LPG TR-11,

PROPANE REFLUX PUMP -A, OVERHAULING

DTD 18.05.2022

GAIL (INDIA) LIMITED

VIJAIPUR, GUNA

Team:
1. Dhananjay Kumar (Manager, O&M)
2. Anil Sharma (Manager, O&M)
3. Vishal Kumar Mishra (SE, O&M)

Prepared By: Vishal

BRIEF DESCRIPTION:
Propane reflux pumps installed in LPG Train 11 and 12 unit carries bottom liquid
of Propane reflux column back to the Propane column, for the reflux purpose.

Pump Tag: 11-P-121A

Pump Make/ Type: Sulzer Pump/ ZE-50-400
Service: Propane
Capacity Max/Min (m3/hr): 60/ 22
Differential head(m): 160
NPSHR (m): 1.6
Suction Pressure(kg/cm2): 15.8
Pump input (KW): 27.3
Speed (rpm): 2920
Oil: Servo System-46
Efficiency %- 71

Mechanical Seal:

Seal Type and Vendor: EPIL

Flushing Plan: Plan 11,76
Mating Ring (IB): SiC
Mating Ring (OB): SiC

Bearing:

DE side: 7310ECP (Back to Back Arrangement)

NDE side: NU 310EC

PROBLEM STATEMENT:

11-P-121A was not developing sufficient discharge pressure on 14.05.2022.

So, its back-pull assembly was replaced with overhauled back pull assembly and
after successful trial run, it was observed that new pump was developing intended
discharge pressure.

Overhauling of old back pull assembly was carried out in Mechanical Workshop
on 18.05.2022.
 ACTIVITIES, OBSERVATIONS AND ACTION TAKEN:

1. First, impeller lock nut was loosened, lock nut gasket compressed found.
Teflon gasket was replaced with new one.
2. Seal gland plate was locked with the help of sliding washer.
3. After that, shaft sleeve grub screw was loosened with the help of Allen
key.
4. Impeller back plate bolts were loosened, and back plate was removed.
5. Further, mechanical seal was disassembled. After disassembly of
mechanical seal, secondary seal was observed to be covered with foreign
particles and dirt.

Figure 1 Foreign particles in secondary seal

6. Shaft axial float before overhauling- 0.04 mm

7. Shaft radial float before overhauling- 0.15 mm
8. It was decided to replace the bearings, so shaft was disassembled from
bearing housing.
9. Shaft cleaning was carried out and run out was checked by placing shaft
on surface plate.
Impeller side run out- 0.02 mm
Coupling side run out: 0.03 mm
10. Now both sides bearings were heated till temperature of 130 deg C and
 bearings assembled on shaft.

Figure 2 Bearing Heater

11.Now bearing housing assembly was completed and float reading was
taken.
Axial float- 0.01 mm
Radial float- 0.09 mm

Figure 2Axial Float Figure 3Radial Float

12.Mechanical seal parts were cleaned with cleaner and cotton cloth. All soft
packings compressed found and faces worn out found.

Figure 4 Carbon Face(IB) Figure 5 Mating Face(IB))

Figure 6 Carbon Face (OB) Figure 7 Secondary Face(OB)

13. All soft packings of mechanical seal were replaced with new one and
both faces of primary seal were replaced with lapped one.

14.Both faces of secondary seal were replaced with new one.

15.Now mechanical seal assembly was completed taking reference from
drawing.
 Figure 8 Assembled Mechanical Seal

SPARES CONSUMED:

Reservation no: 0003031085

S.
No Mat Code Description Qty
30 5210701173 RING, MATING, P/N:300.02, D00028AA 1B 1
40 5210722143 RING, SEAL ASSY, P/N:100.02, D00028AA1B 1
50 5130473103 BRG, CYLINDRICAL, ROLLER, SKF-NU 310 ECP 1
60 5132753103 BRG, CYLINDRICAL, ROLLER, SKF-NU 310 ECJ C3 1
70 5118353103 BRG, BALL, SINGLE ROW, SKF-7310 BECBP 2
80 5210571863 O-RING, P/N:111.22,111.32,111.00 1