Gujarat Refinery

SAFETY TALK
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-----Not following SOP (Standard Operating
Procedure) for lining up of VBU FEED Tank
Causing Starvation of FEED PUMP-78-P-31D
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--
An incident of a Petroleum Refinery

A.K. Singh
Hydrocarbon Safety Professional
Safety Talk

Suction from Tank Tank

1 km away

PSV routed to
Suction

Discharge to Tank 0.8 Km away

Motor

Screw Pump

 4 Seal

 4 Bearing

 Timing Gear
 Safety Talk
• During normal operation the Screw Pump 78P31D carrying viscous
fluid at 120°C, and discharge pressure around 12Kg/cm2 and initial
observation as usual( seal and bearing failure).

• Within 2-3 months, again same problem pop up which leads to failure
of Pump Seal and bearing.

• Mechanical maintenance force to develop substitute Matching gear

pair from local vendors
• Accuracy of timing gear, seal, bearing is a difficult task
• OEM refused to do the job with developed spares
• As per OEM normal life is 3-4 years.
Safety Talk
Cause :

• There was poor Co-ordination between VBU unit & OMS (Established
with DDCS flow of FEED, and Tank Change over and low Tank temp. )

• Steam traps was found to be inadequate in both the suction &

discharge line.

• There was no suction Pr. Gauge at suction to ensure minimum Pr.

Requirement i.e. 0.8 Kg/cm2 (at suction of pump as per data sheet).
While operated some time (0. 4 kg/cm2).

• Suction Tank level was to be maintain normally 30% to avoid starvation

of the pump was not followed sincerely .

• Before failure pump gives high vibration .

 Safety Talk
Lesson Learnt:

 Steam trapping to be checked and direct drain to be opened particularly in winter

when ambient temp is below 10C.

 Starvation of the pump should be avoided.

 Suction Pr. To be maintained at 0.8 Kg/cm2

 Unit to observe trend of FEED flow during tank change over and its temperature
and log the data in both log book of O&MS and unit.

 SOP to be follow while changing the tank and running the pump.

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LEARNING FROM MISTAKES IS ONE WAY TO AVOID FUTURE
INCIDENTS