Nrl training group 2

PUMPS USED IN REFINERIESPUMPS USED IN REFINERIES
Presenting by-
Hirok Jan BarmanHirok Jan Barman (133)(133)
Saurav KonwarSaurav Konwar (056)(056)
Saifuddin Mirza AhmedSaifuddin Mirza Ahmed
(109)(109)
Deepak DolakashoriaDeepak Dolakashoria (107)(107)
Rijuan HussainRijuan Hussain (134)(134)
Lakshi Nandan BorahLakshi Nandan Borah (140)(140)
Feroz Ahmed MazumderFeroz Ahmed Mazumder
(017)
for the training seminar done at -
Don Bosco School of TechnologyDon Bosco School of Technology11

 Introduction to NRL…..Introduction to NRL…..
 Hydraulic Pumps…..Hydraulic Pumps…..
 Sealing's used for pumps….Sealing's used for pumps….
 Anti-friction & Journal bearings…..Anti-friction & Journal bearings…..
 Flow controllers….Flow controllers….
 Distillation units….Distillation units….
 Dismantling techniques….Dismantling techniques….
 A Case Study…..A Case Study…..
Friday, October 28, 2016
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ContentsContents

1. Proposal for Refinery included in “Assam Accord” : August 15, 1985
2. “NUMALIGARH REFINERY LIMITED” incorporated : April 22, 1993
3. Commercial Production commenced : October 1, 2000
4. NRL became subsidiary of BPCL : March 31, 2001
5. BHARAT PETROLEUM CORPORATION LIMITED (BPCL)BHARAT PETROLEUM CORPORATION LIMITED (BPCL), GOVT. OF ASSAMGOVT. OF ASSAM & OIL INDIAOIL INDIA
LIMITEDLIMITEDare the promoters of the company having equity participation of 61.65%, 12.35% & 26%
respectively.
6. NRL is designed to process 3 million metric tonnes perannum(MMTPA) of indigenous crude
oil.
 Products of the major units of the Refinery are LPG, Naphtha, Aviation Turbine Fuel (ATF),LPG, Naphtha, Aviation Turbine Fuel (ATF),
Superior Kerosene Oil (SKO), High Speed Diesel (HSD), Calcite Petroleum Coke (CCU) andSuperior Kerosene Oil (SKO), High Speed Diesel (HSD), Calcite Petroleum Coke (CCU) andFriday, October 28, 2016
3
INTRODUCTIONINTRODUCTION

4
 HYDRAULIC PUMPSHYDRAULIC PUMPS
Pump converts input power
to kinetic energy using
centrifugal force.
Pump converts input power
to kinetic energy using
centrifugal force.
Pump makes to move a fluid by
trapping a fixed amount and forcing
that trapped volume into the discharged
pipe.
Pump makes to move a fluid by
trapping a fixed amount and forcing
that trapped volume into the discharged
pipe.

 Consider a bottle containing water inside.Consider a bottle containing water inside. Figure - 1
 If we make a hole at the bottom of bottle, then the water will comeIf we make a hole at the bottom of bottle, then the water will come
out of the bottle.out of the bottle.
 Now, if we rotate the bottle at some speed, then the water flowNow, if we rotate the bottle at some speed, then the water flow
rate will increase, that is water will come out faster from bottle.rate will increase, that is water will come out faster from bottle.
 This phenomenon is used inThis phenomenon is used in Centrifugal pumpCentrifugal pump.. Figure -
2
 The two main parts of the pump are the impeller and the diffuser.The two main parts of the pump are the impeller and the diffuser.
 Impeller, which is the only moving part, is attached to a shaft andImpeller, which is the only moving part, is attached to a shaft and
driven by a motor.driven by a motor.
 The diffuser (also called as volute) houses the impeller andThe diffuser (also called as volute) houses the impeller and
captures and directs the water off the impeller.captures and directs the water off the impeller.
 Impellers are of 3 types-Impellers are of 3 types- Open, Semi-open & Closed.Open, Semi-open & Closed.
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CENTRIFUGAL PUMPCENTRIFUGAL PUMP
Figure-1Figure-2
Figure-3

6
 Different parts of Centrifugal pumpDifferent parts of Centrifugal pump
1. Single suction pump1. Single suction pump
2. Double suction2. Double suction
pumppump
3. Over hanging pump3. Over hanging pump
4. Between Bearing4. Between Bearing
pumppump
5. Single stage pump5. Single stage pump
6. Multi stage pump6. Multi stage pump
Different classifications are-Different classifications are-

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 Working of centrifugal pumpWorking of centrifugal pump
Water enters through impeller eyeimpeller eye and exits the
impellerimpeller with the help of centrifugal force.
As it leaves the eye a low-pressure arealow-pressure area is created,
causing more water to flow into the eye.
Velocity is developed as the water flows through the
impeller spinning at high speed.
The water velocity is collected by the diffuserdiffuser and
converted to pressure by specially designedspecially designed
passageways that direct the flow to the discharge of
the pump.
A centrifugal pump is not positive actingnot positive acting; it will not
pump the same volume always.
Since the pump is a dynamic device, it is convenient
to consider the pressurepressure in terms of head i.e. meters ofmeters of

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 Cavitation & NPSHCavitation & NPSH
(Net positive suction head)
☻Liquids can vaporizevaporize at very low temperature when they are
subjected to low pressure.
☻Pump cavitationsPump cavitations occurs when the pressure at pump inlet drops
below the vapour pressure of the liquid.
☻It is sudden formation and collapse of low pressure bubblesof low pressure bubbles in the
liquid caused by the continuous rotation of the impeller, that forms highhigh
velocity jetsvelocity jets & impinges on impeller.
☻Due to this impact there is a metal removal processesmetal removal processes from the
impeller, which causes noise, vibration, and damage to pump’s
internal components.
☻Vaporization of liquid being pumped must not occur at any
condition as when liquid vaporizes its volume increases very much, &
less water is pumped.
☻Any decrease in external pressure or rise in operating
temperature can induce vaporization and the pump stops pumping, so
pump always needs to have sufficient amount of suction headsufficient amount of suction head to

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 Net positive suction headNet positive suction head
֍ NPSH Available (NPSH Available (NPSHA):): The available total suction head at
the pump inlet above the head corresponding to the vapour
pressure.
֍ NPSH Required (NPSH Required (NPSHR):): The minimum pressure required at
the suction port of the pump to keep the pump free from
cavitations.
֍ NPSHA is a function of your system and must be calculated,
whereas NPSHR is a function of the pump and must be provided
by the pump manufacturer.
֍NPSHA must be greater than NPSHR for the pump system to
operate without cavitations.
֍Net positive suction head available is calculated from-

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 Characteristics CurveCharacteristics Curve
♠ API 610 (American Petroleum Institute)API 610 (American Petroleum Institute) offers guidelines for pump selection
that will run uninterrupted for a minimum of 3 years and provide minimum 20
years of reliable service. A typical API 610 pump performance curve looks
like this :-
♠ Every pump has a Best Efficiency Point (BEP) which is the flow at which it
is operating at its highest efficiency.
♠ Rated flow is located between 80% -110%80% -110% of BEP. It is a point the customer
chooses to rate the pump.
♠ Preferred operating region should be between 70% - 120%70% - 120% of the BEP, this
is where the pump is expected to operate under normal conditions.
♠ Best Efficiency Curve looks like this :-
♠ Min flowMin flow is the minimum flow below which the pump should not be operated
otherwise it could be in danger of premature failure.
♠ Minimum continuous stable flowMinimum continuous stable flow, set by the manufacturer as the lowest flow
at which the pump can operate without exceeding the vibration limits imposed
by API 610.
♠ Minimum thermal flowMinimum thermal flow is defined as the “lowest flow at which the pump can
a) Always recommended to maintain minimum continuous
flow, or bypass/recirculation line is used for flow less
than minimum continuous flow.
b) Where, a separate pass line is used with a valve
connection to separate the fluid, given based upon how
much discharge is required.

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 RECIPROCATINGRECIPROCATING
PUMPPUMP
►A reciprocating pump isaclassof positive displacement pumppositive displacement pump which
includesthepiston pump, plunger pump and diaphragm pump.
►Often used wherearelatively small quantity of fluid isto behandled and where
delivery pressureisquitelarge. Specially forviscous fluidSpecially forviscous fluid.
►Thefluid sucked ispushed dueto thethrust exerted on it by themoving
member, which resultsin lifting theliquid to therequired height.
►Themotion of thesepartsaremating with a cavity orchambercavity orchamberand the
contact isleakageproof.
►During onedirection of motion of thereciprocating part fluid istaken inside
and during theother oppositedirection of motion of fluid ispushed out.
►Different componentsof areciprocating pump areasfollows-
1.1.Cylinder, Piston/Plunger, Crank/Connecting rod.Cylinder, Piston/Plunger, Crank/Connecting rod.
2.2.Suction/Delivery pipes & valves, Air-vessel.Suction/Delivery pipes & valves, Air-vessel.

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 Working of the pumpWorking of the pump
In suction stroke, thepressurein cylinder decreasesand fluid entersinto the
chamber, suction valve then opens and allowsthefluid to enter thecylinder
and closesat theend of thestroke.
In dischargestroke, thefluid entersthedischargepipeaspressurein the
dischargepipeislessthan in thechamber, thispressureenablesthedischarge
valve to open and suction valve to close.
Thesepumpsaredesigned to do so onceper cyclewhich is single acting
and, if it doestwiceper cyclethen it iscalled adouble acting.
A singleacting displacesfluid only in one direction, but adoubleacting
pump displacesin two directions in twice stroke.
When thewater in delivery pipeisdelivered with greater speed than the
average, then theexcessamount of water isstored in theairvessel which
containsair & getscompressed asthewater entersthevessel.
Thestored water comesout when thedelivery flow becomeslessand thusa
continuousflow ismaintained.
For acontinuous flow of liquid theseair vesselsareused.

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 SCREW PUMPSCREW PUMP
It is a positive displacement pumppositive displacement pump that use one
or more screws to move fluids or solids along the
screw axisscrew axis the screw pumps are used for pumping
high viscous fluidsviscous fluids.
The fluid is sucked from the suction nozzle and
then through linerliner, the fluid is entered into the
screw.
As the screw rotates at high speed, it creates a
pressure difference. Due to which fluid enters into
the screw gaps and with the rotation of the screws,
the fluid is send to the discharge nozzle.
Depending upon number of screws, they are :-
1. Single screw pump- one screw is used to
pump fluid from one place to another.
(Figure-1)……(Figure-1)……
2. Double screw pump- two screws fitted with
intermeshing there screw threads, used
Figure-1
Figure-2

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SEALING’S USED INSEALING’S USED IN
PUMPPUMP
GLANDPACKINGGLANDPACKING - Old fashioned technology, using soft packing of ropes compressed by a packing
gland.
Actually how itActually how it
looks and packing islooks and packing is
done.done.
After this came the use ofAfter this came the use of
Mechanical seals……Mechanical seals……

15
 The mechanical sealThe mechanical seal
 The most effective method of preventing
the leakage of the fluid from pump to the
external surroundings is by using the
mechanical seals.mechanical seals.
 The mechanical seals helps sealing the
rotating part of the shaft against the
stationary part of the pump housing.
 The different designs available, for the
mechanical seals configuration. They are :-
1. Pusher
2. Non pusher
3. Cartridge

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 What & How Mechanical seals?What & How Mechanical seals?
PrimaryPrimary && Secondary seal.Secondary seal.
One component is stationarystationary and the other rotatesrotates against it to
achieve a seal.
One of the faces is usually a non-wearing materials such as
carbon-graphitecarbon-graphite & other face is relatively hard material like silicon-silicon-
carbidecarbide or ceramics.
There are at least three forcesthree forces trying to open the seal faces :-
If the closing forces are the greater forces, the seal will generate
heat that is often destructive, but always a waste of energy and pump
efficiency.
If the opening forces are the greater forces the seal will leak and
that’s never desirable.
Most of the refineries maintain the standard ratiostandard ratio :-
Opening force is always slightly greater so that small amount ofOpening force is always slightly greater so that small amount of
fluid can enter the faces as the lubricating fluid.fluid can enter the faces as the lubricating fluid.
Seal with leakageSeal with leakage

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BEARING’SBEARING’S
 Mostly steel (300 °C), brass (250 °C), polymer (70
°C) within these operating temperatures are used.
 Bearings are classified as anti friction and journal
bearings.
1.Ball bearings
1. Deep grove ball bearing
2. Angular contact ball bearing
2.Roller bearings
1. Cylindrical roller bearing
2. Spherical roller bearing
3. Tapper roller bearing
3.Thrust bearings
4.Journal bearings (high speed bearings)

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 Design aspects of Cylindrical bearingDesign aspects of Cylindrical bearing
NUP – outer ring has
two flanges & inner ring has
one flange.
NU – outer ring has two
integral flanges inner ring
has no flanges.
N – inner ring has two
integral flanges outer ring
has no flanges.
SERIESSERIES

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Bearings positioning used in pumpBearings positioning used in pump
☻ In centrifugal pumps, 2 angular contact2 angular contact
bearingsbearings & a roller contact bearingsa roller contact bearings used.
☻ A sight glasssight glass is used for visual monitoring
of the bearing oil level.
☻ The angular contact bearings are used in
back to back arrangementsback to back arrangements. So, large load
area.
☻ In such arrangement the axial and radialaxial and radial
loads are restrictedloads are restricted in both the directions.
☻ The roller bearing allows the axialThe roller bearing allows the axial
movement of the shaft, due to increased inmovement of the shaft, due to increased in
temperature.temperature.

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VALVES /VALVES /
CONTROLLERCONTROLLER
 A valve is a device that controls & regulates thecontrols & regulates the
flow of a fluid or gasesflow of a fluid or gases, by enabling the opening or
closing the valves.
 Valves are either controlled by hand or operated
automatically.
 Different types of valves are :-
1.1. Ball valve-Ball valve- with hole in between is used for control of flow.
A hollow circular ball is used in this case. If the ball is close,
then we need to move it by 90° to open the valve.
2.2. Gate valve-Gate valve- In gate valve, the valve is in the form of a
gate. The opening or closing of the valve is done by a
screw and nut like arrangement. If we rotate the nut, the
screw portion will come upward making the gate open.

21
֍ Valves or ControllersValves or Controllers
3.3. Globe valve-Globe valve- Glove valve is used for controlling
the flow rate. It is designed in such a way that, the
flow rate can be controlled. The flow takes a
zigzag path for travelling. We can partially open or
fully open the valve as per our requirements.
4.4. Check valve-Check valve- Check valve is a non returning
valve, which is used in the discharge pipe for a
pump. It is so designed that it controls the back
flow of fluid in the discharge pipe. In reciprocating
pumps this type of valve is used in suction and
discharge valve, for controlling the back flow of
liquid. It is also called NRV (Non- Returning
Valve).
5.5. Butterfly valve-Butterfly valve- A circular closed plate type is
used for controlling flow. The plate is restricted in
on direction and opens or closes with the fluid
pressure.

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DISTILLATIONDISTILLATION
PROCESSESPROCESSES
Crude oil stored in the
tanks.
Passed to the closed
pressure vessels.
Then to the De-Salter.
Flowed to the heat
exchangers.
Allowed to pass through
furnace.
Crude Distillation UnitCrude Distillation Unit

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 Distillation ProcessesDistillation Processes
Reduced pressureReduced pressure //Vacuum Distillation UnitVacuum Distillation Unit
760 mm of Hg
760 mm of Hg
100 mm of Hg
100 mm of Hg
We know,
PVPV==nRTnRT
 The feed is distilled in the VDU.The feed is distilled in the VDU.
 &, thus at very low temperature the&, thus at very low temperature the
compounds are distilled.compounds are distilled.

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 DISMANTLING PROCESSDISMANTLING PROCESS
of a Centrifugal pump….of a Centrifugal pump….
1)1) Disassembling the Pump-Disassembling the Pump-
casing. Impeller locknut,
impeller, back plate, mechanical
seal (inspection).
2)2) Pull out the bearing from thePull out the bearing from the
Shaft-Shaft-
3)3) Inspection and Repair-Inspection and Repair- (check
every possible gaps)
4)4) Recondition/Replacement ofRecondition/Replacement of
Parts-Parts-
1) Lateral orAxial Movement
of shaft (End Play)-(End Play)-
2) Radial Movement of shaft
(Whip ordeflection)-(Whip ordeflection)-
3) Shaft Run Out (Bent shaft)-(Bent shaft)-

25
☻ OUR CASE STUDYOUR CASE STUDY
AFTERIMPELLER
DISMANTLING -
1. Im pe lle r we ar ring o ute r diam e te r =
124.7mm124.7mm.
2. Casing we ar ring inne r diam e te r =
125.22mm125.22mm ..
So, the clearance is = 0.520.52. This clearance is
acce ptable as minimum requirement is = 0.60.6..
Our inspection of a Centrifugal pumpOur inspection of a Centrifugal pump….….
OBSERVATIONS :-OBSERVATIONS :-
1. Bearing housing cover is
rusted.
2. Service fluid found inside
sleeve.
3. Service fluid and rusting
found inside mating parts and
rusting found inside rings.
4. Metal removal is found in

26
 Our case studyOur case study
AFTERSHAFT DISMANTLING -AFTERSHAFT DISMANTLING -
1. Radialplay = 0.2mm0.2mm, ((no t acce ptable … . . )no t acce ptable … . . ) 2. Radialrun o ut = 0.02mm.0.02mm. 3. Axialplay = 0.05mm0.05mm
AFTERBEARINGS DISMANTLING-AFTERBEARINGS DISMANTLING-
1 . Be aring o ute r diam e te r = 89.98mm89.98mm.
2. Be aring ho using inte r diam e te r = 90.04mm90.04mm.
3. So, clearance is 0.06mm0.06mm (not
acceptable…)
4. Be aring inne r diam e te r = 39.98mm39.98mm.
5. Shaft diam e te r= 40.00mm40.00mm.
6 . So , the inte rfe re nce is = 0.02mm0.02mm
(acce ptable … . )
1. Bearing thickness = 55.50mm(combining)
2. Housing depth = 45.96mm.
3. Cover depth = 9.5mm
4. So, (45.96 + 9.5 = 55.46mm), but the bearing
thickness is 55.50mm, thus interference is
0.04, (acceptable….).
CONCLUSION :-CONCLUSION :-
1. New bearing housing is used.
2. New shaft is used.
3. Bearings are changed.
4. Mechanical seal ring part is changed.

Friday, October 28, 2016Friday, October 28, 2016
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CONCLUSION……

T
H
A
N
K
‘U’
Friday, October 28, 2016 EVERY ONE

Nrl training group 2

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