INTERNSHIP REPORT

PREPARED BY

Manjunath G Hiremath

01FE16BME086

At

QuEST Global Engineering Services Pvt. Ltd

AEQUS Special Economic Zone

No. 39, 437A, Hattaragi, Hukkeri Taluk,

Belagavi, Karnataka – 591 245, India

This report is submitted to

School of Mechanical Engineering

K L E Technological University, Hubballi

 LIST OF CONTENTS

Chapter No Title Page No

1 INTRODUCTION 1-3

Introduction 1
Industrial training objective 2
The importance of industrial training 3
2 COMPANY BACKGROUND AND
ORGANIZATION STRUCTURE 4-8

Organization Background 4
Organization chart 6
Services Provided 8
3. WEEKLY JOBS SUMMARY 9-10

Weekly Jobs Summary 9

4 TECHNICAL CONTENTS 11-34

 Geometric Dimensioning & Tolerancing 13
 Product Design 15
17
 Predictive Maintenance
20
 Gas Turbines
 Fundamentals of Gas Turbines
 Subsystems Of Aeroengine
 Combustors
 Compressors
 Exhaust system
 Floating Production Storage & Offloading 28
 Types
 Future Trends in FPSO
 Identification of critical shaftline
 Life Extension Methodology for floating production 31
Installations

 Pressure Vessels 34
5 FINDINGS AND RECOMMENDATIONS 37
6 CONCLUSION 38
 LIST OF TABLES

Table no Title Page no

1.1 Weekly activities 09
4.1 Technical Trainings 11
4.2 Catch alert for OR 5 30
4.3 Catch alert for OR 7 31
Image References 41

LIST OF FIGURES

Figure no Title Page no

2.1 QuEST Belagavi Map 05
2.2 QuEST Belagavi 05
2.3 organization structure 06
2.4 Services Provided 07
2.5 Services Provided in Mechanical 07
4.1 GD&T 14
4.2 Generalized Flow 16
Diagram
4.3 Maintenance practices 17
Hierarchy
4.4 PRiSM 19
4.5 Brayton Cycle 20
4.6 Turbo Fan 21
4.7 Subsystems of Aero Engine 22
4.8 Axial Compressors 25
4.9 Centrifugal compressors 25
4.10 Mixed flow compressor 26
4.11 Exhaust collector 27
4.12 Insulation blanket 27
4.13 FPSO Oil RIG 28
4.14 Catch alert analysis for OR 5 30
4.15 Catch alert analysis for OR 7 31
4.16 Pareto chart for OR 5 32
4.17 Replacement of component 33
4.18 Inspection of component 33
4.19 Life Extension process flow 35
chart
6.1 CSR visit 40
6.2 CSR visit 40
 School of Mechanical Engineering

CERTIFICATE

Certified that the Internship work carried out by Mr. Manjunath G Hiremath
USN: 01FE16BME086, a bonafide student of KLE Technological University in partial
fulfillment for the award of Bachelor of Engineering /Bachelor in Mechanical Engineering
during the year 2019-2020. It is certified that all corrections/suggestions indicated for Internal
Assessment have been incorporated in the Report deposited in the departmental library. The
Internship report has been approved as it satisfies the academic requirements in the said
Degree.

Name : Name: Name:

Signature: Signature: Signature:

(Internal Guide) (Head, SME) (Registrar)

External Viva
Name of the examiners Signature with date
1
2.
 QuEST Global Engineering Services Pvt. Ltd
AEQUS Special Economic Zone
No. 39, 437A, Hattaragi,
Hukkeri Taluk,
Belagavi, Karnataka – 591 245, India

CERTIFICATE

Certified that the Internship work carried out by Mr. Manjunath G Hiremath USN:
01FE16BME086, a bonafide student of KLE Technological University, Hubballi in
partial fulfillment for the award of Bachelor of Engineering in Mechanical Engineering
during the year 2019-2020. It is certified that, he has completed the internship
satisfactorily.

Name: Mr.Venkateswara Rao D Name: Mr. Sanjay B K

Signature: Signature:
(Industry Guide/Mentor) (Program Manager)
Chapter 1

INTRODUCTION

Introduction
Quest Global is a leading service-based solution provider in product development and
production engineering. Quest Global serves its solutions in various engineering domains
such as Oil and Gas, Aero engines, Aerospace &Defense, Hi-Tech & Industrial, Medical
Devices, Oil & Gas, Power, and Transportation industries.

Quest Global (Belagavi) has its engineering domain which serves its services to Oil and
gas projects, Aero engine-based projects and also serves in providing the robust
manufacturing methods for an aerospace product to be developed. This center also
provides its support to a aeroengine manufacturer, to a crude oil extraction plant.
Basically, it is an offshore dedicated center whose aim is to provide mechanical related
solutions to the companies for its better efficient continuity.

This is an opportunity given by the college to the 8th semester students who want to have
an exposure of the industry. There has to be training and project to be carried out by the
students in the respective industry on any of the mechanical engineering domain. It
provides a good platform for the students to have an industrial professional background
before actually getting to work in an industry after the graduation.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 1

Industrial training objective
The Internship program here majorly focuses on the industry training and engineering
final year project. The objective of the Industry Training course is to provide basic pre-
requirements for a pre-professional to work in industrial environment. The engineering
center here works on assessing and verifying the design of the aero engine components.
An Engineering graduate needs basic knowledge of gas turbines, manufacturing
processes, engineering drawing reading, GD&T, Tolerance Stack-up and a modeling
software knowledge. There were many basic concepts which we came across in our
tenure of internship training curriculum. We were assigned with the oil and gas
engineering domain for our learning. There we were exposed to couple of projects in
which their objective was to provide a solution based on asset monitoring and life
extension of equipment’s involved in crude oil extraction plants. We were assigned with
the asset monitoring of the crude oil extraction plants, which was done with a commercial
Predictive Maintenance software . This tool was helpful in carrying out the project. Basically,
the project was based on ‘Predictive Maintenance’. Predictive maintenance is a process of
carrying out regular maintenance to the necessary equipment in order to prevent the failure of that
particular component. There are various mechanical ways in which it can be achieved, we were
dealing with the maintenance related to predictive tool. This Commercial software is a tool which
works on machine learning algorithm in which it takes the historical data from the server and
predicts the necessary curve using which the analysts analyze the components of individual plants
and try to prevent the failure occurrence of the components and suggest necessary action to be
taken by the workers in the plant. This is how the workflow is carried out in the domain.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 2

The importance of industrial training to student
An internship will be a structured work experience related to a student's major. This is an
experience that will enhance the student's academic career and personal development. This
internship will be supervised by a professional in the field which will be great learning experience
as an individual. It will be great experience for a college student to work in a team which will be
delivering solutions to the real-world business. Can learn new skills and add to our knowledge
base while gaining confidence in our abilities. This is an opportunity to practice communication
and teamwork skills. Gain industry knowledge first hand from an organization and professionals.
Provide evidence that we have initiative, are reliable, and have a sense of responsibility. Meet
new people and practice networking skills while establishing a network of professional contacts,
mentors, and references. Apply some of the ideas learned in school and provide a bridge between
school and the professional world. Achieve a sense of accomplishment by contributing to an
organization.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 3

Chapter 2

COMPANY BACKGROUND & ORGANIZATION STRUCTURE

Organization Background

Quest Global is a focused global engineering solutions provider serving the product
development & production engineering needs of high technology companies in the Aero
Engines, Aerospace & Defense, Hi-Tech & Industrial, Medical Devices, Oil & Gas,
Power, and Transportation industries. The company that has operations spread across 42
locations in 13 countries including US, Canada, Singapore, UK, Germany, Italy, Spain,
France, Sweden, Romania, Japan, and India was founded in 1997, and employs 11000 as
of October 2018. Quest Global opened a regional operating office in Tokyo in June 2016.
As an organization, it believes in diversification, and over the years it has serviced
Fortune 500 market leaders in various industries. It offers a diverse range of mechatronic
engineering solutions spanning the entire product development, production, and
operations engineering lifecycles.
Quest Global was started in 1997 by Ajit Prabhu and Aravind Melligeri in Schenectady,
New York. The company made its first acquisition in 1998 by integrating Lexical
Engineering. The company later integrated Interface, a Spanish company, for establishing
a Center of Excellence for Technical Data Services, as well as acquired the engineering
arm of GKN Aerospace which brought in rich engineering talent from the UK and
Cincinnati based ASE joining hands offered high-end engineering services to the
customers. Some of Quest Global’s recent acquisitions include the Houston based Beeken
for Oil and Gas, Nest Software for Embedded & Electronics, Medical Devices and other
emerging industries, and EDF, a German automotive engineering services organization.
In mid-2016, Quest Global acquired Singapore based HASK Engineering & Management
Pvt. Ltd. Quest also became an authorized global services partner to a Priori, a leading
product cost management (PCM) software solutions provider. In India, Quest has centers
at Bangalore, Belagavi, Trivandrum, Chennai and Bhubaneshwar.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 4

Vision: To be the Most Recognized and Trusted Global Engineering Partner to our
Customers.

Big things happen by doing small things right. Once we know the right thing to do for a
customer, we hone it to perfection till we know our customers are delighted with the
value we bring on to the table.
Mission: To Drive Transformation for our Customers through Engineered
Solutions.
Focus is the bedrock of our success. We sustain delivery of flexible and customized
engineering solutions to our customers with the same single minded focus that we invest
in acquiring customers. Such carefully crafted solutions for specific needs of our
customers ensure a positive impact to their business and bring about transformational
results over a period off time.

Figure 2.1 Map showing Quest Belagavi

Figure 2.2: Quest Belagavi

(https://www.quest-global.com/)

School of Mechanical Engineering, K L E Technological University, Hubballi Page 5

 Organization Chart of Quest Global Belagavi

Sandesh Shirodkar
( DU1102 HEAD)

Sanjay B K Venkateswara Rao D

(Oil & Gas Program Manager) (Principal Engineer)

Bharat Bellad Pranam Solanki

(Project Manager) (Project Manager)

EDRC India Life Extension Studies

 Arjun G Anand Kanbargi

 Santosh
Kiran Gawde

 Manjunath G Hiremath
 Tejas S L

School of Mechanical Engineering, K L E Technological University, Hubballi Page 6

 Services Provided at QuEST Global

Fig 2.3: Services provided

(https://www.quest-global.com/)

Fig 2.4: Services provided In Mechanical Engineering

(https://www.quest-global.com/)

School of Mechanical Engineering, K L E Technological University, Hubballi Page 7

Design and Development: In this domain, the company has a vast scope in new product
developments, the initiatives to be taken for its accomplishment, product modifications are
carried out, Methodology for investigating a problem, providing a suggestion for an alternative
design. The service focus in design and development is on Life extension of the FPSO, Asset
monitoring of the extraction plants, Design Change Assessments (Design), Design Change
Assessments (Stress), System / Sub System / Auxiliary Design and Cost Engineering.

Manufacturing Engineering: The company is involved in providing solution in the entire

manufacturing lifecycle, it involves initial development process from product definition to
product launch to its high-volume production. The offerings range from part design, cost
engineering, process and inspection planning, plant layout, machine and fixture engineering,
CAM and CMM (Coordinate measuring machine) engineering, shop support, first article
inspection, part and plant transitions, export compliance, and quality clinics. Services can range
from taking responsibility for a complete value stream on the factory floor, to also outsourcing
high-volume tasks like CNC programming to Quest engineering centers. Apart from these
services, Company is also involved in providing robust methods to manufacture a product in order
to save time and increase the efficiency of the customers company.

Testing Services: As there is a product development involved with the company, then the
testing department has its own importance, so as to validate the new product being developed,
also whenever there is a new design modification. The mechanical testing services are Design &
Development of Test Rigs, Model Test Design and Test Method Development &Test Plan.

These are the various departments which is Quest-Global involved into. Each department has their
own potential customers which help in carrying out the business profits.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 8

Chapter 3

WEEKLY JOBS SUMMARY

The Company works for 5 days a week and one Saturday of every month. Total working
hours per week is 47.5hrs. The company works in three shifts viz. First shift (6:00 am to
3:30 pm), Second shift (3:00pm to 12:30 am) and General shift (9:30am to 7:00pm).
Interns are required to undergo industry training, work on college project and
simultaneously understand the workflow in presence of their peers and managers so they
are in General Shift as they can meet all the people in company. Below table shows the
weekly job summary which me as an intern went through.
Table 3.1 weekly activities

Date Activities
6/1/2020 -  Report to HR
11/1/2020  Induction program
 Introduction to managers and assignment of managers
(Week 1)  RFID based access to allocated Engineering center
 Introduction to live project by Principal Engineer
 Work bench and Machine allocation
 Quest Fest
13/1/2020-  Observation of workflow when peer is working
17/1/2020  Self-learning courses
 Rising ticket for installation of Minitab
(Week 2)  GD&T training
 Meeting with MD
20/1/2020-  Introduction to customer tools
24/1/2020  Data extraction for catch alert analysis
 Explanation of workflow from managers and colleagues
(Week 3)  Clients meeting
 Knowledge sharing session on Boilers and its design
 Corporate Social Responsibility (School Visit)
27/1/2020-  Self-tutorial on Quality control tools given by Business
31/1/2020 Excellence team
 Training on Gas Turbines by principal Engineer
(Week 4)  Preparation of slides on data analysis, Hidden Markov
Model
 End of celebration of Quality Month
 Clients Meeting
 Corporate Social Responsibility (School Visit)
3/2/2020-  Self-tutorial on Quality control tools(Continuation)
School of Mechanical Engineering, K L E Technological University, Hubballi Page 9
 7/2/2020  Training on FPSO
(Week 5)  Preparation of ANN PPT
 Pareto chart analysis based on critical shaftline analysis
 Training on Basics of Gas Turbines module
1(Introduction)
 Training on Life Extension
 Clients meeting
 Corporate Social Responsibility (School Visit)
10/2/2020-  Reporting of Pareto analysis results to manager
14/2/2020  Identifying critical shaft lines
 Training on Pressure vessels
(Week 6)  Training on Basics of Gas Turbines Module 2(Fan and
Compressors)
 Knowledge sharing session on Boilers and its design
 Clients meeting

17/2/2020-  Meeting with all project managers

21/2/2020  Deep shaft line analysis for all 9 refineries
 Training on Product design
(Week 7)  Training on Basics of Gas Turbines Module
3(Combustors)
 Training on OGV’s
 Knowledge Sharing session on Vibration
 Clients meeting

24/2/2020-  Graphical interpretation on shaft lines

28/2/2020  Drawing of pie charts for each shaft line
 4 Hours Training session on statistical Data analysis and
(Week 8) interpretation and control tools using software
 Training on safety measures during Fire Hazard by ERT
(Emergency Rescue Team)
 Visit by college faculty for Status Review
2/3/2020-  Final conclusion on Shaft line and identifying the
6/3/2020 components contributing to highest catch and alerts
 Meeting with Project Managers
(Week 9)  Training on Basics of Gas Turbines Module 4(Turbines)
 Training on

9/3/2020-  Rising ticket for Python software installation

13/3/2020  Self-tutorial on Python Jupiter platform installation
 Training on Basics of gas turbines Module 5(Installations
(Week 9) and exhaust Systems
 Training on on Prism Web and Prism Client
16/3/2020-  Collection of data set for identified component of a
20/3/2020 particular shaft line from the manager
 Work from home order due to COVID-19
(Week 10)

School of Mechanical Engineering, K L E Technological University, Hubballi Page 10

Chapter 4
TECHNICAL CONTENTS

4. Industry Training
We were exposed to various concepts related to mechanical domain in our industrial
training period. The trainings undergone are clearly tabulated in the below table. The
various trainings which we undergone were GD&T, Gas turbines fundamentals, Gas
turbines components detailed design, Product design Methodology, FPSO basics,
Predictive PRISM tool and many other concepts which helped us to understand the design
flow followed in the company.

Table 4.1: Trainings under gone.

SL Technical Mode of Trainer Date of Duration
No Training Training Training (Hrs)
1 GD&T training Classroom Gopal Dasari 15/1/2020 2
training
2 Quality Control Self (Contents Shivakumar 27/1/2020 3
tools-1 provided by R
Business
excellence
team)
3 Fundamental Classroom Venkateswar 30/1/2020 2
Principles of Gas Training aRoa D
Turbines
4 Quality Control Self (Contents Shivakumar 3/2/2020 3
tools-2 provided by R
Business
excellence
team)
5 FPSO Classroom Dhruv and 5/2/2020 2
Kiran Gawde
6 Life Extension Classroom Anand 6/2/2020 2
Kanbargi
7 Basics of Gas Classroom VeereshVastr 7/2/2020
turbines Module- ad
1(Introduction)
8 Pressure vessels Classroom Sundaresh 10/2/2020 2
kale
9 Basics of Gas Classroom Pradeep 2
turbines Module-
2(Fans and
compressors)
School of Mechanical Engineering, K L E Technological University, Hubballi Page 11
 10 Boilers Classroom Timmanna 13/2/2020 1.5
11 Product Design Classroom SachinKotika 17/2/2020 2
l
12 Fundamental of Classroom Arjun G 18/2/2020 2
Vibration
13 Basics of Gas Classroom Lucky Singh 19/2/2020 2
turbines Module-
3(Combustors)
14 Statistical Data Classroom Shivakumar 24/2/2020 4
analysis and R
interpretation and
control tools using
Minitab software
15 Basics of Gas Classroom Vinayak Patil 2/3/2020 2
Turbines module
4(Turbines)
16 Python Self - 9/3/2020 -
programming in
Jupyter platform
17 Basics of gas Classroom Sujit Tilve 10/3/2020 2
turbines Module
5(Installations and
exhaust Systems
18 Introduction to Classroom Arjun G 12/3/2020 2
Prism Web and
Prism Client

School of Mechanical Engineering, K L E Technological University, Hubballi Page 12

 Geometric Dimensioning and Tolerancing
GD&T is an engineering language through which the manufacturing laborers
communicate. It provides a clear communication between the design engineers and the
manufacturing workers. It helps in avoiding the gap between these two departments. It
includes various symbols and terminologies which help in understanding the part which is
to be manufactured. These symbols are represented on the engineering drawing, an
engineering drawing is a method of transferring information from design engineer to a
manufacturer engineer. Without an engineering drawing, it is impossible for a product to
be developed in the industries such as aircrafts, automotive, locomotives, ships etc. An
engineering drawing is a must in the company because of which the company is able to
work on non-conformance, concessions which help in material reduction of the aerospace
parts. The benefits added by GD&T are that it provides functional dimensions, reduction
in assembly parts.

Without engineering drawing, it would have been impossible to produce objects such as
aircrafts, automobiles, locomotives, ships etc., each requiring thousands of different
components. Here in the industry, in order to verify the design i.e. to assess the non-
conformance, drawing reading is must skill because we need to identify the location of
the feature on which the verification is needed with the help of zones, views, sections, and
if it’s an assembly drawing, need to identify the part in drawing on which the feature is
affected by referring the Bill of materials. However, the GD&T learning requires a good
experience in the manufacturing department. The next page shows the symbols involved
in GD&T:

School of Mechanical Engineering, K L E Technological University, Hubballi Page 13

 Fig 4.1 : GD&T Symbols
(https://www.fictiv.com/hwg/fabricate/gdt-101-an-introduction-to-geometric-
dimensioning-and-tolerancing)

School of Mechanical Engineering, K L E Technological University, Hubballi Page 14

 Product Design Methodology

Product design is a generalized concept which includes the process of creation of a new
product and the ways in which it can be achieved. In this training we were taught with
various concepts on how the products are designed from the scratch to a well finished
product. It is quite an essential domain which is to be known by the mechanical engineers
for a new product to be launched. We were initially told on idea visualization, then after
we were told to understand the customer needs, then we need to visualize and sketch the
product, then come up with alternative design sketches, then based on various design
considerations such as material, strength, stiffness, cost etc. We manufacture the product
finally. Basically, this training was focused on providing us the methodology which is
carried out in order to come up with a new product or to have any design modification on
the existing product. The following is the methodology we generalized after this training:

1. Finding a new idea

The beginning of the design phase is getting to know a social problem and
visualizing a product for that idea. The idea should be such that it should involve a
product that can be produced in large quantities so that it shares a measurable
profit to the company.

2. Identifying the customer needs

After the idea is accepted, the next stage is to reach to various customers who will
be using it after the product is built. Getting to the needs of the potential
customers, it helps in getting to know the design considerations, its aesthetic part
etc.

3. Creation of the sketches

Once the idea and its design considerations are finalized, next we sketch the
products. It helps in creating a 3D model with the dimensions. Here we can have
many other alternate solutions, finalizing a final sketch from other sketches
involves various charts and checkpoints to be considered and whichever model is
suitable is chosen.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 15

 4. Analyzing the component

After the 3D model is created as a final product, the model is then after handed
over to the analyzers which have the various loads, temperatures and then after
material is selected. The material is selected based on the stress it should
withstand, the temperature it should bear, the stiffness it should possess, the
elasticity it should have etc. Many other factors are included along with the
mentioned factors.

5. Checking for the norms and standards as prescribed by the law:

Once the product is designed and analyzed, it should be checked for the ASME
standards. If the product is not designed according to the standards, it has to be
modified according to law.

6. Selection of the Manufacturing process and arriving at a finished product:

Once the model is put into engineering drawing paper it should be handed over to
the manufacturing department, the manufacturing process should be such that it
involves less cost to manufacture, less time, should be within standards. It should
be compatible for mass production , inspection has to be carried out.

Fig 4.2: Generalized Flow Diagram

(https://www.nap.edu/read/11049/chapter/2)
School of Mechanical Engineering, K L E Technological University, Hubballi Page 16
 Predictive Monitoring Tool

Predictive maintenance software analyze the in-service equipment and accurately make
suggestions on the time and extent of maintenance to be carried out. It aims at ensuring
that maintenance is not only carried out when the equipment actually breaks down but
during carefully calculated periods. This saves the business time that would be spent
fixing problems during the actual shutdown.

Fig 4.3: Maintenance Practices Hierarchy

(Predictive Analytics to Monitor the Health of Refinery Rotating Equipment by
Schneider Electric)

Quest Global Belagavi, has its active department working on predictive maintenance of
the products involved in the crude oil extraction plant working in another country. The
various components involved in this extraction plants are Centrifugal compressor,
Reciprocating compressor, electric motor, centrifugal pumps etc. The main aim of the
department is to priory notice about the behavior of these components towards their
working and keeping a track of the components and suggesting the needful information to
the plant people so that the failure can be avoided. Basically, for this purpose a
commercial Predictive Maintenance software is used . This commercial software is based
on predictive analytics concept. The main aim of this software is to calculate an
upcoming value based on the previous historical data values. The data may be
temperature, vibration, pressure etc. It has the options of taking the values (Yearly,
monthly, weekly) etc.

Once the predicted (calculated curve) is obtained, the actual curve is plotted along with

School of Mechanical Engineering, K L E Technological University, Hubballi Page 17

predicted curve and then the values are analyzed, so as are they crossing the threshold
values, are they deviating from their actual behavior. And if at all something irregular is
happening, it is visualized as the component is not behaving as per its behavior.

The main advantage of this predictive tool is that it helps in predicting the failure of the
component very early (months before) because of which the plant has the better
opportunity to maintain the components very early and hence the components wouldn’t
fail and hence contributing to the efficiency of the plant by offshore detection from the
department in Belagavi .

Some of the commonly, globally and commercially used predictive maintenance tools are

Siemens MindSphere

Siemens MindSphere is an open ,cloud based IoT operating system from Siemens that
connects machines and physical infrastructure to the digital world, and it can harness big
data from billions of intelligent devices to enable the uncovering of transformational
insights across the entire business. MindSphere also provides powerful industrial apps
and digital services that can unleash more productivity and efficiency with a reduction in
downtime, increase output and more effective use of assets. MindSphere from Siemens
offers a cost-effective, scalable cloud platform that’s perfect for developing apps, and it
can be used to integrate apps and services seamlessly.

GE Predix

GE Predix is an industrial Internet of Things(IoT) platform designed for the unique and
complex challenges of industrial data that combines sophisticated asset modeling, big
data processing ,analytics and applications to provide the IT foundation for tomorrow’s
industrial operations. With GE Predix it is possible to innovate quickly, optimize asset
performance ,invest wisely and to plan for the future. GE Predix is an edge-to-cloud
platform that can be used to deploy processing and analytics power to control edge assets
in real time or analyze big data in the cloud using the secure Predix connectivity and
execution environment as Predix’s

Presenso

Presenso is a cloud-based software solution that is pioneer in the application of real-time

artificial intelligence for predictive asset management, and it replaces the rule-based
legacy systems that are costing manufacturers and plant operators millions of dollars a
year because they are reactive and with limited computational power. They are ineffective
School of Mechanical Engineering, K L E Technological University, Hubballi Page 18
 in limiting production downtime . Presenso provides unparalleled operational intelligence
and deep semantic insight which in turn increases production yield and revenues.
Presenso offers big data for asset maintenance to transform the industrial maintenance
operations from reactive to predictive by the provision of clear and constant performance

Avantis PRiSM

Schneider Electric’s Avantis PRiSM software is built on an algorithm called OPTiCS

that uses Advanced Pattern Recognition (APR) and machine learning technology. The
software learns an asset’s unique operating profile during all loading, ambient and
operational conditions through the advanced modeling process. The result of the
modeling process is a unique asset signature that is compared to real-time operating data
to determine and alert upon detection of subtle deviations from expected equipment
behavior. PRiSM is an intuitive system designed so that the user can easily configure it to
monitor different types of equipment with no programming or highly detailed equipment
knowledge.

Avantis PRiSM enables personnel to address subtle variations in equipment behavior

before they become problems that significantly impact operations. Unscheduled
downtime can be reduced because personnel receive early warning notifications of
developing issues. Maintenance costs can be reduced due to better planning. Parts can be
ordered and shipped without rush and equipment can continue running. Additionally,
some suggested maintenance windows can be lengthened as determined by equipment
condition. Other benefits include increased asset utilization and the ability to identify
underperforming assets.

Fig 4.4:Representation of the calculated and actual curve.

(Predictive Analytics to Monitor the Health of Refinery Rotating Equipment by Schneider Electric)

School of Mechanical Engineering, K L E Technological University, Hubballi Page 19

 Fundamentals of Gas Turbines
The gas turbine is an internal combustion engine that uses air as the working fluid. The
engine extracts chemical energy from fuel and converts it to mechanical energy using the
gaseous energy of the working fluid (air) to drive the engine and propeller, which, in turn,
propel the airplane.

An Aero engine typically is a gas turbine in which the expansion of combustion gases
takes place in two phases. Combustion gases are first expanded through the turbine to
develop just enough mechanical shaft power to run the compressor and the auxiliary
systems. The remaining energy from the combustion gases is used to produce the thrust
by expanding them through exhaust nozzle. The gas turbine operates on the principle of
the Brayton cycle, where compressed air is mixed with fuel, and burned under constant
pressure conditions. The resulting hot gas is allowed to expand through a turbine to
perform work. In a 33% efficient gas-turbine approximately two / thirds of this work is
spent compressing the air, the rest is available for other work i.e. (mechanical drive,
electrical generation)

A Simple Gas Turbine: The ideal cycle that the working fluid undergoes in this closed
loop is the Brayton cycle, which is made up of four internally reversible processes:

1: Isentropic compression (in a compressor)

2: Constant pressure heat addition.

Fig 4.5 : Brayton Cycle

(https://id.wikipedia.org/wiki/Berkas:Brayton_cycle.svg )

School of Mechanical Engineering, K L E Technological University, Hubballi Page 20

 There are four main types of aero-engines:

 Turbojet

 Turbofan

 Turboprop

 Turbo shaft

The turbofan is the most common type of gas turbine used for aircraft propulsion today.
Part of the air entering the engine is compressed fully and passed into the combustion
chamber, while the remainder, compressed to a lesser extent, bypasses the combustion
section, to provide cold thrust. This bypass flow re-joins the hot flow downstream of the
turbine. Maximum amount of thrust is produced by the bypass air.

Fig 4.6 : Turbofan

(http://www.financecolombia.com/viva-air-inks-3-2-billion-usd-deal-with-cfm-
for-leap-1a-turbofan-engines-on-its-new-airbus-a320neo-jets/)

School of Mechanical Engineering, K L E Technological University, Hubballi Page 21

 Subsystems of the Aero-Engine:

Compressors are situated at the front section of the engine. the compressor draws air in,
pressurizes it, and then delivers it into the combustion chamber. There are LP compressor
IP compressor and HP compressor in the 3 spool engine in which LP compressor is fan at

Fig 4.7 : Subsystems of Aero Engine

(http://turbofan-engine.blogspot.com/2009/01/high-bypass-turbofan-engines.html)

the front section which sucks the air in, dividing it into bypass and core air. Then IP and
HP compressor compresses the air to required extent and deliver it for combustion. The
primary function of the combustion section is, of course, to burn the fuel-air mixture,
thereby adding heat energy to the air.
There is LP turbine, IP turbine and HP turbine in the 3 spool engine. The turbine consists
of one or more stages of alternate stationary and rotating aero foil section blades. The
rotating blades are carried on discs, in a similar way to the compressor, and the discs are
connected by a shaft to the compressor rotating assembly. The stationary blades, known
as nozzle guide vanes, are housed in the turbine casing. The function of the turbine is to
absorb sufficient energy from the hot expanding gases leaving the combustor to keep the
compressor rotating at its most efficient speed.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 22

Combustors used in Gas Turbines
A combustor is a component or area of a gas turbine, ramjet,
or scramjet engine where combustion takes place. It is also known as
a burner, combustion chamber or flame holder. In a gas turbine engine,
the combustor or combustion chamber is fed high pressure air by the compression system.
The combustor then heats this air at constant pressure. After heating, air passes from the
combustor through the nozzle guide vanes to the turbine. In the case of a ramjet or
scramjet engines, the air is directly fed to the nozzle.

A combustor must contain and maintain stable combustion despite very high air flow
rates. To do so combustors are carefully designed to first mix and ignite the air and fuel,
and then mix in more air to complete the combustion process. Early gas turbine engines
used a single chamber known as a can types combustor. Today three main configurations
exist: can, annular and cannular (also referred to as can-annular tube-annular).
Afterburners are often considered another type of combustor.

Combustors play a crucial role in determining many of an engine's operating

characteristics, such as fuel efficiency, levels of emissions and transient response (the
response to changing conditions such as fuel flow and air speed).

Types of Combustors:

1. CAN type combustor:

Can combustors are self-contained cylindrical combustion chambers. Each ‘Can’ has its
own fuel injector, igniters, liner, and casing. The primary air from the compressor is
guided into each individual can, where it is decelerated, mixed with fuel, and then ignited.
The secondary air also comes from the compressor, where it is fed outside of the liner
(inside of which is where the combustion is taking place). The secondary air is then fed,
usually through slits in the liner, into the combustion zone to cool the liner via thin film
cooling.

In most applications, multiple cans are arranged around the central axis of the engine, and
their shared exhaust is fed to the turbine(s). Can type combustors are easy to maintain, as
only a single can needs to be removed, rather than the whole combustion section. Most

School of Mechanical Engineering, K L E Technological University, Hubballi Page 23

modern gas turbine engines (particularly for aircraft applications) do not use Can
combustors, as they often weigh more than alternatives.

2. CANNULAR type combustor:

The next type of combustor is the Cannular combustor. The term is a of "can annular".
Like the can type combustor, Can annular combustors have discrete combustion zones
contained in separate liners with their own fuel injectors. Unlike the can combustor, all
the combustion zones share a common ring (annulus) casing. Each combustion zone no
longer has to serve as a pressure vessel. The combustion zones can also "communicate"
with each other via liner holes or connecting tubes that allow some air to flow
circumferentially. The exit flow from the Cannular combustor generally has a more
uniform temperature profile, which is better for the turbine section. It also eliminates the
need for each chamber to have its own igniter. Once the fire is lit in one or two cans, it
can easily spread to and ignite the others. This type of combustor is also lighter than the
Can type, and has a lower pressure drop (on the order of 6%). However, a Cannular
combustor can be more difficult to maintain than a Can combustor.

3. ANNULAR type combustor:

The final, and most commonly used type of combustor is the fully annular combustor.
Annular combustors do away with the separate combustion zones and simply have a
continuous liner and casing in a ring (the annulus). There are many advantages to annular
combustors, including more uniform combustion, shorter size (therefore lighter), and less
surface area. Additionally, annular combustors tend to have very uniform exit
temperatures. They also have the lowest pressure drop of the three designs (on the order
of 5%). The annular design is also simpler, although testing generally requires a full size
test rig.
Compressors used in Gas Turbines:
As the name suggests, gas turbine engine compressors provide the compression part of
the gas turbine engine thermodynamic cycle. There are three basic categories of gas
turbine engine compressor: axial compressor, centrifugal compressor and mixed flow
compressor. A fourth, unusual, type is the free-piston gas generator, which combines the
functions of compressor and combustion chamber in one unit.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 24

Types of Compressors used:

1. Axial Compressors:

Axial compressors are used in medium- to large-thrust gas turbine engines, because the
alternative centrifugal units would be too heavy and too large in the cross-sectional area.
At smaller sizes, the axial blading at the rear of the compressor loses its robustness and is
difficult to manufacture accurately. Consequently, manufacturers tend to replace the rear
stages with a centrifugal unit. The compression system is then said to be axial-centrifugal.
In case of power generation, axial compressors are used in turbines which have capacity
to generate more than 5 MW.

Fig 4.8: Axial Compressor.

(https://www.youtube.com/watch?v=K0mScxx4v-I)
2. Centrifugal Compressor:
At even smaller sizes, particularly in turboprop/turboshaft applications, the compression
system is either a single centrifugal or has two centrifugal units connected in series (i.e.
double-centrifugal).

Fig 4.9: Centrifugal Compressor.

(https://www.researchgate.net/figure/Main-components-of-a-centrifugal-compressor-in-
isometric-view_fig2_313065156)

School of Mechanical Engineering, K L E Technological University, Hubballi Page 25

3. Mixed Flow Compressor:
In the future, mixed flow compressors may feature at the small end of the market,
particularly in turbofans, where the relatively large diameter across the diffuser of a
centrifugal compressor is a significant disadvantage.

Fig 4.10: Mixed Flow Compressor.

(http://www.euroasia-tec.com/compressors/)

Exhaust system of an Aero Engine

The exhaust section of the gas turbine engine consists of several components. Although
the components have individual purposes, they also have one common function: they
must direct the flow of hot gases rearward in such a manner as to prevent turbulence and,
at the same time, impart a high final or exit velocity to the gases. In performing the
various functions, each of the components affects the flow of gases in different ways. The
exhaust section is located directly behind the turbine section and ends when the gases are
ejected at the rear in the form of a high-velocity exhaust gases.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 26

 Fig 4.11: Insulation blanket with the temperatures Fig 4.12 : Exhaust collector with welded support
struts
obtained at the various locations
(https://www.aircraftsystemstech.com/p/exhaust-section-exhaust-section-of-gas.html)
The centrally located inner cone fits rather closely against the rear face of the turbine
disk, preventing turbulence of the gases as they leave the turbine wheel. The cone is
supported by the radial struts. In some configurations, a small hole is located in the exit
tip of the cone. This hole allows cooling air to be circulated from the aft end of the cone,
where the pressure of the gases is relatively high, into the interior of the cone and
consequently against the face of the turbine wheel. The flow of air is positive, since the
air pressure at the turbine wheel is relatively low due to rotation of the wheel. Thus air
circulation is assured. The heat radiation from the exhaust cone and tailpipe could
damage the airframe components surrounding these units. For this reason, some means of
insulation has to be devised. There are several suitable methods of protecting the fuselage
structure. Two of the most common are insulation blankets and shrouds.

Floating Production Storage and Offloading(FPSO)

FPSO stands for floating production storage and offloading (FPSO). These vessels are
used extensively by the offshore industry and have become one of the primary methods of
oil and gas processing and storage. An FPSO is a floating vessel that acts as a mobile
offshore production and storage facility. They are typically employed and leased by oil
and gas companies.
The vessels themselves are equipped with processing equipment for the separation,

School of Mechanical Engineering, K L E Technological University, Hubballi Page 27

 storage and offloading of oil and gas that comes from sub-sea oil wells or platforms.
When oil and gas is processed, it is safely stored in the FPSO until it can be offloaded
onto a tanker or a pipeline for transportation ashore.

FSOs were used to store extracted hydrocarbons (a mixture of oil, gas and water) and
transport it from remote locations such as distant seabed’s. However, FSOs can’t process
oil and gas, which is where the FPSO comes in.

Fig 4.13: FPSO oil rig. Coast of Brazil

(https://plsadaptive.s3.amazonaws.com/eco/images/channel_uploaded_images/Gttj0mjj9Y
f0sILJLFIm8OVFaoJFOgrEL4IoLdMb.jpeg)

Types of FPSO

 Floating storage and offloading (FSO) – An FSO is a simplified version of an FPSO. It

has the capability to store and offload oil and gas but it doesn’t possess the ability to
process it.

 Floating storage units (FSU) – Floating storage units to take the form of a large barge in

contrast to supertankers that are associated with FPSOs. Simply put, these units are used
to store oil and gas in large silos placed on top of the vessel. 

 Floating drilling production storage and offloading (FDPSO) – This variant is still

relatively new, with the first of its kind setting sail in 2009. The key difference with this

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 vessel is the modular drill that is attached to the hull of the ship, giving it more utility
than a standard FPSO. With the addition of a drill, an FDPSO can perform nearly all
major functions associated with offshore oil and gas production.

 Floating liquid natural gas vessel (FLNG) – A FLNG is a type of vessel that is more

gas-centric. It has all of the apparatus to enable offshore liquification of natural gas into
liquefied natural gas (LNG).

4.6.1 Future trends in FPSO sector

Oil and gas sector are still lagging in digitization of the plants for better efficiencies and
economic development. Unlike other industries oil and gas industries are slow in adapting
the increased connectivity and high technologies like Internet of Things for better
performance.

The rapid conversion of operational technology and information technology has resulted
in increased efficiency through big data, analytics, sensors, the ability to automate highly
sensitive tasks and more.

Going forward, FPSOs will likely have to incorporate more digitization. From fleet data
to analytics tools and predictive analytics, these technologies can be used to determine
success rates, estimations of topside components and more.

Monitoring technologies are far better now than they were many decades ago when most
FPSOs were commissioned. The digitization of FSPO has helped prolong the shelf life of
many older vessels. Companies now have a better grasp measuring the fatigue of vessels
and how each project impacts a vessels service life. Organization now has data on hulls,
mooring systems, processing equipment and everything in between.

Commercial softwares helps to continuously monitor the performance and machine health
for organized production improvement. Any anomaly observed is immediately identified
and intimated to the plant operators so that production is affected .

School of Mechanical Engineering, K L E Technological University, Hubballi Page 29

 Critical shaftline Identification

Oil Refinery 5
Table 4.2 : Catch Alert Tabulation for Oil Refinery 5

ALERT 100
CATCHES 59
TAG INSTRUMENTATION ASSET OTHERS NA FIR TOTAL ALERTS
CATCHES
SHAFTLINE 1 1 3 0 0 0 4 8
SHAFTLINE 2 1 4 0 0 0 5 10
SHAFTLINE 3 0 1 0 0 0 1 2
SHAFTLINE 4 3 4 0 0 0 7 10
SHAFTLINE 5 4 0 0 0 0 4 7
SHAFTLINE 6 4 2 0 0 0 6 7
SHAFTLINE 7 2 0 0 0 0 2 2
SHAFTLINE 8 2 0 0 0 0 2 2
SHAFTLINE 9 5 4 0 0 0 9 15
SHAFTLINE 10 0 0 0 0 0 0 2
SHAFTLINE 11 1 0 0 0 0 1 2
SHAFTLINE 12 0 1 0 0 0 1 2
SHAFTLINE 13 1 0 0 0 0 1 0
SHAFTLINE 14 0 1 0 0 0 1 1
SHAFTLINE 15 0 1 0 0 0 1 2
SHAFTLINE 16 0 0 0 0 0 0 0
SHAFTLINE 17 0 0 0 0 0 0 2
SHAFTLINE 18 2 0 0 0 0 2 3
SHAFTLINE 19 0 0 0 0 0 0 0
SHAFTLINE 20 1 1 0 0 0 2 3
SHAFTLINE 21 1 4 0 0 0 5 9
SHAFTLINE 22 2 2 0 0 0 4 7
SHAFTLINE 23 0 0 0 0 0 0 0
SHAFTLINE 24 1 0 0 0 0 1 4
TOTAL 31 28 59 100

16
14
12
10
8 TOTAL CATCHES
6 ALERTS
4
2
0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Figure 4.14: Catch Alert plot for oil refinery 5

In the above plot shaftline 13,17,19& 13 shows zero catches and zero alerts.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 30

 Oil Refinery 7

Table 4.3: Catch Alert Tabulation for Oil Refinery 7

ALERT 80
CATCHES 48
TAG INSTRUMENTAION ASSET OTHERS NA FIR TOTAL ALERTS
CATCHES
SHAFTLINE 1 0 0 0 0 0 0 1
SHAFTLINE 2 0 2 0 1 0 3 6
SHAFTLINE 3 0 0 0 1 0 1 0
SHAFTLINE 4 3 0 0 0 0 3 6
SHAFTLINE 5 0 1 0 1 0 2 1
SHAFTLINE 6 0 0 0 0 0 0 2
SHAFTLINE 7 3 0 0 1 0 4 12
SHAFTLINE 8 1 0 0 0 0 1 1
SHAFTLINE 9 1 0 0 1 0 2 1
SHAFTLINE 10 1 0 0 0 0 1 1
SHAFTLINE 11 3 2 0 0 0 5 8
SHAFTLINE 12 2 1 0 1 0 4 9
SHAFTLINE 13 0 4 0 0 0 4 10
SHAFTLINE 14 1 1 0 0 0 2 2
SHAFTLINE 15 1 0 0 0 0 1 2
SHAFTLINE 16 2 0 0 0 0 2 3
SHAFTLINE 17 0 1 0 0 0 1 1
SHAFTLINE 18 0 0 0 0 0 0
SHAFTLINE 19 3 5 0 1 0 9 8
SHAFTLINE 20 1 1 0 0 0 2 3
SHAFTLINE 21 0 0 0 0 0 0 0
SHAFTLINE 22 0 0 0 0 0 0 0
SHAFTLINE 23 1 0 0 0 0 1 3
TOTAL 23 18 0 7 0 48 80

14
12
10
8
TOTAL CATCHES
6
ALERTS
4
2
0
1 2 3 4 5 6 7 8 9 1011121314151617181920212223

Figure 4.15: Catch Alert plot for oil refinery 7

In the above plots shaftline 3,18,21&22 have zero catches and zero alerts

School of Mechanical Engineering, K L E Technological University, Hubballi Page 31

 From the above two plots it is observed that some shaftlines exhibit zero catches and zero
alerts. Some of the possible reasons for the above contexts may be:
 The shaftline is functioning adequately well so no anomaly detected
 The probe itself is malfunctioning resulting into zero catches and alerts
Hence further investigation is required

4.16: Pareto Chart for Oil Refinery 5

From the above Pareto chart analysis it is observed that the Shaftlines 9,4,6,2,21&1 are
the 40% of the shaftlines contributing to the 60% of the faults. Hence rectification of the
problems from these shaftlines reduces the failure percentage by 60%

LIFE EXTENSION METHODOLOGY FOR FLOATING PRODUCTION

INSTALLATIONS
Floating production installations (FPIs) are facilities designed for site-specific application
based on a design life usually defined by the Owner/Operator. A typical default structural
design life is 20 years, though there are installations with other specified design lives. For
different reasons, Owner/Operators may seek to keep the unit in operation beyond the
original design life, either in the same location or at a different site. In these instances, the
Owner/Operator is advised to initiate a life extension process with the assistance of the
Classification Society. This process includes a reassessment of the structure, mooring,
tendon systems, stability, machinery and systems, etc., for the entire installation. This
reassessment includes engineering and survey activities.

School of Mechanical Engineering, K L E Technological University, Hubballi Page 32

 Fig 4.17: Replacement of Component Fig 4.18: Inspection of Critical component
(https://www.ctsom.com/life-extension-project-operating-fpso-petroleo-nautipa/)
Floating installations designed and built to the requirements in the Rules and maintained in
accordance with the applicable ABS requirements are typically intended to have a
structural design life of 20 years. Many are designed for uninterrupted operation onsite
without any dry docking. When a floating installation exceeds the original design life, an
evaluation is to be made and appropriate actions have to be taken to extend the life up to
the new operating life of the installation under the site-specific environmental conditions.

The life extension process generally follows the three phases :

i) Investigation phase

• Data collection and engineering assessment

• Baseline survey

ii) Determination phase

• Reassessment

• Provision of conditions for life extension

iii) Implementation phase

• Conditions implemented

School of Mechanical Engineering, K L E Technological University, Hubballi Page 33

Procedure for Life Extension up to 5 Years at the Same Location

If the first life extension request for an installation remaining at the same location is five
years or less, the following abbreviated approval procedure is to be followed. If a baseline
survey is performed and all required structural repairs are completed, the life extension
may be granted without the need for data collection.

For the life extension to be granted the following conditions are to be satisfied:

• Any modifications to the structure have class approval.

• Critical areas of the original design have been re-examined using NDT techniques and
verified to be satisfactory.

• Additional items to be determined on a case-by-case basis during the life extension

process have been resolved.

Life extension is a continuous process that extends the original life. This abbreviated
process can only be applied once in the lifecycle of a Floating Production Installation.
Once a unit has been granted life extension under this option (abbreviated process),
additional requests for life extension will be considered as the total additional life beyond
the original design life in accordance with the full procedure . For example, if the design
life of an installation is 20 years and it receives a life extension of five years, a second five-
year life extension will be a ten-year extension to the original design life.

If FL or RFL notation was granted for the unit under consideration, to use this abbreviate
procedure, the original fatigue analysis is to show that the fatigue lives of all
joints/critical details are sufficient to cover the extension of use. When the original
fatigue analysis show insufficient remaining fatigue life for the requested extension, the
FL or RFL notation needs to be specially considered

School of Mechanical Engineering, K L E Technological University, Hubballi Page 34

 Fig 4.19: Life Extension Process Flow Chart

Pressure Vessels
Tanks, vessel and pipelines that carry, store or receive fluids are called pressure vessel. A
pressure vessel is defined as a container with a pressure differential between inside and
outside. The inside pressure is usually higher than the outside. The fluid inside the vessel
may undergo a change in state as in the case of steam boiler or may combine with other
reagent as in the case of chemical reactor. Because of such hazards it is imperative that
the design be such that no leakage can occur. In addition vessel has to be design carefully
to cope with the operating temperature and pressure.

Design pressure

The pressure use in the design of a vessel is call design pressure. It is recommended to
design a vessel and its parts for a higher pressure than the operating pressure. A design
pressure higher than the operating pressure with 10 percent, whichever is the greater, will
satisfy the requirement. The maximum allowable working pressure (MAWP) for a vessel
is the permissible pressure at the top of the vessel in its normal operating position at a

School of Mechanical Engineering, K L E Technological University, Hubballi Page 35

specific temperature.

Design temperature

Design temperature is the temperature that will be maintained in the metal of the part of the
vessel being considered for the specified operation of the vessel. However, there is a
maximum design temperature and a minimum design temperature (MDMT) for any given
vessel. The MDMT shall be the lowest temperature expected in service or the lowest
allowable temperature as calculated for the individual parts.

Corrosion allowance

Corrosion occurring over the life of a vessel is catered for by a corrosion allowance, the
design value of which depends upon the vessel duty and the corrosiveness of its content.
A design criterion of corrosion allowance is 1 mm for air receiver in which condensation
of air moisture is expected.

Shell design

The minimum thickness or maximum allowable working pressure of cylindrical shells

shall be the greater thickness or lesser pressure

Circumferential Stress(Hoop Stress)

When the thickness does not exceed one-half of the inside radius, or P does not exceed
0.385SE, the following formulas shall apply:

t = P*R or P = S*E*t
SE-0.6P R+0.6t
Longitudinal Stress

When the thickness does not exceed one-half of the inside radius, or P does not exceed
1.25SE, the following formulas shall apply:

t= P*R or P = 2*S*E*t
2SE+0.4P R- 0.4t

School of Mechanical Engineering, K L E Technological University, Hubballi Page 36

 Where,

P = internal pressure

S = allowable or calculated stress

E =joint efficiency

R=Radius of cylinder

t= thickness

Design codes used for Pressure Vessel

 EN 13445: The current European Standard, harmonized with the Pressure Equipment
Directive (97/23/EC). Extensively used in Europe.

 ASME Code Section VIII, in addition, supported by Sections II (materials), V

(NDT/NDE) and IX (welding). Published by the American Society of Mechanical
Engineers.

 ASME Code Section VIII Division 1: US standard, design by the formula. Almost

exclusively used in North America, widely used worldwide.

 ASME Code Section VIII Division 2: Alternative Rules, design by analysis. 

 ASME Code Section VIII Division 3: Alternative Rules for Construction of High-Pressure

Vessel

 BS 5500: Former British Standard, replaced in the UK by EN 13445 but retained under the

name PD 5500 for the design and construction of export equipment.

 AD Merkblatter: German standard, harmonized with the Pressure Equipment Directive. 

 EN 286 (Parts 1 to 4): European standard for simple pressure vessels (air tanks),

harmonized with Council Directive 87/404/EEC.

 BS 4994: Specification for design and construction of vessels and tanks in reinforced

plastics.

 IS 2825-1969 (RE1977) : code unfired Pressure vessels

School of Mechanical Engineering, K L E Technological University, Hubballi Page 37

CHAPTER 5

FINDINGS & RECOMMENDATIONS

Most of the industries are shifting to Industry 4.0 showcasing the era of Artificial
Intelligence , Machine Learning, Digitalization. Industries seek to reduce time of
production , waste and enhance revenue . Kaizen and Kanban systems are best live
examples for this scenario. Oil and Gas sector is not apart from these things. It is shifting
from conventional oil extraction to digitalized environment. By chance accidentally and
unfortunately if one of the component in a shaftline of a refinery malfunctions then it
consumes a cumbersome time for rectification. A single minute counts in terms of
performance and revenue. This problem can be tackled by digitalizing these refineries.
System can predict the actual or the probable time of failure of component based on the
current performance conditions. Generally softwares can warn 3 months before the failure.
Hence the workforce can consider the intimation and work upon it. There by reducing the
huge loss in revenue and helps in maintaining the consistency in production. The current
predictive software has some luke holes in its performance. The sensor values may hike up
at each run immediately after shutdown. Software considers this itself as the real value and
accounts for predictions. In order to overcome this the visual inspector has to retrain the
model and set the filters. It never encounters the random peaks and troughs.
There are many instances where the failures are intimated 3 days post identification by the
plant employees. Some improvements are required for the anomaly detections and right
intimation to perform predictive maintenance. Digital technologies can make Oil and Gas
capital projects more productive as well . Digital twins, real-time digital replicas of
physical assets created by laser scanning of a construction site, make it possible to do site
inspections and track progress in real time from office. With the use of RFID tags, the
value chain workflow of parts can be automatically tracked from manufacturer to
installation site, improving schedule predictability used in combination, 5-D BIM and
digital twins will likely soon become the new norm for designing and monitoring
construction projects. Using machine learning , data ingestion engines, and innovate
pattern recognition ,oil and gas companies can now rapidly sort through millions of data
points. With this capability ,Oil and Gas capital project owners can compare the impact of
hundreds of performance drivers on project or business outcomes. They can also identify
the obstacles that raise costs and timelines .

School of Mechanical Engineering, K L E Technological University, Hubballi Page 38

CHAPTER 6

CONCLUSION

University has given an opportunity to complete the Industry Internship Project in reputed
companies instead of 8th semester capstone project. It was my fortune to accomplish my
internship cum project in the Campus Recruited company. Ample opportunities were given
in the company to explore new things. Before turning to professional employees in the
industries, it was a fantastic opportunity given to the students of our college to know the
industry environment, the business, the discipline of how the actual industry works and
gain the practical knowledge by working in the live business.
Industry decorum is new to students. Initially I was unaware about the general industry
terms and security policies. Client’s data privacy and commitments are strictly followed in
the companies. It was my great experience to participate in the online weekly clients
meeting and to know about the formalities of such meetings . It realized the
synchronization of the thoughts between the clients and the delivery employee. This
program emphasized me to deeply think about real world live industrial problems.
Oil and Gas department enabled me to learn about the refineries ,failure modes, predictive
maintenance, monitoring, replacing and inspection of the components. Parallely I could
concentrate on the life extension projects which helped me to recognize the critical
components in Oil and Gas field, guidelines for replacements and also virtually realize the
giant size of the FPSO. This program also helped me to learn new softwares which I didn’t
used ever before. A great exposure to commercial softwares provided by the clients helped
me to know deeply into it. A good communication with clients, peers, colleagues,
management staff was established. Team coordination, project management, professional
dress codes, punctuality awareness got inculcated into my curriculum. Many monotonous
breaking events, technical trainings, webinars, social activities were conducted for our
benefits. A session regarding the safety measures to be taken during fire accidents by the
Emergency Rescue Team(ERT) was conducted with live Demo by buzzing the fire alarms.
Knowledge sharing sessions were conducted between the peers during the dwell period.

It was my pleasure to be a part of the Corporate Social Responsibility(CSR) team. It

placed me an opportunity to visit GOVT school and teach Spoken English and computer
classes to nurturing minds . Social activities are necessary for each individual along with

School of Mechanical Engineering, K L E Technological University, Hubballi Page 39

professional career. Engineering ethics ,codes were realized to us in the industrial niche.
Industrial internship training enabled me to learn new things and acquire knowledge. It
gave me a sense of delightness and accomplishment to contribute to company.
I thank QuEST for providing me an opportunity to undergo this auspicious training
program in their organization.

Fig 6.1 & 6.2: Corporate Social Responsibility(CSR)- GOVT School visit to teach spoken
English

School of Mechanical Engineering, K L E Technological University, Hubballi Page 40

 REFERENCES

https://www.cast-safety.org/pdf/3_engine_fundamentals.pdf
http://turbofan-engine.blogspot.com/2009/01/high-bypass-turbofan-engines.html
https://www.oilandgasiq.com/fpso-flng/articles/guide-to-floating-production-storage-and-
offloading-fpso
https://www.theengineeringconcepts.com/pressure-vessel-equipment-design/

Image References
QuEST Global Map Google Maps
QUEST Global https://www.justdial.com/Belagavi/Quest-Global-Engineering-
Belagavi Pvt-Ltd-Belagavi-City
Organization https://www.quest-global.com/
Structure
Services Provided https://www.quest-global.com/
Services Provided https://www.quest-global.com/
in Mechanical
Engineering
Trainings Self
Undergone
Brayton Cycle https://id.wikipedia.org/wiki/Berkas:Brayton_cycle.svg

Turbo-Fan http://www.financecolombia.com/viva-air-inks-3-2-billion-usd-
deal-with-cfm-for-leap-1a-turbofan-engines-on-its-new-airbus-
a320neo-jets/
Sub systems of http://turbofan-engine.blogspot.com/2009/01/high-bypass-
Aero Engine turbofan-engines.html

GD&T symbols https://www.fictiv.com/hwg/fabricate/gdt-101-an-introduction-

to-geometric-dimensioning-and-tolerancing
Maintenance Predictive Analytics to Monitor the
Practices Health of Refinery Rotating Equipment- Journal Paper
Hierarchy
Product Design https://www.nap.edu/read/11049/chapter/2
Methodology.
Axial Compressor https://www.youtube.com/watch?v=K0mScxx4v-I

Centrifugal https://www.researchgate.net/figure/Main-components-of-a-
Compressor centrifugal-compressor-in-isometric-view_fig2_313065156
Mixed flow http://www.euroasia-tec.com/compressors/
compressor
Exhaust collector https://www.aircraftsystemstech.com/p/exhaust-section-
with welded exhaust-section-of-gas.html
support struts
Insulation blanket https://www.aircraftsystemstech.com/p/exhaust-section-
with the exhaust-section-of-gas.html

School of Mechanical Engineering, K L E Technological University, Hubballi Page 41

 temperatures
obtained at the
various locations
FPSO https://plsadaptive.s3.amazonaws.com/eco/images/channel_uplo
aded_images/Gttj0mjj9Yf0sILJLFIm8OVFaoJFOgrEL4IoLdM
b.jpeg

Replacement of https://www.ctsom.com/life-extension-project-operating-fpso-
Components petroleo-nautipa/
Inspection of https://www.ctsom.com/life-extension-project-operating-fpso-
component petroleo-nautipa/
Life Extension ABS Standard Journal
Process Flow Chart

School of Mechanical Engineering, K L E Technological University, Hubballi Page 42