PRANAY REPORT

Maintanance and Case study of pumps
1DFPCL TALOJA
REPORT ON IN-PLANT TRAINING
AT DFPCL
[5th
MAY – 30th
JUNE]

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TOPIC OF PROJECT : MAINTANENCE AND CASE STUDY OF PUMPS IN IPA
PLANT
NAME OF TRAINEE :PRANAY PRAKASH
INSTITUTION : NATIONAL INSTITUTE OF TECHNOLOGY [NIT] , SURAT
(395007),GUJARAT, INDIA.
DEPARTMENT : MECHANICAL ENGG
[IIIrd Year].

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The internship opportunity i had with DFPCL was a great chance for learning and
professional development. Therefore, I consider myself as very lucky individual as i was
provided with an opportunity to be a part of it. I am also greatful for having a chance to meet
so many wonderful people and professionals who led me though this internship period.
Bearing in mind , I am using this opportunity to express my deepest gratitude and special
thanks to the MRS. Katkar ,MRS Rashmi Joshi and MR.Rai who in spite of being
extraordinarily busy with their duties, took time out to hear, guide and keep me on the correct
path and allowing me to carry out my project at their esteemed organization and extending
during the training.
I express my deepest thanks to MR. Dakava,MR Ghughe,MR. Desai and all operators of
respective machines for taking part in useful decision & giving necessary advices and
guidance and arranged all facilities to make life easier at DFPCL. I choose this moment to
acknowledge their contribution gratefully for their careful and precious guidance which were
extremely valuable for my study both theoretically and practically.
I perceive this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with
all of you in the future.
Sincerely,
PRANAY PRAKASH
MECHANICAL ENGG. [3rd YEAR]
NIT SURAT.

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INDEX
SR
NO.
TOPIC PAGE
1. COMPANY PROFILE 5
2. SAFETY MEASURES AT DFPCL 7
3. SAFETY INDUCTION 9
4. INTRODUCTION TO PETROCHEMICALS 10
5. ISOPROPYL AT A GLANCE 12
6. IPA PRODUCTION IN DFPCL 14
7. MAINTENANCE PHILOSOPHY 16
8. PUMPS INTRODUCTION AND ITS TYPES 18
9. PREVENTIVE MAINANACE OF PUMPS 20
10. TRUBLESHOOTING OF PUMPS 24
11. CASE STUDY ON 9101 A/B 26
12. EXAMINATION OF INDIVIDUAL COMPONENTS 28
13. CONCLUSION 31
14. RECOMMENDATION 32
15. REFERENCE 33

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DFPCL(TALOJAWORKS)
Background : Deepak Fertilisers And Petrochemicals Corporation Ltd (DFPCL) was established
in 1979 as an Ammonia manufacturer. DFPCL commenced commercial production of ammonia
in 1983 with a technical collaboration with Fish International Engineers, USA, using natural gas
as feedstock. Later, during 1991, the company integrated forward into methanol and downstream
products of ammonia-nitro phosphate fertilisers, technical ammonium nitrate and various grades
of nitric acids, liquid carbon dioxide and hydrogen. In 2006, the company commenced the
manufacture of Iso Propyl Alcohol. In 2005, the company forayed into realty through a distinctive
Lifestyle Centre, Ishanya. The company forayed into the Indian and global fresh produce market
with the acquisition of Desai Fruits and Vegetables in 2011. DFPCL has now grown to be a
multiproduct, multi-customer conglomerate, agri products and services, fresh produce,
petrochemicals and retail.
 Business Operations: DFPCL is one of Asia’s largest single location manufacturers
of nitric acid, India’s leading manufacturer of Iso Propyl Alcohol and amongst the
largest manufacturers of technical ammonium nitrate in the world. With its plants
located at Taloja, Mumbai, DFPCL operates through an extensive network of dealers,
resellers and stockists across India, a network that is deep, widespread and
formidable. DFPCL has two key subsidiaries viz. Smartchem Technologies Ltd. and
Deepak Mining Services Pvt. Ltd.
 Chemicals : During FY12, the chemicals segment contributed around
57% to the total revenue of the company. The industrial chemicals
division caters to a cross-section of mining and industrial customers, both
small and large. These include all the major companies across mining,
pharmaceuticals, pesticides, resins, textiles, printing, packaging,
petrochemicals, dyes, dyestuff and food sectors. The company has
storage facilities at the plant in Taloja as well as at JNPT. As on March
31, 2012 the installed capacity for ammonia stood at 128,700 MTPA,
TAN at 469,000 MTPA, CNA at 138,600 MTPA, DNA at 702,900,
Methanol at 100,000 MTPA and that of IPA stood at 70,000 MTPA.
 Agri Products & Services/Fertilisers : DFPCL is one of India’s largest
and most reputed manufacturers of nitro phosphate fertilisers and
speciality fertilisers like sulphur bentonite. During FY12, the agri sector
contributed around 41% to the total revenue of the company. DFPCL has
an installed capacity of 229,500 MTPA for nitro phosphate fertilisers and
25,000 MTPA of bensulf. The company manufactures 24:24:0 prilled NP
fertilizer containing nitrogen in nitrate and ammoniacal forms as well as
water soluble phosphates. The company also sells various grades of other
fertilizers, both bulk and specialty, under two prominent brand umbrellas,

6DFPCL TALOJA
viz. Mahadhan and Bhoodan. Its brand strengths in the fertilizer markets
that it caters to across Maharashtra, Karnataka, Gujarat, Punjab, Haryana,
UP and MP are formidable. DFPCL operates through a two-tier
marketing network. First, through its own dealership network comprising
nearly 4,500 dealers and secondly, through institutional networks, such as
sugar co-operatives, who in turn, sell its fertilizers to the farmers.
Moreover, the company has entered into strategic tie-ups with various
marketing federations, namely Fertilisers Co-operation of India and
Duncans. DFPCL’s fertilisers are sold across Maharashtra, Karnataka,
Gujarat, UP, MP, Punjab, Haryana and WB among others. DFPCL is the
first company in India to provide total nutrient management services to
the Indian farmers through its Mahadhan Saarrthie Centres, which bring
agricultural production technologies to the door-step of
DFPCL is now focussed on global growth, drawing strengths from its existing product and
plant synergies and adding new product lines, new plants and augmenting manufacturing
capacities.
 In Technical Ammonium Nitrate (TAN) it’s moving from a domestic market leader to being a
global player, while moving further forward into Mining Services and Contract Mining
 In Agri-business, DFPCL has moved from bulk fertilisers to specialties/customised products
and farm solutions and further into produce management
 In Chemicals, the Company is moving up the value chain from bulk chemical commodities to
high-value petrochemicals
 It has built India’s first true Lifestyle Centre, Ishanya, that re-creates a unique consumer
experience that is part retail, part entertainment and part public space
 Future Plans : DFPCL plans on further doubling the existing capacity at its
integrated fertiliser complex at Taloja , Maharashtra with an investment of around `
3.6 bn in the proposed project that will enhance the capacity of its NPK grades
complex fertilisers from 229,000 MTPA to 600,000 MTPA. It will gain additional
flexibility to produce all NP/NPK grades with fortification of micro-nutrients. The
company is also coming up with a 32,000 MTPA greenfield new bentonite sulphur
plant to be set up at a cost of ` 0.55 bn near Panipat, Haryana. Both projects are
expected to be completed in a 30-months timeframe from commencement.

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Safety Procedures/Measures at DFPCL
1. SHE (Safety,Health,Environment) Policy : Manufacturing of fertilisers and petrochemicals
involves handling,processing and storage of no.of hazardous chemicals. SHE organisation to
coordinate and monitor systems and it is manned by professionally qualified personnel.For
safety barricades define and proper usage of colured tape :
“YELLOW”- Means caution .
“RED AND WHITE(RED)” - Means Danger.
“PYLONS” - Orange pylons can be used to designate
Parking spaces.
2. HOUSEKEEPING: Good skills are essential for personnel safety,reducing potential hazards
and keeping work areas safe,clutter free,maintain walk ways,ensure office lighting is
adequate,never walk on wet floors,no office shall be placed in hallways or exit ways.
3. MATERIAL STORAGE : No storage of materialsin aisles,corners or passage ways.Books should
be kept on shelves or neatly stored.Heavy objects should be located on low shelving,no chemical
storage in office areas. “Carpeting” should be in good condition to prevent trip hazards,secure
electrical cords and wires away walkaways.
4. SAFETY PERMIT PROCEDURES :
 To ensure proper authorisation of non-routine work.
 To make clear to persons carrying out the job,the risks involved and precaution to be
taken.
 To ensure that person responsible for an area is aware of all work being done there.
 In DFPCL, Class I and Class II permits are followed.
 Jobs of high risk nature are included in Class I and of no risk are covered in Class II.
 Class I – Jobs involving use of open flame or spark,gas cutting,welding jobs,entering
into vessels and confined spaces, work at fragile roof tops,drilling of pipelines and
equipment.
 Class II – Jobs involving work on de energised systems,painting jobs,maintanence
work,drilling on walls.

8DFPCL TALOJA
5. SAFETY IN MATERIAL HANDLING : Plan a route that is free from tripling and slipping
hazards.Judge weight of load for sharp edges. Wear gloves,safety shoes.
(Before lifting , Lifting , Carrying , Unloading ).
Stand as close to load as possible. Grasp load firmly.
6. PERSONAL PROTECTIVE EQUIPMENT :
 Head protection(helmets).
 Hand and arm protection(gloves,PVC gloves).
 Foot protection(safety shoes).
 Body protection(rubber/pvc).
 Ear protection(ear plugs).
 Safety belts.
7. HOSES :
 Area shaft engg.is responsible to implement these practices.
 Use of hose is allowed only temporary for steam and air.
 A steam hose should be inspected for any visible physical defects.
 Check hose surfaces for blisters.cracks or cuts.
 Hose should not be placed across hot lines.
 Sharp bends should be avoided.
 Compressed air should not be used to blow air.
 Drain valve on air receiver should be opened periodically.
 Tight connections.
8. HAND TOOLS & POWERTOOLS :
 Select the proper tools.
 Check the tool before starting up the job.
 Wherever necessary use clamps or vice to secure jobs.
 Grinder should not be used for redressing the heat treated tools.
 Ensure proper earthing to power tools.
 Disconect power tools before adjusting or repair when they are not in use.
9. GRINDING WHEELSAFE PRACTICES :
 Grinding wheel if breaks in running condition may cause serious even fatal accidents.
 Never use a whell that has any sign of a fracture.
 Holes on wheels should never be altered.
 Excessive tightening of mounting nut is dangerous.
 All guards should be in piston.

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SAFETY INDUCTION AT DFPCL
The safety induction was presented to us by MR. Deshmukh at safety hall downsides plant
building.During this induction of around 2 hrs.we were acquired with very useful knowledge
regarding safety at chemical and fertilisers and their consequences if ignored or following
wrong parametres of the same.The presentation was indeed an eye opener to us,as we weren’t
aware about such importance given to safety in chemical factories to eliminate risk.
Following are the important parameters whivh must be considered to eliminate risk at every
aspect during working at chemical/fertilisers plants :-
1. Elimination : This means that see and inpsect physically if you can eliminate a particular
or in other words think if is necessary to do that kind of job. If not just try to
eliminate it.
2. Substitution : After you get clearance from above inspection and if the job or process
appears risky,just sunstitute with a simpler and safer process requirement.
3. Engineering Design: This is one of the important factors which relates engineering
knowledge with the safety concerns. Design the systems such that no
accident can take place irrespective of conditions.
4. Administrative Control : Operators should strictly follow standard operating
procedures[SOP] related to each process conditions. SOP are certified and
checked by higher authorities and then forwaded to the operators for ease of
understanding of process.
5. PPE : Personal-Protective-Equipment(or PPE’s) should be used wherever required. Eg
include such as safety shoes,safety eye goggles,helmet .
In general, authorities tend to give a high stress on PPE;s, instead they need to manage the
Difference between hazard and risk in any process involved and apply the important
Procedures mentioned above to completely demolish risk involved in any job.

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WHAT ARE PETROCHEMICALS?
Petrochemicals, also called petroleum distillates, are chemical products derived from petroleum
petroleum are also obtained from other fossil fuels, such as coal or natural gas, or renewable
sources such as corn or sugar cane.
The two most common petrochemical classes are olefins (including ethylene and propylene) and
aromatics (including benzene, toluene and xylene isomers). Oil refineries produce olefins and
aromatics by fluid catalytic cracking of petroleum fractions. Chemical plants produce olefins by
steam cracking of natural gas liquids like ethane and propane. Aromatics are produced by
catalytic reforming of naphtha. Olefins and aromatics are the building-blocks for a wide range of
materials such as solvents, detergents, and adhesives. Olefins are the basis for polymers and
oligomers used in plastics, resins, fibers, elastomers, lubricants, and gels.
Primary petrochemicals are divided into three groups depending on their chemical structure:
1. Olefins includes ethylene, propylene, and butadiene. Ethylene and propylene are
important sources of industrial chemicals and plastics products. Butadiene is used in
making synthetic rubber.
2. Aromatics includes benzene, toluene, and xylenes. Benzene is a raw material for dyes
and synthetic detergents, and benzene and toluene for isocyanates MDI and TDI used in
making polyurethanes. Manufacturers use xylenes to produce plastics and synthetic
fibers.
3. Synthesis gas is a mixture of carbon monoxide and hydrogen used to make ammonia and
methanol. Ammonia is used to make the fertilizer urea and methanol is used as a solvent
and chemical intermediate.
Petrochemicals do not reach the final consumer - the man in the street; they are first sold to
customer industries, undergo several transformations, and then go into products that seem to
bear no relation whatsoever to the initial raw material. As a result, few of us make the
connection between the petrochemical industry and their GP's equipment, their DVDs, food
packaging or computers; few realise the amount of scientific efforts that went into these
commonplace objects. Although benefiting daily from end products that have been made
thanks to the input of the petrochemical industry, more often than not we see no obvious
connection between these everyday commodities and petrochemistry.

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Some of the petrochemical products used in our daily lives
A Petrochemical plant in Saudi-Arabia

12DFPCL TALOJA
ISOPROPYL AT A GLANCE
Isopropyl alcohol (IUPAC name propan-2-ol), also called isopropanol or dimethyl carbinol,
is a compound with the chemical formula C3H8O or C3H7OH or CH3CHOHCH3
(sometimes represented as i-PrOH). It is a colorless, flammable chemical compound with a
strong odor. As a propyl group linked to a hydroxyl group, it is the simplest example of a
secondary alcohol, where the alcohol carbon atom is attached to two other carbon atoms,
sometimes shown as (CH3)2CHOH. It is a structural isomer of 1-propanol. It has a wide
variety of industrial and household uses.
PROPERTIES:
Isopropyl alcohol is miscible in water, ethanol, ether, and chloroform. It will dissolve ethyl
cellulose, polyvinyl butyral, many oils, alkaloids, gums and natural resins.It is insoluble in
salt solutions.Unlike ethanol or methanol, isopropyl alcohol can be separated from aqueous
solutions by adding a salt such as sodium chloride, sodium sulfate, or any of several other
inorganic salts, since the alcohol is much less soluble in saline solutions than in salt-free
water. The process is colloquially called salting out, and causes concentrated isopropyl
alcohol to separate into a distinct layer.
Isopropyl alcohol forms an azeotrope with water, which gives a boiling point of 80.37 °C
(176.67 °F) and a composition of 87.7 wt% (91 vol%) isopropyl alcohol. Water-isopropyl
alcohol mixtures have depressed melting points.[6] It has a slightly bitter taste, and is not safe
to drink. Isopropyl alcohol becomes increasingly viscous with decreasing temperature. At
temperatures below −70 °C (−94 °F), isopropyl alcohol resembles maple syrup in viscosity.
Isopropyl alcohol has a maximum absorbance at 205 nm in an ultraviolet-visible spectrum.
APPLICATIONS:
Solvent:-
Isopropyl alcohol dissolves a wide range of non-polar compounds. It also evaporates quickly,
leaves nearly zero oil traces, compared to ethanol, and is relatively non-toxic, compared to
alternative solvents. Thus, it is used widely as a solvent and as a cleaning fluid, especially for
dissolving oils. Together with ethanol, n-butanol, and methanol, it belongs to the group of
alcohol solvents, about 6.4 million tonnes of which were utilized worldwide in 2011.
Examples of this application include cleaning electronic devices such as contact pins (like
those on ROM cartridges), magnetic tape and disk heads (such as those in audio and video
tape recorders and floppy disk drives), the lenses of lasers in optical disc drives (e.g., CD,
DVD) and removing thermal paste from heatsinks and IC packages.
Intermediate:-
Isopropyl alcohol is esterified to give isopropyl acetate, another solvent. It reacts with carbon
disulfide and sodium hydroxide to give sodium isopropylxanthate, a herbicide and an ore
flotation reagent. Isopropyl alcohol reacts with titanium tetrachloride and aluminium metal to
give titanium and aluminium isopropoxides, respectively,the former a catalyst, and the latter

13DFPCL TALOJA
a chemical reagent.This compound may serve as a chemical reagent in itself, by acting as a
dihydrogen donor in transfer hydrogenation.
Medical:-
Rubbing alcohol, hand sanitizer, and disinfecting pads typically contain a 60–70% solution of
isopropyl alcohol in water. Water is required to open up membrane pores of bacteria, which
acts as a gateway inside for isopropyl. A 75% v/v solution in water may be used as a hand
sanitizer.Isopropyl alcohol is used as a water-drying aid for the prevention of otitis external,
better known as swimmer's ear.
Automotive:-
Isopropyl alcohol is a major ingredient in "gas dryer" fuel additives. In significant quantities,
water is a problem in fuel tanks, as it separates from the gasoline, and can freeze in the supply
lines at cold temperatures. Alcohol does not remove water from gasoline; rather, the alcohol
solubilizes water in gasoline. Once soluble, water does not pose the same risk as insoluble
water, as it will no longer accumulate in the supply lines and freeze. Isopropyl alcohol is
often sold in aerosol cans as a windshield de-icer. Isopropyl alcohol is also used to remove
brake fluid traces from hydraulic braking systems, so that the brake fluid (mineral oil) does
not contaminate the brake pads, which would result in poor braking.
Toxicology:-
Isopropyl alcohol and its metabolite, acetone, act as central nervous system (CNS)
depressants.Symptoms of isopropyl alcohol poisoning include flushing, headache, dizziness,
CNS depression, nausea, vomiting, anesthesia, hypothermia, hypotension, shock, respiratory
depression, and coma.Poisoning can occur from ingestion, inhalation, or skin absorption,
therefore, well-ventilated areas and protective gloves are recommended. Around 15 g of
isopropyl alcohol can have a toxic effect on a 70 kg human if left untreated.However, it is not
nearly as toxic as methanol or ethylene glycol.
Isopropyl alcohol does not cause an anion gap acidosis (in which a lowered blood serum pH
causes depletion of bicarbonate anion) unlike ethanol and methanol. Isopropyl alcohol does,
however, produce an osmolal gap between the calculated and measured osmolalities of
serum, as do the other alcohols. Overdoses may cause a fruity odor on the breath as a result of
its metabolism to acetone, which is further metabolized to produce the nutrients acetate and
glucose.

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ISOPROPYL ALCOHOL PRODUCTION IN DFPCL
Having set up India's largest plant for producing Iso Propyl Alcohol with an installed
capacity of 70,000 MTPA, DFPCL manufactures IPA through an extremely efficient and
environment friendly, direct hydration process, producing a colourless product of high purity,
with no undesirable odour or by-product formation. The product meets international quality
standards for use in pharmaceuticals, coatings and inks, specialty chemicals and cosmetics.
For critical applications in the pharma sector, DFPCL offers IPA conforming to stringent
standards such as USP, PhEuro and IP to name a few.
DFPCL has a fully automated drumming facility for catering to small consumers and for
meeting the increasing demand from neighbouring countries for exports. Our product has
been well accepted in various markets such as USA, EU, AFRICA, MIDDLE EAST and
FAR EAST. DFPCL also offers GMP Grade IPA which is Benzene free which meets the
monographs of all the international pharmacopoeias.
BASIC PLANT DESCRIPTION:
The basic raw material for isopropanol manufacture is the chemical grade propylene with a
minimum purity of 98%. As we donot have the direct source of this gradeof propylene
refinery grad, propylene is purchased from BPCL which contains 70-75% of propylene and is
further purified by fractionation by seperating out the propane content and other light
impurities.
The plant uses the above purified propylene gas and demineralised water to produce the IPA
product.
The production of isopropanal is used in production of
 AMINES
 ESTERS
 GLYCERINE
 JET ENGINE FUELS

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 JET ENGINE FUELS
 SPECIALILY IN KS
The phosphoric acid catalyst is held within the reactor on an inert silica fill.The 95%
unreacted propylene gas is recovered by the recycle gas compressors.
The crude IPA from reaction is fed to distillation section of the plant where unwanted
byproducts such as ethers, acetone, NPA, hexene are removed giving final pure IPA product.
DESIGN CONDITIONS OR INFORMATION:
Due to the metallurgy of the carbon steel used for construction, minimum operating
temperature of the system is limited to -28degrees to avoid chilling of the steel and it is
subsequent embrittlement.This is of particular concern when liquid propylene is flashed into
the system at low pressure during start up.The maximum design temperature of the system
doesnot allow steaming out of equipment in shutdown.
DESCRIPTION AND CONTROL:
The top 5 trays in the tower acts as a pasteurising section to remove mainly ethane, methane,
ethylene.The distillation section consists of a number of coloumns and their associated
drums,exchangers etc.
The plant storage facility has dedicated tanks for product and by-products.The important
auxillary systems associated with IPA plant are demineralised water plant:-
 DEMINERALISED WATER PLANT
 COOLING TOWER
 STEAM AND CONDENSATE STEAM
 HOT WATER SYSTEMS
 FLARE SYSTEMS

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MAINTENANCE PHILOSOPHY
Maintenance is the process of keeping a particular machine or asset in its normal operating
condition without any loss of time or breakdown.Machines are to be machined in such a way
so that it can be utilized to fullest extent.Maintenance raises equipment performance but adds
cost of production.We have to strike a balance for optimum maintenance cost and
productivity.
OBJECTIVES :
1. Equipment/Facilities always to be in optimum working conditions.
2. Delivery schedule to customer not to be affected by equipment availability.
3. Performance of equipment to be reliable.
4. Down time of machines to be minimum.
5. Maintenance cost to be monitored to control overhead cost.
6. Spare parts management to be optimized.
7. Maximize operational efficiency.
CHALLENGES :
1. Rapid growth in techmology makes current technology obsolete.
2. Advent of new diagnostic tools,rapid repair system.
3. Requirement to keep both outdated and modern machines with latest technology.
4. Added responsibilities includes- upgradation of existing plant and equipment,training
of maintenance personel to attain reqd.skills.
5. Effective equipment of old equipment for higher availability.
6. Cost optimization of all maintenance function.
TYPES :
 UNPLANNED: Unplanned maintenance is also known as: reactive maintenance,
corrective maintenance, breakdown maintenance.Unplanned maintenance occurs in any
asset maintenance plan and unfortunately is unavoidable. A common example of this
type of maintenance (and the inconvenience that it can cause) is having your car break
down on the side of the road, and having to wait for a mechanic to come to repair it. The
trigger for this type of maintenance is a breakdown trigger.Because this maintenance
type is both unplanned and unscheduled this method of performing maintenance
activities is highly inefficient. Time needs to be spent investigating and determining the
problem as well as determining a maintenance plan to get the equipment fixed quickly.
Time is also likely to be spent waiting for parts, supplies or other personnel to complete
the maintenance task.This type of maintenance can also be very expensive. Additional
costs include time spent waiting, the premium costs that may be spent on fast part orders
and shipping, and the possible overtime payments that may be required for additional, or
specialized personnel needed to complete the task. In addition, because it is likely that
the operation of other parts of the facility will be negatively impacted by the breakdown

17DFPCL TALOJA
of the machine in need of repair, the costs of lost production need to be also factored into
the cost of this type of maintenance.
 PLANNED : It is a organized type of maintenance,it takes care of control and record
required for this type of work.Maintenance work is planned before hand.
OVERHAULING : Overhauling is the process of physical inspection of individual parts to
assess their condition and to rectify and to bring it to normal state to ensure trouble-free
operation till next overhaul. We should perform overhauling when performance is
poor,consuming more power,machine produces more noice,vibrates heavily or fixed as per
manual.
 Equipment downtime is decreased and the number of major repairs are reduced.
 Better conservation of assets and increased life expectancy of assets, thereby eliminating
premature replacement of machinery and equipment.
 Reduced overtime costs and more economical use of maintenance workers due to
working on a scheduled basis instead of a crash basis to repair breakdowns.
 Timely, routine repairs circumvent fewer large-scale repairs.
 Improved safety and quality conditions for everyone.

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PUMPS
A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical
action. Pumps operate by some mechanism (typically reciprocating or rotary), and consume
energy to perform mechanical work by moving the fluid.Pumps operate by some mechanism
(typically reciprocating or rotary), and consume energy to perform mechanical work by
moving the fluid. Pumps operate via many energy sources, including manual operation,
electricity, engines, or wind power, come in many sizes, from microscopic for use in medical
applications to large industrial pumps.
Mechanical pumps serve in a wide range of applications such as pumping water from wells,
aquarium filtering, pond filtering and aeration, in the car industry for water-cooling and fuel
injection, in the energy industry for pumping oil and natural gas or for operating cooling
towers. In the medical industry, pumps are used for biochemical processes in developing and
manufacturing medicine, and as artificial replacements for body parts, in particular the
artificial heart and penile prosthesis.

19DFPCL TALOJA
Possitive diplacement pumps: A positive displacement pump makes a fluid move by
trapping a fixed amount and forcing (displacing) that trapped volume into the discharge
pipe. Liquid flows into the pump as the cavity on the suction side expands and the liquid
flows out of the discharge as the cavity collapses. The volume is constant through each cycle
of operation.
A positive displacement pump can be further classified according to the mechanism used to
move the fluid:
Rotary-type positive displacement: internal gear, screw, shuttle block, flexible vane or
sliding vane, circumferential piston, flexible impeller, helical twisted roots (e.g. the
Wendelkolben pump) or liquid-ring pumps
Reciprocating-type positive displacement: piston or diaphragm pumps.
Centrifugal pumps: Centrifugal pumps are used to transport fluids by the conversion of
rotational kinetic energy to the hydrodynamic energy of the fluid flow. The rotational energy
typically comes from an engine or electric motor. The fluid enters the pump impeller along or
near to the rotating axis and is accelerated by the impeller, flowing radially outward into a
diffuser or volute chamber (casing), from where it exits.
Common uses include water, sewage, petroleum and petrochemical pumping. The reverse
function of the centrifugal pump is a water turbine converting potential energy of water
pressure into mechanical rotational energy.
How it works: Like most pumps, a centrifugal pump converts rotational energy, often from a
motor, to energy in a moving water or fluid. A portion of the energy goes into kinetic energy
of the water or fluid. Water or Fluid enters axially through eye of the casing, is caught up in
the impeller blades, and is whirled tangentially and radially outward until it leaves through all
circumferential parts of the impeller into the diffuser part of the casing. The water or fluid
gains both velocity and pressure while passing through the impeller. The doughnut-shaped
diffuser, or scroll, section of the casing decelerates the flow and further increases the
pressure.

20DFPCL TALOJA
Preventive maintanance of pumps :
1. ONLINE –
 Tightening of Gland Nuts.
 Tightening of Flange nuts.
 Top up with oil.
 Replenishment of Grease.
 Oil leakages.
 Observations.
2. SHUTDOWN –
 Gland packing.
 Bearing replacement.
 Alignment.
 Coupling pads, bushes.
 Suction filters/Foot valves.
 Valve replacement.
 Oil/Grease replacement.
 Repairs, which cannot be taken online.

3. OVERHAULING- Overhauling of a pump is the process of physical inspection of the
individual parts to assess their condition and to rectify and to bring it to normal state to
ensure trouble free operation till next overhaul.
Conditions for Overhauling :
 When there is no sufficient flow.
 When there is no sufficient head.
 It consumes more power.
 Pump produces more noise.
 Pump vibrates heavily.
 Pump breakdown is frequent.
 Fixed period as per manual.
Overhauling Activities :
 Shut down.
 Remove from base.
 Dis-assembly.
 Clean and inspection.
 Repair at workshop.
 Manual Repair.
 Assembly.
 Fixing on base.
 Alignment.
 Test Run.

21DFPCL TALOJA
 Handover.
Refilling of gland Packings:
 Remove old packing. Use packing hook.
 Note location of the seal cage or lantern ring.
 Clean interior of box thoroughly.
 Check-shaft protection sleeve for wear.
 Replace sleeve ,if damaged.
 Check shaft run out.(Maximum-0.02 to 0.03mm).
 Measure new packing length.
 Cut to size. (Preferably at an angle.)
 Insert new packing,inside the box.
 Stagger joints of successive packing rings.
 Tightening nuts to keep packing in proper position.
 Loosen the nuts and keep them hand tight.
 Adjust gland leak after filling pump with liquid.
Pump dismantling :
 Drain oil and remove bearing housing.
 Remove gland packing and then the stuffing box.
 Punch identification number on stage casing.
 Unscrew nuts on connecting rods and remove them.
 Remove outlet cover with diffuser.
 Dismantle the impellers,distance bush and stage casing in sequence.
 When the last casing is removed,pull shaft together with last impeller. Remove impeller,shaft
protection aleeve from the shaft.
 Stack stage casing on top of one another.
Inspection and Measurements :
 Check ‘Out of round’of shaft and impellers.(0.02-0.03mm).
 Examine contact surfaces of stage casings(Max.tolerance 0.05mm).The surface roughness
must not exceed Ra=1.6m.
 Inspect impeller for signs of damage.
 Inspect Distance bushes,keys and keyways.
 Make spare parts available at site before starting assembly.
Dynamic Balancing of rotor with all rotating parts , should be carried out ,if any repair
has been done on them or any part has been replaced.

22DFPCL TALOJA
Assembly :
 Before reassembly,the axial face to face length must be measured. E1=E2.
 Coat all rotating parts with MoS2.
 Fix the shaft protection sleeve with the “Out ring on inlet side of shaft.”
 Insert shaft into the inlet cover.
 Mount stage casings with diffusers and Impellers assembly stage by stage.
 Total Axial clearance. Sa1+Sa2.
 Tighten connecting rods as per correct tightening torque.
 Fix stuffing box assembly,then the bearing housing. Lock the bearing.
 Fix coupling half.
 Put gland packing inside the stuffing box.
 Align the pump with the motor.
 The Pump is ready for operation.
LUBRICATION
When two parts are in relative motion,there is every possibility of friction between
the two
Surfaces.Friction causes wear,heat generation and also more power consumption. To
reduce
Friction and wear,Lubrication is needed.In Pumps,lubrication is done in the
bearings,by
Either OIL or GREASE.
1. OIL REPLACEMENT :
A. Shutdown machine :-
 Stop machine.
 Drain oil.
 Clean inside.
 Clean with flush oil.
 Fill with proper grade ,contaminant free oil.
 Restart machine.
 Temperature will rise at first,but will fall to normal after sometimes.
B. Running machine :-
 Fill fresh oil from top of the bearing housing slowly and gradually.
 Simultaneoulsy drain from the bottom such that the level in the sump remains almost
constant.
 When the old oil is completed replaced by the new oil,close drain and stop filling.

23DFPCL TALOJA
2. REGREASING OF BEARINGS :
a) Shutdown Machine :-
 Stop machine.
 Open housing cover.
 Remove old grease and clean bearing and housing.
 Fill the bearing with grease.
 Fill 50% to 60% of the housing with grease.
 Fit the cover and start machine.
b) Running machine :-
 Open the drain plug.
 Fill grease by the grease gun through the nipple at top.
 Observe old grease coming out of the drain.
 Continue greasing till all old grease comes out and some new grease starts coming.
 Stop pumping any more grease.
 Allow all excess grease to come out.
 Close plug.

24DFPCL TALOJA
TROUBLE SHOOTING OF PUMPS
SCREW PUMP FAULT ANALYSIS
FAULT POSSIBLE CAUSES
NO DELIVERY OR REDUCED
DELIVERY
 Inlet and outlet wrongly connected.
 Wrong direction of rotation.
 Excessive suction lift.
 Viscosity not within permissible range.
 Relief valve incorrectly adjusted.
 Air leakage into inlet.
 Inlet pipe diameter inadequate.
 Low pump speed
 Inlet stainer clogged.
PUMP SEIZED  Foreign parts jammed inside.
 Pump operating dry.
 Misalignment
PUMP VIBRATES OR IS NOISY Excessive suction lift.
 Air leakage into inlet.
 Foundation bolts loose.
 Inadequate suction pipe diameter.
 Gland packing or mechanical seal damaged.
 Bearings damaged.
NO LIQUID FLOW  Pump not vented properly.
 Suction too close to reservoir.
 Speed too low or too high.
 High back pressure.
 Foreign bodies inside impeller.
LESS LIQUID FLOW  Casing wearing rings badly worn out.
 Impeller damaged or disintegrated.
 Leakage through casing partitions.
 Suction filter choked.
TOTAL HEAD TOO LOW  Speed too high.
 Reverse rotation.
 High back pressure
 Rotating elements foul with fixed elements.
 Casing wearing rings worn out.
EXCESSIVE GLAND LEAKAGE Mis-alignment.
 Bent shaft.
 Bearings damaged .
 Shaft protection sleeves ‘O’ rings worn.
 Stuffing box badly packed.
 Improper size and quality of packing.
 Rotor vibration.

25DFPCL TALOJA
PUMP VIBRATES  Suction line incompletely primed.
 Pump operates at too low flow rate.
 Foreign bodies inside impeller.
 Pump misaligned.
 Shaft bent.
 Rotary elements foul with fixed elements.
 Bearings badly worn.
 Impeller damaged.
 Faulty bearing assembly.
BEARINGS LIFE TOO SHORT  Pump Misalignment.
 Pump not in level.
 Shaft bent.
 Rotating elements foul.
 Rotor vibrations.
 Lubricants not proper.
 Faulty bearing assembly.
 Rearing brackets not tightly fixed.
 Ingress of water into bearing housing.

26DFPCL TALOJA
Study On 9101 AIB Verticle Centrifugal Pump
1) Erection(Installation at site) : A special base frame must be fitted flush on shims in the
foundation or cover aperture to receive the pump set. The concrete base must have set
before the base feame is fitted.Carefully level the machined seating face for the barrel flange
using a precision spirit level,use stainless steel shims to compensate for any differences in
height..
2) Checking the direction of rotation : The direction of rotation of the driver must coincide
with the directional arrow on pump.The direction of rotation check must be carried out with
the driver disconnected from the pump.The driver is automatically centered in the flange of
the motor lantern after being placed and bolted on motor lantern.
3) Start up : Opening the isolating valve in the suction line fully,keep the isolating valve in the
discharge side fully and switch on the pump.Only after the pump has attained its full
operating speed should the isolating valve in the discharge line be opened slowly and
gradually,and used to adjust the operating duty point.Then vent valves on the discharge side
should be closed.
4) Maintenance :
 The pump must run smoothly,quietely and free from vibrations at all times.
 The pump must never be allowed to run dry.
 Prolonged running against a closed discharge valve must be avoided.
 The liquid level must always be situated at an adequate height above the
pump inlet.
 The temperature in the thrust bearing of the pump may be allowed toattin
upto 50C above ambient temperature,but should not exceed +90C,measured
at the outer wall of the bearing housing.
 The isolating valves in the supply lines must not be closed whilst the pump
is running.
 The gland packing should drip slightly whilst the upmp is running.The
gland should only be tightened lightly.
 If standby pumps are installed,these should be switched on and switched off
again immediately once a week,in order to maintain them in a state of
readinesss for intant start ups in an emergency.
 The proper functioning of the auxillary connections must be checked and
supervised.
5) Lubrication : The support bearing is lubricated by the oil fill in the bearing housing.An
oil elevator tube inside the centering sleeve supplies oil to antifriction bearing.The requisite

27DFPCL TALOJA
oil level is maintained by a constant level oiler.The reservoir of this constant level oiler must
therefore always be kept topped up with oil.
The first oil change should take place after the first 300hours of operation and subsequent oil
changes should be effected after every 3000hours of operation,but atleast once a
year.Unscrew and remove the drain plug on the bearing housing and drain the oil.After
draining of the bearing housing,replace the drain plug and fill in fresh oil.The pump bearings
and intermediate shaft bearings are lubricated directly by the product pumped.No special
maintenance of these bearings is necessary,but pump must not be allowed to run dry.
6) Packing the box :
 Fitting new packing :- Throughly clean the packing compartment and the
shaft protection sleeve and coat them with molybdenum disulphide.Insert neck
ring(457) and press it home until it abuts ,insert the packing rings individually
and push them with the aid of the stuffing box gland and seal cage ring.The
ring butt of each packing ring should be offset 90 degrees in relation to the
joints of the adjoining rings.Insert seal cage ring(458) so that it registers
opposite connection.Then insert the remaining packing rings
individually.Leave a sufficient clearance gap at the entrance of the stuffing
box for the positive guidance of the gland.The inserted packing rings should
only be lightly compressed by the gland and the nuts.
 Removing the packing :-Slacken clamping ring(184) and remove it from
shaft protection sleeve(524),undo stuffing box gland(452) and pull it out of
stuffing box housing(451).Pull the top packing rings out of stuffing box
housing with the aid of a packing ring extraxtor,pull out seal cage ring,them
remove the remaining packing rings and examine shaft protection sleeve for
signs of damage.Clean the packing compartment and coat it with molybdenum
disulphide.Pack the stuffing box.
7) Cooling sealing liquid : If the temp of product pumped exceeds 105C,a heat barrier is
fitted between the distributor casing and the stuffing box housing.The stuffing box housing is
provided with a cooling cover with connections7E/7A for the cooling liquid.Water from the
an outside source with hardness upto 8DH,calcium hardness ,or collled product can be used
for cooling purposes.If an aggressive coolant is used,the parts in contact with the coolant
must be made of suitably resistnt material.

28DFPCL TALOJA
Examination of individual components:
 Shafts : Inspect the bearings sleeves shrunk onto the shafts for signs of galling,Slight
traces of damagecan be removed by grinding within the permissible clearance limits.If
the touching up works should result in the permissible clearances being exceeded,then
new bearing sleeves must be shrunk on.Carry out an out of round check on a lathe
between dead centres.The max. permissible shaft whip must not exceed
0.03mm.Make sure the shaft is accurately centered on the lathe,as otherwise the
readings will be erroneous.If certain rotor components are replaced by new ones,or
have been touchedup,or if a new shaft has been fitted,the pump rotor must be
balanced dynamically,preferably at the max.
 Bearing arrangement : Even if they only exhibit slight discoloration marks or
specks of rust,or signs of damage to the running surfaces,the bearings must be
replaced by new ones.Observe the greatest cleanliness when mounting the
bearings.Use washing oil to clean the old bearings. After washing,the bearings should
be dried and immediately sprayed with oil.
 Shaft seals : Use new packing material every time the pump is overhauled.The shaft
protection sleeve may only be touched up very lightly by grinding.If it exhibits signs
of damage, a new shaft protection sleeve should be fixed.
 Dynamic balancing of pump rotor : Assembly proceeds from the front end;slip
stage sleeve onto pump shaft until it abuts against the shaft shoulder.Insert key and
slip final stage impeller onto the shaft ubtil it abuts.Mount the stage sleeve-keys and
impellers of the remaining stages in sequence as described.Fit the split ring an
key.Push on the bearing sleeve and suction impeller.Before dynamic balancing ,the
rotor should be checked for true running(out of round) at the impellers and at the
neraings.The measured out of round value must not exceed 0.03mm.The rotor should
then be dynamically balanced at max.pump operating speed if possible.

29DFPCL TALOJA
Characteristics curve for a typical centrifugal pump
Sooner or later, most maintenance professionals who work with pumps will encounter a
pump curve and its key parameters, one of which is Best Efficiency Point (BEP). The BEP
graphically represents the point on a pump curve that yields the most efficient operation. For
electric motors, efficiency varies with load, with the best efficiency being at about 75% of
load. With rotodynamic pumps (which includes centrifugal and axial flow types), efficiency
depends on three important pump curve parameters—head, flow (i.e., capacity or volume)
and power—as expressed in the above equation:
As the equation shows, power is inversely proportional to efficiency, which basically means
pumps use less power when operating more efficiently. But power is also directly
proportional to flow X head (Q X H), both of which vary with demand in a rotodynamic
pump system. If the system restricts the discharge of the pump, as when a discharge throttle
valve is closed, the flow decreases and the head increases. Conversely, less restriction from
the system means greater flow and less head.

30DFPCL TALOJA
Effect of flow rate : To visualize how flow affects pump efficiency, imagine the flow of
traffic on a highway, with efficiency measured as cars per minute. Late at night with no cars
on the road (and therefore no traffic), efficiency is zero. Early in the morning, traffic moves
quickly, but with few cars traveling, efficiency remains low. During rush hour traffic volume
greatly increases, so bottlenecks form, traffic slows to a crawl and efficiency plummets.
Usually, there is a time just before rush hour with lots of fast-moving traffic when the
highway handles the most cars per minute—i.e., its BEP.
The BEP for a pump is similar (see Fig. 3). With the discharge valve closed (“dead head”)
and zero flow, efficiency is zero. As the discharge valve opens (i.e., the discharge restriction
is gradually reduced), flow and efficiency gradually increase, until the flow through the pump
becomes more turbulent. At that point, efficiency will start dropping and then continue to
drop as the pump approaches “run out” condition (zero). As with traffic flow on a busy
highway, somewhere between “dead head” and “run out” condition, there is a flow rate at
which the efficiency is maximum—i.e., the BEP.
Effect of impeller design : Impeller design is the most significant factor for determining the
BEP of a pump because it dictates how efficiently power (brake horsepower or BHP) is
transmitted to the liquid being pumped (“pumpage”). A properly designed impeller optimizes
flow while minimizing turbulence.
Pumpage enters the impeller eye and accelerates as it travels radially outward toward the
impeller discharge. As the liquid discharges from the impeller, it merges with liquid already
in the impeller housing. If the impeller vanes are at just the right angle relative to the flow
rate, incoming pumpage will merge smoothly with the swirling pumpage in the housing,
minimizing turbulence, maximizing efficiency and yielding the BEP for that impeller.
Designers use a series of vectors to calculate impeller vane angle for a certain flow rate. As
shown in Fig. 4, vector Vt represents the speed of the vane tip (tangent and relative to the
impeller), and Vr represents the radial velocity of the pumpage flowing out of the impeller.
The discharge angle of the flow is Vm, the sum of vectors Vt and Vr, which should match the
impeller vane angle at the discharge. The length of vector Vr changes with flow rate, so
greater flow through the pump means the pumpage must move faster as it exits the impeller.

31DFPCL TALOJA
Conclusion:
After completing this report we conclude that the during this project I have attained deep
knowledge about different types of pumps used at chemical and fertiliser industry and
performed a detailed case study on 9101 A/B Verticle Centrifugal Pump.
The conclusion that we made that with an increased of speed of the pump it will cause the
properties and characteristic to varied accordingly which in turn effect the overall efficiency,
and with the increased of speed it is relevant that the efficiency also increased. The maximum
operating condition is at 90% pump speed, where the efficiency is 40% at 1.7 m3/s capacity
this is called BEP
The most important thing to remember from this discussion is that any modification of the
impeller will change the BEP of the pump. Trimming the outside diameter (OD) of an
impeller, replacing an impeller with one of different diameter or number of vanes or changing
the rotating speed of the impeller will alter the BEP for the pump.
Before modifying an impeller in any way, make sure that you determine how the change will
impact the pump curve, the efficiency curve and the BEP.

32DFPCL TALOJA
Recommendation:
USE OF NICKEL RESIST IRON:-Ni-Resist irons are alloy cast irons in which a
substantial addition of nickel has produced an authentic matrix structure.The matrix is
tough,heat-resisting and stable under chemical attack giving outstanding performace in
contact with a wide range of commonly occuring corrosives.They are not completely
stainless,but they form adhering film of rust which prevents further corrosion and doesnot
flake off to contaminate the product handled.
They show to advanatge in many environmentswhen compared with carbon steel and
ordinary cast irons.
Ni-Resist pumps can also be used in other water services.The resistance of Ni-Resist irons to
sea water corrosion at higher temperatures can lead to their increasing use in desalination
feedwater and brine pumps.

33DFPCL TALOJA
References:
 Centrifugal and axial flow pumps –Stepanoff.
 Pump application and engineering-Hicks and Edward.
 Metering pumps-Poypton.
 wikipidea

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