37 critical machineries connected to this network.
Online monitoring equipments DHDT 5 SRU 3
VGO 9 MS Block 9 DCU 3
PPU 6 FCCU 2
37
June 4, 2014
Copyright © HPCL-Mittal Energy Ltd.
OFFLINE CONDITION MONITORING ( EMERSON)
782 equipments which are not covered under the on-line condition monitoring system shall be monitored using portable analyser Emerson CSI-2130.
Condition monitoring frequency shall be fixed for each equipment based on the criticality of the equipment, safety and environmental aspect. (as per guide line of OISD 124); Functional criticality analyses (FCA)
Equipments covered under offline condition monitoring are regularly trended using the RBM ware software.
Vibration Analysis and Recommendation (VAR) Reports shall be generated for the equipments which exceed the alarm limits configured in the RBMware software as per ISO 10816. Both on line and off line vibrations shall be monitored in Condition monitoring lab in workshop on large display.
Oil Analysis shall be done as per schedule for equipment defined in Oil analysis in reference to OISD standard. We shall be on line with OEM of extruder ( M/s Coperion) in PPU for condition monitoring of lubrication oil of gearbox (having 64 bearings).
Refinery Rotating Equipment Engineer - Challenges SAFETY:
HSEF and Fire fighting:
JOB SAFETY ANALYSIS & RISK ASSESSMENT Scaffolding Safety , Ladder Safety for Contractor Supervisors, WP Issuers &
Acceptors INCIDENT INVESTIGATION
Codes & Standards (API 617, 611, 612, 610, 682, 670, 686) Bearings & Lubrication Centrifugal Pumps Positive displacement Pumps Centrifugal compressors Reciprocating compressors Screw Compressors Steam Turbines Gas Turbines Alignment Balancing Turbines Governing system & electronic governors On line Vibration monitoring system Vibration Analysis Pneumatic tools Mechanical seals
Instrumentation : Fire & gas detection system, Process optimization, Overview of DCS & PLC, Electrical : Hazardous area classifications, Motors ELECT. SAFETY- Electrical Insulations/Static Electricity Hazard/safety measures
All rounder: SAP PM Module
• What Went Wrong?, Learning From Incident / Case studies • Metallurgy • Process • RCA • Economist • Should be able to work under pressure • Good team player • Industrial Engineering (scheduling , planning & Control) • Inventory Management • Innovative (jugads). • Extracting best work from technicians/ contractors
Dry Gas seals Couplings Fans, Blowers & Extruders Jet Pumps Condition Monitoring, Vibrations analysis, Lube
oil analysis Anti surge system
14
PM Philosophy – Rotary Equipment
Equipment Type Preventive Maintenance Frequency Centrifugal Pump 6 month Sundyne (Pumps & Compressor) 6 month Booster Pump 6 month Vacuum Pumps 6 month Vertical Pump (VS1 & VS4) 6 month Gear Box Clubbed with Parent Equipment Dosing pumps 9 month Agitator (ETP) 3 months Agitator (PPU Reactor) Opportunity based Agitator (Dosing Skid) 6 months Agitator (Tank Farm) 6 months Fans and Blower 6 month Air fin cooler 3 month Turbines (Pump Drive) 1 year / opportunity based Turbine (centrifugal compressor drive) Stroke check only on yearly basis, detail inspection plan will be OEM specific Reciprocating Compressor Based running in Hours as per OEM specific Integral Geared compressor Annual Inspection as specified by OEM Screw Compressor Annual Inspection as specified by OEM Centrifugal Compressor OEM specific work schedule Single line machine Included in Predictive Maintenance, Overhaul in Opportunity Shut down
Proprietary & Confidential
Predictive / Condition Monitoring Schedule
Criticality Frequency of Vibration capturing Frequency of Signature analysis No of equipment’s
Super critical 7 Days weekly 18
Critical 7 Days only for those equipments which run
above threshold limit 551
Semi critical 15 Days only for those equipments which run
above threshold limit 832
Essential 30 Days only for those equipments which run
above threshold limit 564
Proprietary & Confidential
1. Revised frequencies for Preventive maintenance based on
equipment performance/ experience from 3 months to 6 months for
pumps. Advantage:- prevents over maintenance & related costs
…….Moving towards condition based maintenance
2. Clocking for recip machines (PM based on running hours)
3. Internal Audit for quality SAP order closure – history
4. LLFS
Action on
Preventive Maint. schedule for critical machines
Proprietary & Confidential
Best Practices Adopted In Maintenance:
• Selection of Proactive maintenance strategy for plant and equipment's. • E-SPIR for spare part interchangeability across tags and review for spares inventory optimization.
• Hydraulic torqueing and tensioning for the critical & hydrocarbon joints thus avoiding
hydrocarbon leakages.
• Fully functional state of art Workshop providing continuous support for maintenance,
machining, repairs, testing, assemblies, fabrications, Mechanical seal refurbishing for
API seals, making new parts by reverse engineering, with attempt to carry out all
repairs in house, reclaim damaged parts. • Soft footing correction of electrical motors by blue matching thus avoiding vibration related problems in motors. (28 LT motors, 8 HT motors, resulting smooth operations of machines without vibrations) • In house Mechanical seal refurbishment shop, thus ensuring equipment availability and safety. • Mechanical run test of compressors / Water trials of Pumps done before taking in line with Hydrocarbon thus avoiding any leakage of hydrocarbon. • In-house capability of attending problems in major rotating equipment. • Engineers trained by OEMs and on job thus capable of resolving maintenance
problems in critical areas. • Boroscopic inspection of suction pipe line and inlet nozzles before commissioning. • Hot alignment of Hot pumps is very essential.
Proprietary & Confidential
Baroscopic inspection of Pump suction
(DHDT)
•It was originally planned to run delayed coker unit fro 10 days and then
shutdown it fro 12 days to make other units ready.
•We overhauled the turbine in this opportunity and replaced the turbine rotor
with spare rotor. Complete overhauling of steam turbine done sucessfully
Demonstration of
turbine rotor barring
done manually
• Skilled persons, spares , dedication,
tireless working is key to success in
rotary equipment. Passions towards
rotary machines
• Temporary innovative repair resolutions in
Turbomachinery can save a significant
amount of downtime. Permanent resolution
can implemented at a later opportunity like
a planned turnarounds etc.
Some Leanings