Welcome

Welcome
To
To
Mechanical
Mechanical
Maintenance
Maintenance
 Mechanical Maintenance
M e c h a n ic a l M a in te n a n c e O r g a n o g r a m

B .C .S h u k la
V P (M )

T .V .S u j i t K .S .K o p p a l k a r
G M (M e c h M a in t) G M ( M .P la n .)
1 nos

H .P .P a i K .S iv a s u b r a m a n i
D G M (M e c h ) H a r is h D a m o d a r
A d a rsh G A

W S /M O D I CPP C R /C M S R U /C C R O M & S /E T P J e ttty /B D F U H C U /H Y D C D U /V B U /G O H D S

N ir a n ja n R a o K esh av a N ay ak D eepak V N S V e n k tra m a n a S .G .A r u n M anohar N ayak H S R a je e v S u d h ir H e g d e
S r .M a n a g e r S r.M a n a g e r M anager S r .M a n a g e r DGM M anager M anager S r .M a n a g e r

W /sh o p CPP C r itic a l/R o ta r y SR U O M & S /E T P J e tty H C U /H Y D C D U /V B U /G O H D S

K ir a n B / S a t h is h R a g h a v e n d ra H S / S u n il K / S a t y a s e e la n M a n ju n a t S a s t r y U m e sh U d u p a / S u re sh K u m a r J Sandeep R ao P . S u re sh K u m a r/
M odi M ah esh M P / C o n d .M o n . CCR S r ik a n t B h a t / BDFU A ru n H R R avi K um ar
L a k s h m ia h / V B K a lla n D in e s h M / R a je n d r a A r u n K u lk a r n i R K R ao G an esh M V B H ic h k a d M anoj K um ar

T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s T e c h n ic ia n s
 The Works

Daily meeting of DGM, GM & VPs in the morning

Weekly meeting of Engineers with respective heads
of the department
Monthly meeting of Managers with VP
Quarterly meeting of Technicians with concerned
Area In charges & GM
Monthly Workshop area Safety Committee meeting
Monthly meeting on Preservation committee of
materials in the Stores
 Work Force Set Up

Refinery Process Units includes Crude Block/

Hydrogen Block/ OMS/ CPP
Workshop(Includes Process Modification)
Critical Rotary/Condition Monitoring Cell
Maintenance Planning
 Maintenance Job Management

Rotary Maintenance and Regular Maintenance jobs through

MRPL supervision and assistance of contracts
ARC
JWS
Specialist jobs
 Major ARCs
Annual Rate Contracts for
Item Rate

Shutdown ARCs

For catalyst related jobs

Fabrication

Scaffolding

Insulation

Fabrication w.r.t Modification for TS schemes

Stress Reliving

Furmaniting

Coating and wrapping

Painting
 ARC continued
Fire hydrant Maintenance
Maintenance of Sarpady
ARC for Exchanger Maintenance
ARC for Boiler related jobs
Tank Cleaning
Specialist services:
Like epoxy coating/Foam seal for Floating roof

tanks/Scroll repair in ETP/Lettering/

Workshop Support-Overhaul of engines

Refractory jobs
Operation of BDFU
Removal of sand for filters in WWTP
 Other ARCs
Other major ARCs
Rotary Maintenance
Bearing

Seals

Lube Oil

Coupling

Belts

Gaskets for Exchangers

Steam Traps
Consumables for workshop
Diesel
Burners for heaters
 Mechanical Maintenance expertise

Shutdown Maintenance
Routine Maintenance
Includes
Rotary jobs
Jobs with Static Equipment
A sneak preview of our Work Management

Work Request taken from Operation either through

MMS or Verbally
Internal work request are given by condition
monitoring.
Logistics:Used for indenting material and raising work
request
Work Request and Work History
Raising indents and Work Requests
Shutdown Maintenance
Planned
Inspection Statutory requirement
Factories act testing of Static equipment once in 4 years
PSVs to be tested every year
Operation Analysis
Improvement/enhancement
Operations
Maintenance/Avoid failure
Emergency
 Shutdown Maintenance
Areas which come under Shutdown-broadly into 8 categories
1. Columns/Strippers
2. Vessels
3. Reactors/vessels with catalyst replacement
4. Exchangers/Including Air Coolers
5. Heaters
6. Modifications
7. Tagged Jobs
8. Safety Valves
Major type of Column
columns
Major Mechanical Jobs
Inspection requirements /support for thickness survey
Repairs identified by Inspection.Change in
metallurgy/Thickness
Tray repairs/Structural work
Chimney tray Hydrotest
Repair/maintain nozzles
Gasket replacement
Replacement repair of packings-Structured and Random
Repair of Demisters
Vessels
Major Jobs
Statutory Hydrotest /Water fill test
Cleaning
Repair of Filters/colescers/Demisters
Replacement of Gaskets
Inspection Support/Repairs identified
 Reactors/Vessel with Catalyst
Change
Arrangement done on types of loading:
Sock Loading
Dense Loading
What guides type of contracts for catalyst jobs?
Condition of entry/gases present/Temperature
Time
Type of catalyst
Repair/Maintenance of internals
Nozzles
Gasket replacement
Inspection support for thickness survey
Inspection and repair of Johnson screen.
Exchangers
Major jobs
Statutory hydrotest requirements
Cleaning as required by OA/Operations
Bundle Replacement
Repair of tubes/replacement of tubes
Plugging of tubes
Types of Exchangers
Based on Front Stationary Head
Shell Type Rear Head
Removable One pass
A Channel cover E shell L,M,N
Bonnet integral Outside packed
B cover F 2 Pass shell P floating head
Split ring-floating
head with backing
C Channel Integral G Split flow S device
with Tube sheet & Double split Pull through floating
N Removable cover H flow T head
Special High
D Pressure closure J Divided flow U Tube Bundle
Kettle type Re- Externally sealed
K Boiler W floating Tube Sheet
X Cross flow

Types of exchangers in the Refinery:

AES/AKU/DEU/AKT
Vertical exchangers(In VBU)
TEMA-Exchanger types

Type A Front Stationary

head
A:One tube side pass
B:two side passes
C:Four tube side passes
D:photograph of a front
stationary head
TEMA-Exchanger types

Type B Front
Stationary Head
A:One tube Side
B:Two tube side
C:Four tube side
Type C front Stationary
head
A:One Tube side pass
B:Two tube side pass
C:Four tube side pass
Type N
Front stationary head one
tube side pass

Type D
Front Stationary head
 Type E shells

Shell with A Distribution

Dome
B Vapor belt
Type F shell
A :shell with two passes and
a longitudinal baffle
B: 2-2 exchanger
C:2 4 exchanger
Split flow shells
A: Type G
B:Type H
Type J shells with a divided
flow
A:one inlet,two outlets
B:Two inlets,one outlet

Type J with a change in

Phase
A:Reboiler
B:Condenser
Type J shells in series

Type J shell with a

vapor belt
Type K(kettle) Shell

Type X shells-cross
flow
Rear head type L,M,N

Type P floating head

Type S floating head

Type T Floating Head

U-type bundle

Type W Externally sealing

floating tube sheet
Ex:Ejector Condensers CDU2
Major Jobs with Fixed
Tubesheet Exchangers
Hydrotest
Cleaning
Plug Tube
Expand tubes
Gasket replacement
Ex:most of the coolers in the Ref
Major Jobs associated with U-
tube Exchangers:
Tube repair/Expansion
Hydrotest
Plug tubes
Bundle Replacement
Gasket replacement
Major Jobs associated with
Reboilers:
Hydrotest
Tube repair
Bundle replacement
Gasket replacement
Highest % available in the
ref
Major Jobs with AES
exchangers:
Bundle Cleaning
Hydrotest
Gasket replacement
Tube Repair/Replacement
Bundle Replacement
Mech Workshop have
replaced many AES typle
bundles and u-type bundle
in house
Fin Fan Coolers

Major Jobs Associated with Air Fin Coolers:

Cleaning
Hydrotest
Gasket replacement
 Safety valves
Spring

Seat/Disc

Orifice

Major Jobs Associated with Safety Valves:

Resetting Cold Set pressure
Lapping Seats
Overhaul
Replace springs/Internals
Safety Valves
for compressible fluids/steam and other gases.Where there are demands for quick
over pressure relief
Discharge either to atmosphere or back to a system
Relief valves
handle non compressibles
Discharge to low pressure systems
Heaters

Convection

Radiant

Burner Block
 Burner Details
Burner repair and Maintenance
Major Jobs In heaters:
Inspection Jobs-Support
work
Spalling/Steam Air Decoking
Burner repair/maintenance
Refractory maintenance
Tube repairs
Support repairs
APH wash/Repairs
Modifications like replace
peep doors
 A brief on Refractories
RefractoryJobs
Refractories are made of material with low thermal conductivity
Mainly classified as
Acid
Basic
Neutral
Used as
Brick Type
Dense Type

Insulating Type

Monolithics
Insulating Castable

Dense Castable

Ramming material

Plastics

Ceramic Fibre Blankets

Calcium Silicate material
 Modification
Requirement
Operations
Flexibility in operation
Operations/Operation Analysis
Improvement
Methodology
Design and Drwaing from Tech Services
Material Procured by Tech Services
Fabrication through contracts
Hydrotest by maintenance/Contracts
NDT by Inspection
Stress relieving if required by Maintenance
Tagged jobs
Some of these jobs can be done during normal operation if the
equipment can be isolated.
Jobs are classified under tagged for convenience/planning
They include:
Mainly Related to Pipes and their fittings or those jobs
which are a part of large equipments-auxillaries like soot
blowers,ejectorsRequires shutdown
Hydrotest requirements of IBR(some vessels get included)
Pipe line repairs
Valves:
Gate valves/Plug valves/Butterfly valves/Angle valves

Steam Traps-can be isolated(will be discussed with CM cell)

 Most used valves in the Refinery

Globe Valve
Gate Valve

Flow to stop or Flow to be

open regulated/throttled.
Cannot operate in reverse
direction
 Most used valves in the refinery

Angle Valve NRV Butterfly

Hig volume/change in
UniDirectional flow
flow when opening or
closing is less
 Major Jobs associated with valves

Seat lapping to improve performance

Replacement of Gland and packing
Testing of valves
Drop Seat!
Miscellaneous equipments

Jobs Associated with Ejectors

Clean nozzle

Jobs Associated with Soot Blowers:

Maintain drives
Change lancers
Boiler Maintenance
Major Jobs:
Annual IBR Hydrotest
Burner maintenance
Refractor repair
Inspection jobs
Tube Repairs
APH cleaning
APH repairs
Floating Safety
Valve/Safety Valve
Calibration
 Most Important Joining processHeart of
Maintenance activity

Welding:
Different Welding Processes involved
Arc Welding
Gas welding
Electric Resistance welding
Plasma Transferred Arc Welding
Electron beam Welding
Different Arc Welding Processes

Arc Welding:
An electric arc is established between an
electrode and work piece
Electric arc releases Thermal energy which
heats the joint to be welded
Some of the widely used processes are:
Shielded (manual( Metal Arc Welding
Tungsten inert gas Welding(TIG/GTAW)
Gas Metal Arc Welding (GMAW/MIG/MAG)
Flux Cored Arc welding(FCAW)
Submerged Arc welding(SAW)
 Most widely used welding process in
the Refinery

Sheilded(Manual) metal Arc Welding

Arc developed between a consumable flux
coated electrode and the job-gives heat
Flux around the electrode generates a
gaseous sheild
Filler material is normally of higher
strength than the jobs being welded
Extremely versatile-used both in ferrous
and non ferrous

Electrode:
Solid metallic wire-called core wire
Coated with flux
25 to 40 mm left bare at one end for grip
of electrode holder
Striking end-is left exposed to facilitate
arc striking
 TIG welding
Tungsten Inert gas Welding:
TIG:Electric Arc Stuck between Work
piece and Non Consummable Tungsten
electrode.
Arc and Weld Zone is protected by an
inert gas(argon/Helium or a mix)
Filler materila is added externally to the
arc in the form of a bare wire
HF(High Freq )Unit generates HF High
Voltage is superimposed on the Weld
Current
Gases are ionised and free element forms
a conducting path between job and
electrode
Therefore no direct contact is necessary
between job and electrode
Tankages
Floating Roof
Fixed Roof
Spheres
 Tankages
Inspection jobs
Failures-Repairs
Preventive maintenance
Mixers
Type Of Mixers
Sachony/jet mixers
Painting/prevention of corrosion
Recalibration of Safety valves in spheres
Servicing roof vents/valves/PVRV
Cone Roof Tanks
Floating Roof Tank
 Major Jobs in Floating roof tanks
Major jobs

Hydrotest of
Foam tenders
Emergency roof Drain
Steam coils
Service Valves
Major Repair work
Foam Seal
Weather Shield
Bottom plate/test with vacuum box
Tank Pad
Pontoons
Jetty/BDFU/ETP
Jetty
Maintenance jobs with Loading Arms
BDFU:
Rollers and conveyors
Handling Drums
Exchanger maintenance
ETP
Various conveyors/skimmers
Maintenance of storage area-Ponds
Filters
Rotary/reciprocating equipments
ROTARY MAINTENANCE
 Major Rotary Maintenace
Pumps
Compressors
Fans
Transmission devices
Turbines
Rotary Maintenance
Rotating machines-1610(Excluding Projects)
Pumps-1076(so we need to discus in greater detail)
Compressors 42
Fans 426
Field maintenance
All rotary<Recip equipments <1 MW
Critical Rotary Group
All rotary /reciprocating machines >1 MW
Machine that Can lead to Plant Shutdown
Condition Monitoring group
Philosophy followed Predictive Maintenance
 Pumps Fundamentals

Works on Bernoullis Principle

Pressure Energy+Potential Energy +Kinetic Energy=Constant

Total Energy has to remain constant!!

Centrifugal Pumps:
Provide s high s Kinetic Energy and converts To Pressure

Energy by change in area

Running Centrifugal pumps with closed discharge for a longer

time causes Churning

Positive Displacement Pumps:
Displace liquid to a higher pressure system.(Physically Displace)

Never operate Positive Displacement pumps with closed

discharge!
Fundamentals of Pump
Operations

BEP
Pumps Based on types of impellers

Based on const
Closed:Liquid is
clean/High Pressure
Semi Open:Incl of solids
Open:Mainly slurry appln

Based on Design:
Radial:High Pr Medium
Flow
Mixed:Medium Pr Very High
Flow
Axial:Low Pr High Flow
 Centrigugal Pumps-parts maintenance
Criteria
1 Suction
Typical Centrifugal Pump 2 Impeller
3 Discharge
4 stationary Casing
5 Rotating Shaft
3 6 Mechanical Seal in Stuffing Box
7 Gland
8 Radial & Thrust Bearings to Support the Shaft
8 Must be lubricated at all times.

2 4 7
1 5

6
 Centri Fugal Pump-Multistage
Pump
Single Stage Double Suction Pump
 Multistage
Multistage
Barrel Type
Axially Split
Reactor Charge Pump
Barrel Type
Sundyne Pumps

Low Flow
High Pressure
NPSH avble is low
Mainly used in
Naptha or lighter
ends
Vertical Pumps
Major Jobs:
Impeller
Shaft damages
Bearings
Seals/Gland
replacement
Most Critical sometimes
as its used for handling
slops
A little Deeper into Pumps

Mechanical Seals!!
A continual improvement commitment
of
Mechanical Engineers!!!
Mechanical Seals By Arrangement

Single Multiple

Inside Double Back to Back

Outside Double Face to Face
Tandem
Staged
 Mechanical Seals By Design

Unbalanced Single Spring Pusher Type Flexible Face on

Balanced Multiple Spring Non-pusher Type Rotor Rotor
Flexible Face on
Rotor Stator
Bellows Seal
O-Ring
V-Ring
Metal
Wedge Ring
Elastomer
TFE
 Seals
Consists of Rotary
and a Stationary
Part

Rotary Stationary
Typical Seal Arrangement and their
leaking places

1.Gland to pump face -

sealed with a gasket
2 2.Over the top of the seal -
O-ring
3.Under the seal - O-ring
4.Between the faces
 Some Problems associate with Seals

Basic Pusher Seal

Gasket hang-up occurs when solids build-up sufficiently to impede gasket movement.
The springs closing force is disrupted and heavy leakage soon develops.
 Some types of Seal arrangement
The secondary seal does not have to move along the shaft or sleeve to
maintain face contact

Pusher Seals Non Pusher Seal

 Types of seal arrangement

Tandem Seal Back To Back

Sealing liquid Outlet

Sealing Liquid Inlet

Sealing Points Sealing Points

 Used mainly in vertical Pumps

Single Outside Seal

 Major Checks Done for Seal assy

Gland Register or Stuffing

Deflection End Play
Box Concentricity

Stuffing Box to Shaft

Perpendicularity Shaft Run-Out
 API Plans-Most important ones
Bypass Flush from Pump Discharge
Single Inside Seal

API Plan 11
ANSI Plan 7311
 API plans
Recirculation from Seal Chamber to Suction
Single Inside Seal

API Plan 13
ANSI Plan 7313
 Api plans
Bypass Flush through Heat Exchanger
Single Inside Seal

API Plan 21
ANSI Plan 7321
 Api Plans
Recirculation through Heat Exchanger
Single Inside Seal
with Pumping Ring

API Plan 23
ANSI Plan 7323
 Api plans
External Flush
Single Inside Seal

Close
Clearance
Throat
Restriction

API Plan 32
ANSI Plan 7332
Api Plans
Flush and Quench
Single Inside Seal

API Plan 11 & 62

ANSI Plan 7311 & 7362
 Api Plans
Induced Circulation Through
Supply Tank with Cooling
Coils
Tandem Seals

API Plan 52
ANSI Plan 7352
Positive Displacement Pumps
Major Jobs Associated with
screw pumps:
Replacement of screws
Bearings
Timing gears
Preventive maintenance
Metering pumps
Metering Pumps

Major Jobs with metering

pumps:
Service of valves
Stroke adjustment
mechanism repair
Bearing replacement
Diaphragm/Plunger repair
Gland repair/replacement
Preventive maintenance
Reciprocating Pumps
Major Jobs with Reciprocating
Pumps:
Valves
Plunger
Replacement of Packings
Problem with Crank case
and cross head guides
Bearings
Seals
Other Positive Displacement Pumps

Major Jobs with Lobe

and Gear pumps:
Timing Gear
Wear of mating parts
in case not properly
lubricated
Bearings-heart of Maintenance
Antifriction
Discussed ahead
Journal bearing
Plain/Journal
Tilted pad
Bearings Types
Bearings used in MRPLsome stats

Sl Bearing Types % installed

1 Angular contact ball bearing 30.00
2 Deepgroove ball bearings 30.00
3 Cylindrical roller bearings 16.00
4 Spherical roller 10.00
5 Taper roller 5.00
6 Needle roller 1.00
7 Thrust ball bearings 2.00
8 Thrust needle bearings 1.00
9 Self alinging ball bearings 5.00
10 Spherical Taper roller bearings 2 nos
Total 100.00
Unit Desc Value
Nos Bearin consumption/year 1450
lacs Cost of Bearings consumed/year 24
 Journal bearing
Plain Bearings Thrust pad Bearings

Used in Very heavy loads

Shaft diametres are very high
 Compressors
Types:
Reciprocating
Centrifugal
Reciprocating Compressors Fundamentals

1-Suction
2-pressurise to discharge
pressure
3-Valve opens-ideal case no
pressure loss
4-gas trapped in clearance
volume expands
 Types of compressors
Single-Acting
suction
side

delivery
side

drive cylinder

Double-Acting
suction side

end

head end
crank

crank crosshead delivery side

drive cylinder
To understand Double acting
General Arrangement

Cylinder

Distance Piece

Frame/Crank
Case
 Major Parts
Unloading cylinder Suction duct
Unloader Valve cover

Piston rod Valve cage

Distance piece Suction valve

Suction valve nest

Piston
Piston rings
Cylinder head

Discharge valve nest

Piston rod Discharge valve
packings
Valve cage
Valve cover
Cylinder diameter
Cylinder liner Delivery duct Cooling water channels
 Drive transmissions-Linkages
Cross head Connecting Rod

Crank shaft
 For Further clarification
Crank Shaft Connecting Rod
Major Elements

Piston Rings
Seal the compression chamber
between the piston and the liner

Rider Rings
Support the weight of the piston and
half of the rod weight,
but should not seal gas pressure.
Packings

Main Pressure Packing Intermediate Packing

Task : Create a positive seal at the piston rod
Types : Main Pressure Packing - Intermediate Packing

Double Double
Acting Distance Crosshead Crankcase
Cylinder Piece
 Task and Types of Wiper Packings

Task : Keep away crank oil from distance piece

by removing it from the piston rod
Types : Oil Scraper Packing, Oil Tight (OT) Packing

Double Double
Acting Distance
Cylinder Piece Crosshead Crankcase
 Main Pressure Packing
Seals the inboard compression chamber to distance piece
in the area of the piston rod. Can be lube or non lube.
Pressure range from vacuum to 3000 bar.
O-Rings Piston rod
Cups or Containers
Flange

Purge
inlet

Tie rods

Ring sets
Flange bolts
and nuts Cooling Design example
 Intermediate Packing
Intermediate Packings seal the first distance piece
to the second distance piece in the area of the piston rod.
Usually they are not lubricated and not water cooled.

Flange Ring sets

Flange bolts
and nuts Piston rod

Cups or
Containers

Purge (plugged)
Tie rods
Design example
 Function of Pressure Packings
Seal gas or oil
in compression chamber
in intermediate piece

Maintain a positive seal

at the piston rod even though there is
lateral movement of the rod
axial clearance
clearance
radial

lateral

axial

piston rod
 Function of Pressure Packings

garter springs

seal rings

piston rod

The rings segments are held together by garter springs until

the gas pressure is such that they are forced on to the rod
to create the seal.
Sealing rings are pegged together so that the gaps between
the ring segments of one ring are covered by the ring segments
of the other to reduce leakage.
Rings can float axially and radially in the grooves of the cups
to compensate for rod movement.
 Vent and Purge Arrangement
Pressure and Intermediate Packing are purged.
A flow of Nitrogen purge gas is inlet into the packing to stop possible
leakage
It could also contaminate oil and lower its flash point.

Crankcase side Nitrogen IN Cylinder side

to distance
Nitrogen piece vent Nitrogen Dangerous
gas

Piped controlled leakage

Oil drain to dangerous gas/nitrogen vent Lubrication (on top)
 Wiper Ring
Scraper or Wiper edges

Piston movement
rod

Crank oil
Crankcase
side

Oil return Force of garter springs

to crankcase is greater than with
or drain pressure packings
 Wiper Ring
Oil wiper packings scrape the crank gear oil from the rod
and return it to the crankcase.

Flange Cups or Containers

Distance oil
piece side

Tie rods Crankcase

side
vent or
purge
pressure
Oil Scraper Ring sets
Seal Ring set
Major Components
Major Jobs with
Valves:
Repair/Replacement
of plates
Springs
 Centrifugal Compressors

Barrel
Axial Split
High volume Medium High volume High Pressure
pressure
Major Jobs so far on Centrifugal
Compressors

Seal replacement
Bearing replacement
Lube Oil
 Turbines

No. Nomenclature No. Nomenclature

1 Woodward Governor 17 Turbine Shaft
2 Governor Spring 18 Governor Lever
3 Governor Cover 19 Lever Support
4 Trip Spring 20 Governor Valve Spindle
5 Governor Drive Shaft 21 Governor Valve Cover
6 Thrust Ball Bearing 22 Oil Tank
7 Bearing 23 Oil Filter
8 Oil Shelter 24 Cooling Coil
9 Sleeve 25 Bearing Box
10 Turbine Casing 26 Steam Chamber
11 Turbine Rotor 27 Nozzle
12 Packing Box 28 Stationary Blade
13 Packing Spring 29 Turbine Casing
14 Carbon Packing 30 Oil Ring
15 Bearing Cover 31 Bearing Box
16 Sleeve
Major Jobs So far on Turbines

Bearings replacement
Lube Oil changes
Major Overhaul done in STG5 in 2004
LP side blades repaired
Labys were replaced
Turbine blades were repaired
Inspection of HP/LP controlled extractions
Hydraulic Setup
Maintenance of Governors
Over speed test
 Most used Transmissions systems

Gears Belt Drive

Coupling
Major Jobs associated with couplings

Connect drivers to equipment hence

play a important role in control of
vibration
Alignment
Repair /replacement of broken part
Mis alignment of these transfer load onto
bearings hence they are given special care
Predictive maintenance
Problems in rotary equipments occur
from
Process Upsets
Coupling
Bearings
Supports
 Fundamentals of Condition
Monitoring
How do we manage
Predictive Maintenance
Total rotary equipments today in the refinery are 3220(including
motors)
Divide and conquer!
Critical
Semi-critical
Non critical
Focus!
The inspection interval is based on the criticality of the machines, which is as
follows.
Critical Machines ( 106 no.s ) once a week
Semi Critical Machines ( 437 no.s ) once a fortnight

Non Critical Machines ( 1067 no.s ) once a month
Create a base line alarm for major components
 Our Arsenal !
The Condition Monitoring cell is equipped with following state-of-the-art diagnostic equipments.
SKF Microlog CMVA 60,55 & 40
Vibration data collector cum FFT analyser cum field balancer, along with SKF Prism4
software for data storage and reports
SPM : Bearing condition detector
Predict Navigator : for assessing lube oil condition
Industrial Fibroscope : For internal inspection of Gearbox, Turbines etc
Sound level meter
Trap Man : For assessing Steam Trap condition
Anemometer Digital laser Thermometer
Stroboscope
Dynamic Balancing machine
Lube Oil Analyser kit, consisting of a Microscope, Patch kit & Visc Gauge
Ultrasonic Detector
Modal Analyser
Details of Condition Monitoring and steam trap Maintenance
will be handled by Mr Arun Kulkarni
 Spares Philosophy/Procurement
Insurance Spares
Classification
For replacement of the part if whole unit is to be shutdown
Life of component is almost equal to life of Equipment
Cannot manufacture inhouse and unit cannot continuously operate without that
equipment
Not an off shelf item and needs to be manufactured against requirement
Quantity shall not be more than the probable quantity that can be damaged in one
unforseen event
Regular Consumption
As required(On demand)
Auto Indent(Including Consumables)
Preservation Committee
Setup Of the Preservation Of Committee

Person Item
Arun H R Gaskets(Exchanger )
Satish.S Shafts
Mahesh Seals
Arun Kulkarni Bearings
Sunil K Impellers/Pump
assembly
 Our Commitment to Quality
ISO 9001 what we are looking into?
Quality Objective:
Failure without Notice less than 5% of installed rotary equipments
No repetitive failures
Continual Improvement:
Improve Seal Life
Present average:5 yrs
Standarised on only two vendors
Troubleshoot intensely on failures
Improve Bearing Life
Present average:5 yrs
All bearing failures undergo Analysis
Best in the refineries across India
Standardized Bearings
Life Force of any moving part
Lubrications
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 Maintenance Planning

Civil Maintenance
Raw Water Pumping Station
Computation & control of Revenue & Capital Budgets
Contractors bill certification
Allocation of centralised services such as Insulation,
Scaffolding & On line sealing
Shutdown Planning
Co-ordination with other depts.
Insurance claims
Monthly Reports
 Brief on Raw Water Station

Located in Sarpady
The pumping station consists
weir across a river
3 jack well high lift pumps
2 centrifugal low lift pumps
2 no.s DGs
Fire water system.
Major Jobs in Raw Water Station
Maintenance of Diesel Engine
Maintenance of Pumps
 Workshop
Classification
Machine Shop
Availabile equipments
Lathes
Milling machine
Drilling Machine
Fabrication
Avaliable Facility
Heavy Equipments/Transport facility
Cranes
Hydras
Fork Lifts
Tool Room
Work shop will be dealt in detail by Satish