MANAGEMENT ASSOCIATES

MONTHLY PROGRESS REPORT

REPORT NO. _01__ PERIOD COVERED 06-Aug-2023 TO 06-Sep-2023

NAME: Zunair Noor DATE: 07-Sep-2023

DESIGNATION: Management Associate
P.NO: 3232 APP. BATCH: 26th TO: Unit Manager - L&D

DEPT./ SECTION: Maintenance (Mechanical) Thru: ________/_________

UM / Sec. Head / Dept. Mngr.
TRAINING PROGRESS
Compliance to Training Plan (%) Validated APIs
No. of written tests conducted Average Score (%)
Test wise Score (%)
No. of Technical Interviews Conducted No. of sessions with
Mentor
*Note: Description of tests to be mentioned in Activities Performed section and test record to be maintained.

OBJECTIVE
Summary for the Month of August regarding activities performed and jobs observed.

ACTIVITIES PERFORMED

JOBS OBSERVED
1. Delivered presentation on the topic of Oil Floating Seals. It was a 30minutes
presentation, in which I explained:
a. Working Principle of Oil Floating Rings.
b. Its construction.
c. Seal Oil Circuit and its auxiliaries, specifically discussed for Synthesis Gas
Compressors (K-306).
d. Securities installed on Seal Oil Circuit of Synthesis Gas Compressors (K-306).

2. Involved in shut-down activities:

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 a. Overhauling of GCV and GSV
b. Replacement of secondary filter for Dry Gas Seal of Natural Gas Booster
Compressor (K-1003).
c. Strainer cleaning of GT-106
3. Assisted in drafting the job report for overhauling of Aqueous Ammonia pump (G-301-
B). High vibrations were being reported on this pump and despite previous attempts to
address the vibration issue, the problem persisted. Thus, it was decided to overhaul the
pump. During overhaul, it was found that the impeller locknut threads on the pump shaft
were worn out, thus pump shaft was replaced. Several components replaced includes: lip
seals, mechanical seal faces, bearings, and wear rings for suction side. Also, for the
proper seating of the stuffing box head on the pump casing guide-rings with a uniform
clearance of 0.25mm were installed.
Despite this overhaul activity the vibrations persisted, and as per the inspection report of
‘Zita Solutions’, the cause of this vibration is resonance. Therefore, actions need to be
taken to modify the design of pump skid and support such that the natural frequency of
the system would be changed.
4. Assisted in the drafting the job reports for Gas Control Valve (GCV) and Gas Stop Valve
(GSV) installed on the Gas Turbine of loop A Synthesis Gas Compressor (KGT-306-A).
These valves were decided to be overhauled as there were issues in the controlling of Gas
Turbine, specifically during the start-up of gas turbine.
During the overhauling of GCV and GSV, the contact of valve seat was found okay,
hydraulic piston, piston rings and seal gland was also found to be in satisfactory
condition. For GSV the major items replaced were gasket for spring housing, Garlock
Klozure seals for gas side and oil side. For GCV the major items replaced were universal
bearings installed on the pilot valve connecting links, also the gasket for spring housing,
and Garlock Klozure seals for gas side and oil side were replaced.
5. Observed box-up activity of step-down gearbox for Granulator (DB-121). Gearbox had a
step-down ration of 17.635. This gearbox consisted of pinion gear, an intermediate gear
and a bull gear. On the pinion shaft spherical roller bearings (Brg no. 22322 C3) were
installed, on the intermediate shaft, cylindrical roller bearings with no cage (Brg no.
SL19-2326 INA) were installed and on the bull shaft cylindrical roller bearings with no
cage (Brg. No NCF 3040 CV/ C3) were installed.
During the box-up the backlash of intermediate-bull was found to be 0.13~0.14mm, and
for pinion-intermediate it was found to be 0.11~0.12. Also, the axial float of pinion shaft
was found to be 0.28mm, for bull shaft float was found to be 0.75mm, this was brought
down to 0.25mm, within the provided standard value of 0.2 ~ 0.5mm.

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 SELF-STUDY AND COURSE ATTENDED
1. Training and validation for Quality Assurance (QA).
2. Attended Skill improvement program on:
a. Gear Box Maintenance
b. Hot Gas Generators (HGGs)
c. Materials at FFBL
3. Studied API of Accident Control Techniques

Name: - Zunair Noor

Signature: ___________

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