AVC COLLEGE OF ENGINEERING

1. AVC COLLEGE OF ENGINEERING MANNAMPANDAL MAYILADUTHURAI REVIEW 2

2. STUDY ON REPAIR AND MAINTENANCE OF LPG STORAGE BULLET PROJECT GUIDES TEAM MEMBERS • INTERNAL GUIDE Mr.S.KANNAN, M.E., (Ph.D), ASSOCIATE PROFESSOR, AVC COLLEGE OF ENGG. • EXTERNAL GUIDE Mr.S.DEEPAK,B.Tech, (MAINT/PLANNING-PROJECTS), CPCL PANNANGUDI. M.ANAND (80107144005) P.SENTHILKUMAR (80107144045) S.SUDHARSANAN (80107144048) G.PRABHU (80107144504) FINAL MECHANICAL

3. OBJECTIVE • To study about the Maintenance and Repair of the LPG bullets in Chennai Petroleum Corporation Ltd (CPCL). • To make recommendations for the recurring problem.

4. BULLET • Bullet is a LPG storage unit used in the oil refinery Industries. • It is look like in the shape of diesel or petrol tankers in the lorries.

5. LPG STORAGE BULLET

6. BULLET SPECIFICATIONS • Diameter : 4m • Length : 16m • Wall Thickness : 28 mm to 32 mm • Material : SA 516 Gr70(high quality carbon steel) • Design code : ASME sec 8 div1-1989 • Operating temp : 450c • Hydrostatic pressure : 22.5 Kg/cm2

7. 2D VIEW OF LPG STORAGE BULLET

8. BULLET DIAGRAMS

9. SECTIONAL VIEW OF THE BULLET

10. BULLET MATERIAL MATERIAL SA 516 GR 70 • It is a high quality carbon steel plate for boiler and pressure vessel. • Carbon : 0.27-0.31% • Manganese : 0.79-1.3% • Phosphorous : 0.035%max • Sulphur : 0.035%max • Silicon : 0.13-0.45%

11. Maintenance methodology (Existing) • De commissioning • Erection of scaffolding • Cleaning inside the bullet for NDT tests • Ultrasonic Flaw Detection Testing • Ultrasonic thickness measurement • Hardness testing • Spot Radiography tests • Cleaning outside the bullet for NDT tests • Nozzle replacement • Stress relieving process • Hydro testing of bullets • Box up the nozzles

12. After studying about the existing maintenance methodology the frequently faced problems were found out.

13. PROBLEMS FACED: • It was observed that shell external, shell nozzles, nozzles flanges were found heavily corroded. • Therefore nozzles and nozzle flanges were replaced with approval from Chief controller of Explosives, Nagpur. • Maintenance cost was increased due to replacement of nozzles. • Downtime is also increased.

14. recommendation • Insulation to be provided and aluminium sheet to be covered over the insulation (or) to reduce the external corrosion around the bullet every year it should be painted.

18. Existing maintenance cost For 40 years (the life time of the plant) Total maintenance action – 8 times Total maintenance cost – 2 crores i.e.8times X 25 lakhs = 2 crores.

19. According to our recommendations • Total cost for insulation material with Aluminium cover plate Rs.100000. • Total cost for water sealing compounds with shed arrangement is Rs.20000. (including labour cost)

20. LIFE TIME OF THE BULLET AND SAVING COST NOZZLES. • By providing the insulation with Aluminium cover plate we can increase the life from 5 years to 8 years. • The capacity of the plant is 40 years. • i.e. for 8 times X 5 years = 2 crores. (25 lakhs per time) • for 5 times X 8 years = 1.25 crores. (25 lakhs per time) • So that the maintenance cost is reduced up to 75 lakhs

21. For providing Aluminium plate covering with insulation

22. By providing the water sealing compounds with the shed type arrangement we can increase the life time of the nozzle form 5 to 6 years. • The capacity of the plant is 40 years. • i.e. for 8 times X 5 years = 2 crores. (25 lakhs per time) • for 7 times X 8 years = 1.75 crores. (25 lakhs per time) • So that the maintenance cost is reduced up to 25 lakhs (approximately.)

23. For providing water sealing compound

24. ADVANTAGES • Maintenance cost is reduced. • Life time of the nozzle is increased. • Downtime is also decreased. • It is one of the method to avoid the major LPG tank accident

25. THANK YOU