AVC COLLEGE OF ENGINEERING

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AVC COLLEGE OF ENGINEERING

• MANNAMPANDAL
• MAYILADUTHURAI
• REVIEW 2

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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

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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.

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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.

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LPG STORAGE BULLET
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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

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2D VIEW OF LPG STORAGE BULLET
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BULLET DIAGRAMS
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SECTIONAL VIEW OF THE BULLET
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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 0.035max
• Sulphur 0.035max
• Silicon 0.13-0.45

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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

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

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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.

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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.
• 
  

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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.

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• 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)

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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

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For providing Aluminium plate covering with
insulation
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• 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.)

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For providing water sealing compound
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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

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THANK YOU