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Introduction to Rotary Equipment in Refinery

March,2014
arun.kumar@hmel.in

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
SRU
VGO
MS Block
DCU
HGU
CDU
FCCU

44
54
44
52
66
10
38
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
MS Block-

Integrally geared centrifugal compressors : 11

3
3
6

HMEL Criticality Matrix


Area
CDU
DCU
SRU
CT and IAC
DHDT
ETP
FCCU
CPP
HGU
LPG Treater
RODM
RWTP
VGO
Offsite
MS Block
PPU
Total

Super critical

1
1
1

2
4
5

1
3
1
19

Critical
46
53
48

Semi critical
58
65
76

Essential
48
44
28

Total
152
163
152

8
32
47
58
29
19

15
52
80
62
43
20

22
24
53
28
75
18

46
109
180
150
151
62

9
29
16
31
52
74
109
660

22
66
35
66
98
74
0
832

10
44
33
26
45
66
0
564

41
139
84
124
195
217
110
2075

Rotating Equipment Organization

AGM Rotating equipment

Managers -Rotating equipment


Regular maintenance

AM Workshop Rotary equipment,


Mechanical seal refurbishing, Oil
Analysis, Balancing

Manager- Reliability Rotary


AM-Condition monitoring

AM- Spares & Services

Why Rotating Equipment are most critical & heart of Refinery ?


Some special features :

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.

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

Predictive / Preventive Maintenance


Preventive maintenance:
preventive maintence , based on:
OEM recommendations,
Behavior pattern of similar machines at other sites. Mainly for equipments having standby.
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
SRU
VGO
MS Block
DCU
PPU
FCCU
Copyright HPCL-Mittal Energy Ltd.

5
3
9
9
3
6
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).
June 4, 2014

Copyright HPCL-Mittal Energy Ltd.

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

Dry Gas seals


Couplings
Fans, Blowers & Extruders
Jet Pumps
Condition Monitoring, Vibrations analysis, Lube
oil analysis
Anti surge system

Instrumentation :

Fire & gas detection system,


Process optimization,
Overview of DCS & PLC,

Hazardous area classifications, Motors


ELECT. SAFETY- Electrical Insulations/Static Electricity Hazard/safety measures

Electrical :

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

PM Philosophy Rotary Equipment


Equipment Type

Preventive Maintenance Frequency

Centrifugal Pump
Sundyne (Pumps & Compressor)
Booster Pump
Vacuum Pumps
Vertical Pump (VS1 & VS4)
Gear Box
Dosing pumps
Agitator (ETP)
Agitator (PPU Reactor)
Agitator (Dosing Skid)
Agitator (Tank Farm)
Fans and Blower
Air fin cooler

6 month
6 month
6 month
6 month
6 month
Clubbed with Parent Equipment
9 month
3 months
Opportunity based
6 months
6 months
6 month
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


14

Predictive / Condition Monitoring Schedule

Criticality

Frequency of Vibration capturing

Frequency of Signature analysis

No of equipments

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

Action on
Preventive Maint. schedule for critical machines
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
1.

2.

Clocking for recip machines (PM based on running hours)

3.

Internal Audit for quality SAP order closure history

4.

LLFS

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)

Proprietary & Confidential

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

Some Leanings

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.

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