1. AVC COLLEGE OF ENGINEERING MANNAMPANDAL MAYILADUTHURAI REVIEW 2 3 September 20151

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 September 20152

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. 3 September 20153

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. 3 September 20154

5. LPG STORAGE BULLET 3 September 20155

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: 45 0 c  Hydrostatic pressure: 22.5 Kg/cm 2 3 September 20156

7. 2D VIEW OF LPG STORAGE BULLET 3 September 20157

8. BULLET DIAGRAMS 3 September 20158

9. SECTIONAL VIEW OF THE BULLET 3 September 20159

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% 3 September 201510

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 3 September 201511

12. After studying about the existing maintenance methodology the frequently faced problems were found out. 3 September 201512

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. 3 September 201513

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.  3 September 201514

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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. 3 September 201518

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) 3 September 201519

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 3 September 201520

21. For providing Aluminium plate covering with insulation 3 September 201521

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.) 3 September 201522

23. For providing water sealing compound 3 September 201523

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 3 September 201524

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