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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


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


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

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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


Essential 30 Days only for those equipments which run



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


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.


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

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