BRIEF ON ROTARY EQUIPMENT

S L MAURYA
CHIEF MAINTENANCE MANAGER
MAINTENANCE OBJECTIVE

OBJECTIVE OF MECHANICAL MAINTENANCE IS TO: -

IMPROVE RELIABILITY OF EQUIPMENT & ENHANCE
PLANT AVAILABILITY AND RUNLENGTH.
 CONTINUOUSLY UPGRADE THE SKILL FOR
INCREASING PLANT RELIABILITY, SAFETY AND
PERFORMANCE.
 OPTIMIZE THE MAINTENANCE COST.
 TO ACHIEVE CUSTOMER DELIGHT THROUGH
QUALITY MAINTENANCE AND FULFILLING THE
EXPECTATIONS & NEED OF THE CUSTOMERS
 MAINTENANCE OBJECTIVE CONTD..

•
 TO COMPLY WITH THE STATUTORY &
REGULATORY REQUIREMENTS RELATED
TO THE EQUIPMENT.
 TO CONTINUALLY IMPROVE THE
MAINTENANCE EFFECTIVENESS FOR
HIGHER PRODUCTIVITY & RELIABILITY
 TO UPGRADE THE SYSTEM, TECHNOLOGY
AND SKILL FOR COMPETITIVE EDGE.
 MAINTENANCE SET UP

• ZONAL/UNIT MAINTENANCE
• CENTRALIZED MAINTENANCE -WORKSHOP/
HEAVY EQUIPMENT
• PLANNING CELL
 MAINTENANCE PHILOSOPHY

• PREVENTIVE MAINTENANCE - TBM

• PREDICTIVE MAINTENANCE - CBM
• CORRECTIVE MAINTENANCE - BM
• SHUT DOWN MAINTENANCE - PM
 MAINTENANCE PHILOSOPHY

PREVENTIVE MAINTENANCE
IT IS BASED ON TIME INTERVAL AS WELL AS
PREDICTIVE MANTENANCE MONITORING
QUARTERLY, HALF YEARLY TO PREVENT
EQUIPMENT BREAK DOWN.
PREDICTIVE MAINTENANCE
IT IS BASED ON CONDITION MONITORING OF ROTARY
EQUIPMENT WEEKLY BASIS TO ASSESS THE HEALTH
OF THE EQUIPMENT.
 MAINTENANCE PHILOSOPHY(CONTD…)

CORRECTIVE MAINTENANCE
IT IS BASED ON ROOT CAUSE ANALYSIS TO
PREVENT REPETIVE FAILURE.
SHUT DOWN MAINTENANCE
IT IS BASED ON THE PLANNED SHUT DOWN SLATE
& UNDERTAKEN FOR THE COMPLETE UNIT.
MAINTENANCE EFFECTIVENESS

• PM EFFECTIVENESS – 98%
• PDM EFFECTIVENESS – 100%
• PLANT AVAILABILITY – 98%
• MAINTENANCE INDEX – 6.18 US$/ EDC
MAINTENANCE ACTIVITIES AT A GLANCE

A) MAINTENANCE JOBS IS PERFORMED THROUGH WORK

REQUEST SYSTEM IN SAP - 100%
B) MATERIAL PROCUREMENT THROUGH SAP –100%
C) CONTRACT ESTIMATE BILLING THROUGH SAP – 100%
D) PREVENTIVE MAINTENANCE SCHEDULING &
MONOTORING THROUGH SAP – 100%
E) SHUT DOWN SCHEDULING & MONITORING THROUGH
PRIMAVERA – 100%
F) CONDITION MONITORING THROUGH SOFTWARE PRO46 –
100%.
CLASSIFICATION OF EQUIPMENT
 ROTARY - 1075 NOS
– PUMPS, COMPRESSORS, TURBINES,
BLOWERS, A F COOLERS, COOLING TOWER
FANS, ID& FD FANS AND MIXERS
 STATIC - 915 NOS
– COLUMNS, REACTORS, VESSELS,
EXCHANGERS, COOLERS, CONDENSERS,
TANKS, FURNACE/HEATERS.
 PIPING - >25000 KM
ROTARY EQUIPMENT

 PUMPS - 825
 CENT. COMPRESSORS - 12
 REC. COMPRESSORS - 30
 TURBINES - 23
 AF COOLERS & CT FANS - 134
 ID & FD FANS - 29
 MIXERS - 66
 SOOT BLOWERS - 22
TYPES OF PUMPS
 PUMPS CLASSIFICATION IS BASED ON
 Operating Principle
– Centrifugal
– Reciprocating/Plunger/Diaphram
– Rotary
 Gear pumps
 Screw pumps
 Lobe/Vane pumps/ 2
07/04/24
PUMP CLASSIFICATION (CONTD.)

 CONSTRUCTIONAL FEATURES
– Single stage (balanced/cantilever design)
– multistage

 SERVICE REQUIREMENTS
– Pressure
– Temperature
– Type of fluid handled etc. 4
07/04/24
MAJOR COMPONENTS - PUMPS
 SHAFT
 IMPELLER
 SLEEVE
 CASING
 BEARING
 IMPELLER WEAR RINGS
 CASING WEAR RINGS
 THOAT BUSH
 STUFFING BOX
MAJOR COMPONENTS – PUMPS
(CONTD..)
 MECHANICAL SEAL
 OIL SEALS
 LANTERN RING
 OIL INDICATOR
 DISTANCE SLEEAVE
 BALANCING DISC/DRUM
 COUPLING
 BEARING HOUSING
Single stage cantilever pump
MULTISTAGE PUMP
PUMP DETAILS (SCREW)
BEARING HOUSING
REASONS OF FAILURES OF PUMPS

 LACK OF LUBRICATION
 HIGH VIBRATION
 STARVATION
 MECHANICAL LOOSENESS
 DEFECTIVE PARTS/MATERIAL
 OPERATING UNDER
ABNORMAL/OVERLOAD CONDITIONS
 OPERATING BEYOND SERVICE LIFE
STEPS NEEDED TO AVOID PUMPS
FAILURE

 ENSURE SPECIFIED QUALITY OF LUBRICATION

 CHECK OIL/GREASE CONDITION AT REGULAR
INTERVALS
 ARREST ANY OIL LEAK
 AVOID RUNNING UNDER HIGH VIBRATION
CONDITION
 STOP IMMEDIATELY ON HEARING ABNORMAL
SOUND
 ADHERE TO PREVENTIVE/PREDICTIVE MAINT.
SCHEDULE
STEPS NEEDED TO AVOID PUMPS
FAILURE (CONTD.)

 USE STANDARD QUALITY BEARINGS/SPARE

PARTS
 ENSURE SUFFICIENT FLOW THROUGH THE PUMP
 INSPECT/CLEAN SUCTION FILTERS AT REGULAR
INTERVALS
 CHECK AND CORRECT ALIGNMENT IN CASE OF
HOT PUMPS
 REMOVE PIPING TENSION IF ANY
 OBSERVE SOUND/NOISE REGULARLY
 AVOID RUNNING EXTENDED LIFE
REASONS FOR HIGH VIBRATIONS

 MIS ALIGNMENT
 UNBALANCE
 MECHANICAL LOOSENESS
 DEFECTIVE BEARINGS
 PHYSICAL CONTACT OF ROTATING PARTS
 DEFECTIVE COUPLING TEETH/BUSHES
 OIL WHIRL
 STARVATION
Causes of Bearing Failures

 Excessive radial or thrust load

 Excessive/lack of grease/oil
 improper dissipation of heat or failure of
cooling medium
 Dirt/foreign matter in lubricant
 improper installation of bearings
 rusting of bearings
Causes of Bearing Failures (contd.)

 Mis-alignment/bent shaft or vibration

 liquid deflector not fitted
 quality of lubricant improper.
TYPES OF BEARINGS
 ANTIFRICTION
– BALL
 Deep groove
 Angular contact
– ROLLER
 Cylindrical roller
 Taper roller
 JOURNAL / BABBIT LINED
– Simple journal
– Tilting pad
 SLEEVE/ BUSH
BEARING LUBRICATION

 FORCED FEED LUBRICATION

 OIL LEVEL
 GREASE
 SELF LUBRICATION
Pre-commissioning checks

 Pump rotates freely

 Direction of rotation of pump/motor is correct
 sealing connection if any is properly tightened
& adjusted
 Ensure complete priming of the pump
 Stuffing box is packed properly & gland is
tightened
Pre-commissioning checks (contd)

 Valve on delivery side is closed

 Flush the suction & discharge piping to avoid
entry of foreign material into pump
 In case of mechanical seal, Flushing,
Quenching & cooling lines should be started
well in advance
DON’T’S FOR PUMP OPERATION

Do not run the pump,

 Outside the recommended range
 without lubricating the bearings with oil or
grease
 with liquid other than specified
 with less NPSH than recommended
 with discharge valve fully shut for long
DON’T’S (contd.)

 With high vibration & abnormal noise

 without lubricant to the stuffing box
 With undue tension in suction & discharge lines
 when suction strainer is choked/removed
Commandments of pumping
operation

 Always read operating instructions

 Regular check for lubricating oil & its quality
 Never starve the pump
 Avoid overloading of the pump
 monitor & maintain the process parameters
Maintenance Cycle

Check Inspection interval

Daily Weekly Monthly Yearly
Oil level 
Oil leakage 
Oil quality 
vibration  
Brg. Temp.  
noise  
Maintenance Cycle (contd.)
Check Inspection interval
Daily Weekly Monthly Yearly
Seal leak 
CW flow  
CW leak  
Suction Pr.  
Disch. Pr.  
current  
Maintenance Cycle

Check Inspection interval

Daily Weekly Monthly Yearly
voltage  
overhaul 
CW inlet &  
outlet temp.
Calibration of  
measuring
instrments
MAJOR COMPONENTS - CENT. COMP.

 BARREL/SPLIT CASING
 INNER CASING
 ROTOR
 DIAPHRAMS/STAGE CASING
 SEALS
 DIAPHRAM SEALS
 BEARINGS
 COUPLING
 BALANCING DRUM
 INTERMEDIATE SEALS
MAJOR COMPONENTS – REC. COMP.

 CYLINDER
 PISTON
 PISTON ROD
 PISTON RINGS
 RIDER RINGS
 CONNECTING ROD
 CROSS HEAD
 SLIDE BODY
 CONNECTING ROD BEARINGS
MAJOR COMPONENTS – REC. COMP.
(CONTD..

 SUCTION / LOADER VALVES

 DISCHARGE VALVES
 CYLINDER HEAD
 CYLINDER LINER
 CRANK SHAFT
PUMP IMPELLER
TURBINE ROTOR
THANKS