SUMMER TRANING REPORT

ON
PUMPS USED IN GAS PROCESSING UNIT (GPU)
AT

GAIL (India) Limited

Petrochemical Complex Pata,
Auraiya(U.P)

SUBMITTED T0: SUBMITTED BY :

MR. P.K JAIN SANDEEP KUMAR MANDAL
(DGM) (Mechanical Engg. 2nd year )
Registration No. :20163018
Duration: 04/06/18 to 04/07/18

MOTILAL NEHRU NAIONAL INSTITUTE OF

TECHNOLOGY ALLAHABAD
 ACKNOWLEDGEMENT
The training opportunity I had with GAIL (India) pata, was a great
chance for learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I am also grateful for having a chance
to meet so many wonderful people and professionals who led me
though this 15 days training period.

Special thanks to Mr.R.K Singh under whose guidance I was able

to learn about the process of Gail Pata plant and giving me specific
knowledge and necessary information for my project report. I would
also like to thank Mr. Pankaj Singh and Gopal lal kumawat for
their unwearyingly efforts and helping me out for the successful
completion of my project and special thanks to other staff members
of MECHANICAL ENGG. for giving information of various
equipment and processes involved.

It was indeed a great experience to have maiden industrial exposure

at GAIL PATA.

SANDEEP KUMAR MANDAL

(B.Tech 2nd year)
 CONTENT

1) Introduction
a) HVJ pipeline on map

2) Overall process discription

a) Gas sweetening unit
b) Gas processing unit
c) Gas cracking unit
d) LLDP/HDPE unit
e) High density polyethylene

3) Pumps
a) Classification of pumps
b) Centrifugal pump
i) Working principle
ii) Construction feature
iii) Cavitation
iv)Seal
v) Bearing
c) Rotary pumps
i) Gear pump
ii) Vane pump
iii) Lobe pump
iv)Screw pump
d) Reciprocating pump
i) Working principle
ii) Advantages
iii) Disadvantages
iv)Major application
e) Comparision of reciprocating and centrifugal pump

4) Conclusion

5) References
 INTRODUCTION
 HVJ PIPELINE AND GAIL PATA PLANT ON MAP

UTTAR PRADESH
HARYANA
DADRI
DELHI BABRALA

SHAHJAHANPUR

RAJASTHAN JAGDISHPUR
AURIYA
KOTA

ANTA
GUJARAT KALOL
KADI VIJAIPUR
KHERA MADHYA
BARODA
JHABUA PRADESH
VAGHODIA

GULF OF HAZIRA
KUTCH
SOUTH BASSEIN MAHARASHTRA

MUMBAI
BOMBAY HIGH URAN
HEERA THAL
The GAIL (India) ltd. Petrochemical unit has been set up at PATA district Auraiya of
Uttar Pradesh to produce polyethylene pellets for plastic processing industries. It is an
integrated grass-root petrochemical unit based on natural gas as feedstock from
GAIL’S HVJ pipeline, which has been set up in accordance with GAIL’s mission to
maximize the value addition from each fraction of natural gas.
The plant consists of four
major units i.e.; gas
processing unit (GPU),
gas cracking unit (GCU),
HDPE and LLDPE unit.
Current capacity of the
cracker plant is 400,000
TPA of ethylene. This acts
as a feedstock for the three
major downstream units
with an annual production
capacity of 2*100,000
TPA HDPE and 2,10,000
TPA of LLDPE/HDPE respectively . Gail’s product range comprises of a wide range of
polyethylene products named as G-LEX and G-LENE (HDPE and LLDPE) comprises
of various grades, which are used by plastic processors to manufacture a large variety
of products for industrial, agricultural and domestic uses.

TECHNOLOGY
The upstream (GPU and GCU)
and downstream (LLDPE and
HDPE) plant of GAIL, Pata are
based on the best technologies
available in the world.
Technology for the gas cracker
unit has been licensed by stone
and Webster, USA.
Technology for the HDPE unit
has been licensed by Mitsui of
Japan and nova chemicals,
Canada for the swing plant of
HDPE and LLDPE unit.
Ethane, a constituent of natural
gas is converted into ethylene
as its main product in the gas cracker unit based upon latest t5echnology from USA,
which is a feedstock for three downstream units namely two HDPE plants and a swing
LLDPE/HDPE plant.

MARKETING
GAIL has appointed adequate number of consignment stockiest for various
consumption centers and has opened offices countrywide to service the requirements of
its consumers. GAIL has set up a real time connectivity through LAN/WAN/V-SATS
for its marketing operations with its consignment stockiest. The entire business process
are connected by ERP (Enterprise Resources Planning) for speedy decision making and
to minimize response times
GAIL India ltd. Pata petrochemical plant enjoys two major advantages. It is the
petrochemical plant in northern India and its feedstock (natural gas) is served from
GAIL’s own HVJ pipeline. Apart from this GAIL is the major supplier of HDPE and
LLDPE with the back up of two separate technologies. Some of the polyethylene market
segments to whom GAIL’s products are used are injection molding, woven sacks, pipe
and fittings, roto molding, HM film, IM crates, luggage, blow molding, HM blow
molding etc.
 OVERALL PROCESS DESCRIPTION

The HDPE plant produces high density polyethylene with grades of density ranging
from 0.950 to 0.968 gm/cm3. The applications of these grades include injection
molding, blow molding, woven sacks, monofilament, pipe and film. The LDDPE plant
produces linear low density polyethylene e with grades of density ranging from 0.919
to 9.960 gm/cm3. The plant can also produce different grades of high density
polyethylene. The applications of the grades produced by LLDPE plant include
injection molding, blow molding, woven sacks, monofilament, pipe, film, roto molding
and conduit. The LLDPE plant includes captive butane-I plant to meet its own process
requirement
The polyethylene pellets are produces from polymer grade ethylene that is produced in
the gas cracker unit (GCU). The cracker produces ethylene by thermal cracking of
ethane propane feedstock, which is recovered from rich natural gas of HVJ pipeline in
gas processing unit (GPU) after removal of carbon dioxide from the natural gas in gas
sweetening unit (GSU). The rich natural gas is received from Dibiyapur compressor
station and lean gas is returned to the same Dibiyapur station on HVJ pipeline system
of GIL.
Beside this, a LPG recovery unit is being installed and successfully started producing
258250 TPA of LPG and 71000 TPA of propane from the same natural gas.
Various utilities like cooling water system , compressed air, nitrogen, demineralized
water, steam , power, fuel and systems like flare stack, caustic plant, waste water
treatment plant and treated effluent water disposal pipeline have been provided to meet
the requirement of the complex. Various off-site facilities including storage system,
unloading/handling/transferring of raw material, intermediate products as well as
finished product are provided to meet the requirement of the complex.

GAS SWEETNING UNIT

The feed gas received from Auraiya compressor station of GAIL’s HVJ pipeline, will
contain 5-6% (V/V) of CO2 .This can interfere with C2-C3 recovery. The removal of
CO2 up to 20 ppm level is achieved in GSU unit.
The sour feed gas enters the bottom of the absorber where it contacts counter currently
with the descending lean DEA solution .The acid gas components in the gas absorbed
by the DEA and the sweet gas evolves from the top of the absorber .The DEA solution
loaded with acid components is drawn from the absorber bottom and flashed into the
flash drum so as to recover dissolved hydrocarbons and use as fuel gas
The flashed co2 rich solution is then fed to the regenerator through ha rich/lean
exchanger. In the regenerator the acid components are stripped off by the re-boiled
vapor generated through the regenerator re boiler and the Solvent is recovered as co2
lean solvent which is recycled to absorber top.
The acid gas stream from the regeneration top is cooled in the regenerator O/H
condenser and sent to the reflux drum to separate the acid gas and condenser water. The
condenser water is recycled back to the regenerator for reflux.
The lean solution from the bottom of the regenerator after heating the incoming rich
solution in the lean/rich exchanger is cooled in the solution acetylene gets converted to
ethylene. Ethylene is further separated in ethylene fractionation and is sent to product
storage.

GAS PROCESSING UNIT

The sweet gas from GSU is fed to a drum for entrapped liquid removal .The gas ids
further taken into moisture separator when condensed water is separated. Gas is then
passed through molecular sieve beds .After drying the feed gas is taken to demethaniser
bottom re-boiler where it further cools down to 5-10 °C. Feed gas further enters into
main chiller 1 . The feed gas is chilled down to -35 to -40 °C. The gas further goes to
column side re-boiler and back to chiller where it goes down to -60 °C. The condensate
is removed in two steps to cool down the gases to -67/68 °C. This gas is now expanded
in expander compressor. This expansion brings down the temp to -98 °C and some
condensation takes place. The vapor/ liquid mixture is fed on the top of demethaniser.
Demethaniser separates out C2/C3 which is taken away by product pumps and is stored
separately. The lean gas is compressed in gas turbine driven compressors and sent back
to the HVJ pipeline system at Dibiyapur compressor station. The exhaust gases of gas
turbine are used to generate very high pressure steam in heat recovery steam generators.

GAS CRACKER UNIT

The ethane/ propane stream obtained from previous section is cracked in this unit to
produce ethylene/ propylene to be used as raw material in the downstream plants.
The ethane/ propane feed is vaporized and mixed with dilution steam. Thus mixture is
heated further in convection section furnaces. This is now cracker under controlled
conditions in cracking coils. The output effluent is cooled in transfer line exchangers.
The cooled gas is further passed through water quench tower where direct contact
cooling takes place. This output is now compressed in a 4 stage CG compressor. The
output of the compressor is chilled in plate fin exchangers. The gases are further
demethanised and fed to deethaniser. Deethaniser separates a C2 stream (overhead) and
C3 stream (bottoms) C2 stream is led to a reactor.

PRODUCTS OF CRACKING :

1. Main products are ethylene, methane, propylene and gasoline

2. Lesser quantities of other HCS ranging from H2 and acetylene to heavy
Aromatic compounds
3. Carbon is deposited inside the radiant coil as coke.

LLDPE/HDPE UNIT (SWING PLANT)

Dupont’ssclairtech solution phase reaction system is used for the polymerization. This
plant is designed to produce both LLDPE and HDPE. The plant consists of the following
section / areas:
 a) Reaction area ;area 100
b) Recycle area; area 200
c) Finishing area; area 300
c) Vaporizers; area 400

Process specifications:

Type of reaction: solution phase reaction

Solvent: cyclohexane
Monomer: ethylene
Co-monomer: butene-I and octane-I
Chain terminator: hydrogen
Basic catalyst: Ziegler – Natta

This process uses Ziegler type catalyst system .The same catalyst system is used for
pricing grades of high density and linear density polyethylene. However the dozing ratio
of the catalysts is required depending on the grades produced.
Ethylene co monomer and hydrogen are used in stirred tank polymerization reactor
.Ethylene from battery limits is absorbed in recycle solvent (cyclohexane). Co-monomer
from battery limits is also fed to recycle solvent. Polymerization in reactor is carried out
in a solution phase at temperature between 105 to 200 °C and at 200 kg/ cm2 pressure.
Reacted products consist of polymer solvent and unconverted monomers .Dissolved
inert gas is flashed vessel.
In order to minimize the volatile organic compound in the polymer melt solution from
the reactor is preheated and flashed in flash vessels. The vapor from the top of the vessel
passes through a separation system for removal of entrained polymer and water. Organic
phase is then sent to monomer, co monomer and solvent recovery system. The liquid
phase from the second flash vessel is fed to the vented extruder. Additives are dosed to
the master batch extruder together wit polyethylene pellets. The master batch is then
added to the polymer in extruder. The polymer pellets from pelletizer are separated from
pelletizing water in screens and dried in pellets drying unit. The pelletizing water
recycled to the pelletizer via water and water cooled by means of a pump. The dry pellets
are transferred to analysis bins by pneumatic transport system.
The product is held in the analysis bins for some period in order to complete the analysis
and to decide whether to send the product to off spec silo or to homogenizing silo.
Homogenizing silos are gravity bending systems in which lots are blended together in
order in order to make bag to bag products uniform. These are then transferred to
product storage silos for bagging and dispatch.
Vapor stream for flash vessels is passed through a battery of columns to separate the
co monomer and solvent before recycling to the process to produce entire range of high
density polyethylene (HDPE).

HIGH DENSITY POLYETHYLENE

This plant is designed to produce entire range of high density polyethylene (HDPE).
The plant consists of the following process sections:
a). Catalyst preparation area
b). Reactor area
c). Separation and drying
d). Pelletizing components
e). Storage and bagging
f). Solvent recovery

Catalyst system consists of two components, which are diluted with solvents (hexane)
and charged to the reactors.
Polymerization is carried out in autoclave type reactors. Ethylene co monomer and
hydrogen are fed to the reactors. Reaction takes place in the slurry state under mild
conditions of about 80 °C temperature and below 8 kg/ cm2 pressure. Small amounts of
dissolved ethylene and co monomer in the reactor are separated in the flash drum.
The slurry discharged formed polymerization section is fed to a centrifuge where
polymer and solvent are separated. The wet is conveyed to a steam tube drier where dry
powder is formed. The dried powder is then sent to the extruder where it is melted due
to the heat produced by friction because of the rotation of the screws.
The melted solution is forced to the die where it comes out in an elongated tube like
forms and then the cutter cuts the tube like form into rounded pellets.

Chemicals used in HDPE Plant

 Raw materials- ethylene as monomer
  Butane and propylene as co-monomer
 Hydrogen as chain terminating agent
 Solvent cyclohexane
 Catalysts- PZ and RZ
 Co- catalyst- TEAL (AT)
 Additives (Stabilizers)
 Antioxidants
 Calcium stearate
 Uv additive
 Optical brightener

PUMPS

Pump is the machine that lifts liquids, moves them from place to place, pressurizes
them for a number of tasks converting mechanical energy from a prime mover such as
impeller, turbine etc.
The reliability & availability & efficiency of the different type of pumps depend a lot
on the behaviour of these machines. Pumps can be classified on the basis of the
application they serve, material from which they are constructed, the liquid they
handle. However, the more basic system of classification is the principle by which the
energy is added to the liquid.
Under this system, the pumps can be classified as:
1. DYNAMIC TYPE
In which the energy is continuously added to increase the fluid passes through
a volute while increases the pressure.
• DISPLACEMENT TYPE
In which the energy is periodically added by application of force to one or more
moveable boundaries of any desired number of enclosed, fluid containing
volumes, resulting into direct increase in pressure up to the valve required
moving the fluid through valves or ports into discharge line.
 CLASSIFICATION OF DYNAMIC PUMPS

PUMP

DYNAMIC DISPLACEMENT

CENTRIFUGAL

AXIAL MIXED FLOW / RADIAL FLOW

SINGLE STAGE MULTI STAGE SINGLE SUCTION DOUBLE SUCTION

CLOSED IMPELLER OPEN IMPELLER OPEN IMPELLER SEMI OPEN IMPELLER CLOSED IMPELLER

CLASSIFICATION OF DISPLACEMANT PUMPS

PUMP

DISPLACEMENT DYNAMIC

RECIPROCATING ROTARY
PISTON / PLUNGER

SINGLE ACTING DOUBLE ACTING SINGLE ROTOR MULTIPLE ROTOR

VANE GEAR
SIMPLEX
PISTON LOBE
DUPLEX
FLEXIBLE MEMBER SCREW
TRIPLEX
SCREW
MULTIPLEX
 DYNAMIC PUMPS

 CENTRIFUGAL PUMPS
 WORKING PRINCIPLE :-

A centrifugal pump works in the principle that when a fluid is made to rotate in a closed
circular path a forced vortex is formed and a low pressure is at the centre of the vortex
due to which more fluid is sucked in from a sump at a lower head.
It is the machine that moves fluid by spinning it with a rotating impeller in a casing that
has a central inlet & a tangential outlet. The path of the fluid is an increasing spiral from
the inlet at the center to the outlet tangent to the annulus. The (pressure) head develops
against the inside wall of the annulus because the curved wall forces the fluid to move
in a circular path, thus converting velocity head to pressure head.

As mentioned above Centrifugal Pumps are classified into three general

categories:

 Radial Flow - A centrifugal pump in which the pressure is developed wholly by

centrifugal force.
 Mixed Flow - A centrifugal pump in which the pressure is developed partly by
centrifugal force and partly by the lift of the vanes of the impeller on the liquid.
 Axial Flow – A centrifugal pump in which the pressure is developed by the
propelling or lifting action of the vanes of the impeller on the liquid.

 CONSTRUCTION FEATURES

Centrifugal pump essentially consists of:

– Impeller
– Shaft with sleeve
– Casing ( Volute / diffuser)
– Support bearings & bearing housings
– Wear rings
– Pump sealing (Gland packing / Mech seal)
 – Coupling
– Prime movers (Electric motor / turbines / engines)
– Suction flange
– Discharge flange

General components of Centrifugal Pump

All the above mentioned components can be classified into two main components:
I. A stationary component comprised of a casing, casing cover, and bearings.

II. A rotating component comprised of an impeller and a shaft.

I.Stationary Component

 Casing

Casings are generally of two types: volute and circular. The impellers are
fitted inside the casings.

a. Volute casings: build a higher head. A volute is a curved funnel increasing

in area to the discharge port. As the area of the cross-section increases, the
volute reduces the speed of the liquid and increases the pressure of the
 liquid. One of the main purposes of a volute casing is to help balance the
hydraulic pressure on the shaft of the pump. However, this occurs best at
the manufacturer's recommended capacity. Running volute-style pumps at
a lower capacity than the manufacturer recommends can put lateral stress
on the shaft of the pump, increasing wear-and-tear on the seals and
bearings, and on the shaft itself. Double-volute casings are used when the
radial thrusts become significant at reduced capacities.
b. Circular casing: have stationary diffusion vanes surrounding the impeller
periphery that convert velocity energy to pressure energy. Conventionally,
the diffusers are applied to multi-stage pumps. Circular casings are used
for low head and high capacity.

The casings can be designed either as solid casings or split casings. Solid casing implies
a design in which the entire casing including the discharge nozzle is all contained in one
casting or fabricated piece. A split casing implies two or more parts are fastened
together. There are two types of split casings-horizontally split & vertically split.
Casing Wear rings act as the seal between the casing and the impeller

 Suction and Discharge Nozzle

The suction and discharge nozzles are part of the casings itself. They commonly have
the following configurations.

a. End suction/Top discharge- The suction nozzle is located at the end of and
concentric to, the shaft while the discharge nozzle is located at the top of the case
perpendicular to the shaft. This pump is always of an overhung type and
typically has lower NPSH (required) because the liquid feeds directly into the
impeller eye.
b. Top suction Top discharge nozzle-The suction and discharge nozzles are located
at the top of the case perpendicular to the shaft. This pump can either be an
overhung type or between-bearing type but is always a radially split case pump.
c. Side suction / Side discharge nozzles - The suction and discharge nozzles are
located at the sides of the case perpendicular to the shaft. This pump can have
either an axially or radially split case type.

 Bearing housing

The bearing housing encloses the bearings mounted on the shaft. The bearings keep the
shaft or rotor in correct alignment with the stationary parts under the action of radial
and transverse loads. The bearing house also includes an oil reservoir for lubrication,
constant level oil, jacket for cooling by circulating cooling water. In large pumps,
lubricating coolant is circulated in the bearing housing by using another pump.
II. Rotating Components-

 Impeller

The impeller is the main rotating part that provides the centrifugal acceleration to the
fluid creating a low pressure at the eye of the impeller. They are classified in many
ways.

~Based on major direction of flow in reference to the axis of rotation

 Radial flow
 Axial flow
 Mixed flow

~Based on suction type

 Single-suction: Liquid inlet on one side.

 Double-suction: Liquid inlet to the impeller symmetrically from both
sides.

~Based on mechanical construction

 Closed: Shrouds or sidewall enclosing the vanes.

 Open: No shrouds or wall to enclose the vanes.
 Semi-open or vortex type.

0
fig.: Impeller types

Closed impellers require wear rings and these wear rings present another maintenance
problem. Open and semi-open impellers are less likely to clog, but need manual
adjustment to the volute or back-plate to get the proper impeller setting and prevent
internal re-circulation. Vortex pump impellers are great for solids and "stringy"
materials but they are up to 50% less efficient than conventional designs. The number
of impellers determines the number of stages of the pump. A single stage pump has one
impeller only and is best for low head service. A two-stage pump has two impellers in
series for medium head service. A multi-stage pump has three or more impellers in
series for high head service.
 Wear rings:
Wear ring provides an easily and economically renewable leakage joint between the
impeller and the casing. If clearance becomes too large, the pump efficiency will be
lowered causing heat and vibration problems.

 Shaft

The basic purpose of a centrifugal pump shaft is to transmit the torques encountered
when starting and during operation while supporting the impeller and other rotating
parts. It must do this job with a deflection less than the minimum clearance between the
rotating and stationary parts.

 Shaft Sleeve:

Pump shafts are usually protected from erosion, corrosion, and wear at the seal
chambers, internal bearings, and in the waterways by renewable sleeves. The shaft
sleeves are less expensive to replace than the expensive shaft. The sleeve shall be
sealed at one end with the help of a keying arrangement.

 Coupling:

Coupling is the joint between the rotating shaft of the generator and the pump. Shaft
couplings can be broadly classified into two groups: rigid and flexible. Rigid
couplings are used in applications where there is absolutely no possibility or room
for any misalignment. Flexible shaft couplings are more prone to selection,
installation and maintenance errors. Flexible shaft couplings can be divided into two
basic groups: elastomeric and non-elastomeric

a. Elastomeric couplings use either rubber or polymer elements to achieve

flexibility. These elements can either be in shear or in compression. Tire
and rubber sleeve designs are elastomers in shear couplings; jaw and pin
and bushing designs are elastomers in compression couplings.
 b. Non-elastomeric couplings use metallic elements to obtain flexibility.
These can be one of two types: lubricated or non-lubricated. Lubricated
designs accommodate misalignment by the sliding action of their
components, hence the need for lubrication. The non-lubricated designs
accommodate misalignment through flexing. Gear, grid and chain
couplings are some examples. Disc and diaphragm couplings are non-
elastomeric and non-lubricated.

Rigid couplings are not always preferred as there a need of allowance in the coupling
due to misalignment.

CAVITATION
Cavitation is defined as the phenomenon of formation of vapour bubbles of a flowing
liquid in a region where the pressure of the liquid falls below its vapour pressure.
Cavitation is usually divided into two classes of behavior: inertial (or transient)
cavitations and non-inertial Cavitations. Inertial capitation is the process where a void
or bubble in a liquid rapidly collapses, producing a shock wave. Such cavitation often
occurs in pumps, propellers, impellers, and in the vascular tissues of plants. Non-inertial
cavitation is the process where a bubble in a fluid is forced to oscillate in size or shape
due to some form of energy input, such as an acoustic field. Such cavitations’ is often
employed in ultrasonic cleaning baths and can also be observed in pumps, propellers
etc.
Cavitations are, in many cases, an undesirable occurrence. In devices such as propellers
and pumps, cavitation causes a great deal of noise, damage to components, vibrations,
and a loss of efficiency.

When the cavitations bubbles collapse, they force liquid energy to very small volumes,
thereby creating spots of high temperature and emitting shock waves, the latter of which
a source of noise.

Photographs taken at Central Workshop

Wear ring Cavitations marks

Volute Casing on the non-suction side of a centrifugal pump (Gland plate)
fig. : Impeller of a centrifugal pump viewed from the discharge side.

Balancing Hole Keying arrangement Wearing ring

The balancing holes are provided to balance the high pressure liquid on the suction side by by-
passing the fluid to the low pressure side.

Vortex Break

The double volute of a centrifugal pump. At the suction end, there is a low pressure due
to which the fluid is sucked in. this process leads to formation of a vortex at the eye of
the suction.
Due to this a vortex breaker is installed that breaks the vortex and prevents a low suction
pressure.
The other very important parts of pumps are the bearings and the seals. In fact most
pump problems occur due to defects in these parts. They are discussed in detail in the
later parts.
Seals:

Seal chambers have the primary function of protecting the pump against leakage at the
point where the shaft passes out through the pump pressure casing. If the pump handles
suction lift and the pressure at the bottom of the seal chamber (the point closest to the
inside of the pump) is below atmospheric, the seal chamber function is to prevent air
leakage into the pump. If this pressure is above atmospheric, the function is to prevent
liquid leakage out of the pump. When sealing is accomplished by means of a mechanical
seal, the seals are installed in a seal chamber .When sealing is
accomplished by means of packing, the seal chamber is commonly referred to as a
stuffing box.

Mechanical Seals:
In simple terms, external seals have two main functions:
-to prevent lubricating oil from leaking out, and ,
-to prevent dust, water, and other contaminants from entering the bearing.
When selecting a seal, the following factors need to be taken into consideration: the type
of lubricant (oil or grease), seal peripheral speed, shaft fitting errors, space limitations,
seal friction and resultant heat increase, and cost.
Seals may be generally sub-divided in to:
a. Dynamic Seals - Seals that are used to seal parts in relative motions.

b. Static Seals - Seals that are used to seal stationary parts.

Dynamic seals can be used with either rotary or reciprocating motions. There are other
types of seals examples of which include labyrinths and bellows. Labyrinths are
commonly used in sealing the bearing housing in the coupling end side.
Apart from Static and dynamic, the Sealing devices for rolling bearings fall into two
main Classifications:
a. Contact Seals.
b. Non-contact Seals.

1. Contacting liquid lubricated seals:

2. • Normally, a single seal arrangement is cooled and lubricated by the liquid being
sealed. This is the most cost-effective seal installation available to the industry.
• Dual seals are arranged to contain a pressurized or non-pressurized barrier or buffer
liquid. Normally, this arrangement will be used on applications where the liquid being
sealed is not a good lubricating fluid for a seal and for emissions containment. These
arrangements require a lubrication system for the circulation of barrier or buffer liquids.

2. Non-contacting gas lubricated seals:

• Dual non-contacting, gas-lubricated seals are pressurized with inert gas such as
nitrogen.
• Dual non-contacting, gas-lubricated seals are used in a tandem arrangement and
pressurized by the process liquid being sealed, which is allowed to flash to a gas at the
seal. A tandem seal arrangement is used on those liquids that represent a danger to the
plant environment. For non-hazardous liquids, a single seal can be used.

Seal Parts

Fig. : Basic Parts of a Mechanical Seal

 Faces

 Springs

 Packing/O-ring

 Gland plate
  Sleeve

Mechanical seal consists of a set of very fine machined/lapped faces (one stationary
the other rotating). A minimum spring load is provided to keep faces in closed
position when pump is not running. The stuffing box pressure is controlled by seal
design. A thin liquid film is maintained between seal faces to provide lubrication and
check leakage.
All the above described components can be categorized into three main
components:
1) The rotating component that moves together with the rotating shaft.
2) The stationary component that is fixed to the pump housing.
3) The spring that presses the rotating component onto the stationary component
axially.

Rotating Component:
This is a ring, usually consisting of 2 types of materials - a soft carbon piece with a
highly polished axial surface, and a rubber material or o-ring that is able to grip the shaft
for sealing against water leak through the shaft surface.

Stationary Component:
The stationary ring is usually made of stainless steel, although there are some made of
ceramic or similar hard materials. The axial surface is also highly polished. At the
circumference of the stationary piece, a rubber o-ring will be installed to seal against
water leak through the pump housing.

Spring:
The spring(s) is installed around the shaft and rotates with the rotating component. The
purpose of the spring is to press the rotating component of the mechanical seal against
the stationary component so that the matching surfaces are in contact with each other
axially to the shaft.

Because the axial rubbing surfaces in contact are very highly polished, there is almost
no leak there. Water does not leak through the pump housing opening because of the o-
ring pressed between the stationary component and the pump housing. Water will also
not leak through the shaft because of the o-ring in the rotating component gripping
against the shaft. It must be noted that seals are used at another location in a pump. Seals
are used to prevent leakages of lubricating oil from the bearing housing.

An actual seal and its parts

BEARINGS:

Bearings are vital engineering devices that are widely used to reduce friction between
stationary and rotating parts in rotationary motion. Bearings reduce friction by
providing smooth metal balls or rollers, and a smooth inner and outer metal surface for
the balls to roll against. It permits a relative motion between the contact surfaces of the
members while carrying load.
The function of bearings in centrifugal pumps is to reduce friction between the rotating
shaft and the fixed housing and also to keep the shaft or rotor in correct alignment with
the stationary parts under the action of radial and transverse loads.

Classification of bearings:

Bearings are classified according to the directional positioning they can offer.Bearings
that give radial positioning to the rotor are known as radial or line bearings, and those
that locate the rotor axially are called thrust bearings. In most applications, the thrust
bearings actually serve both as thrust and radial bearings.
Ball bearings with their high-speed capabilities and low friction make them ideal for
small and medium-size pumps, while roller bearings are more common in larger, slower
speed pumps where a heavy capacity is required.
Ball bearings are further sub-divided into the following basic types. However there are
many modifications done to them leading to many other different types of ball bearings.
 Deep Groove Ball Bearings (contains grooves in both inner and outer rings)
 Angular Contact Ball Bearings (the load is carried over from one ring to the other,
both axial and radial load capacity)
 Self aligning Ball Bearings (can adjust for misalignment between shaft and
housing)

Roller bearings are further sub-divided into the following basic types:
 Cylindrical Roller Bearings(can carry high prevailing radial loads)
 Taper Roller Bearings(can carry both axial and radial loads)
 Needle Roller Bearing(can carry radial loads)
 Spherical Roller Bearings(can carry both radial and axial loads and adjust
misalignment)

Fig. : Types of Bearings

Components of a Bearing:

The basic components of any anti-friction bearings are inner ring, outer ring, rolling
elements, seal, and shield, cage. The inner ring remains fixed to the shaft of the rotor
and rotates with the shaft. As fixing the shaft and inner ring by means of a keying
arrangement will affect the mechanical performance of the bearing, it is close fitted to
the shaft by induction heating the bearing before fitting, which later ensures a tight fit
on the shaft. The outer ring is fixed to the casing and generally remains fixed. It is also
fitted y induction heating as other locking arrangements will affect its performance. It
must also be noted that according to industry specifications, a bearing once removed
from a casing should not be fitted again on the machine. This is because removing the
bearing involves hammering the outer ring of the bearing.
The rolling elements are the most important components of the bearings. These elements
roll between the inner and outer rings. They may be ball types or cylindrical types, or
tapered type or needle type etc depending on the type of load they are required to
carry(as mentioned above).The cage holds the bearing elements in place and prevents
them from coming into contact with each another. If ever they came into contact, the
bearing would fail as two bearings in contact would rotate in opposite direction and
hence at very high speeds, they will simply fail. The cage also allows for some clearance
required for lubrication. There are mainly 3 types of cages: Machined, Pressed and
Plastic type cages. Either shields or seals serve the same purpose of keeping away
foreign matter

Fig. : Bearing Components

Bearing Materials:

Bearing can only be as good as the material from which it is made. Bearing
manufacturing companies has developed steel making techniques that ensure the highest
quality and cleanliness of its steel, for maximum performance in operation. “Clean
steel” means that the presence of inclusions (which can initiate cracking and fatigue
spalls) is at an extremely low level. Standard bearing steels are of the “52100” grade,
generally considered high carbon steel. Compared to stainless steels, which contain 10
to 18 percent of chromium and other elements, bearing steels are susceptible to
corrosion. Stainless steels are available in some types and sizes, but bearing life is
reduced. New developments include ceramics (such as silicon nitride), which are an
option in harsh or extremely demanding environments. Pressed steel and brass cages are
used for small and medium sized bearings. Heat treatment of the bearing
components(especially the rolling elements and the rings) is a preferred method of
toughening and hardening the bearings. The most common through-hardening steel used
for rolling bearings is carbon chromium steel containing approximately one percent
carbon and 1.5 percent chromium. For bearing components with large cross-sections,
steels alloyed with manganese and molybdenum are used for their superior through-
hardening properties. Particular attention is paid to cleanliness. Modern bearing steels
have such small contents of macro and micro slag that it is unlikely that bearings
operating under ideal conditions will fail from fatigue. Hardening incorporates
compressing strength which reduces the tendency for cracks. There are mainly four
types of hardening for bearing steels: Martensite hardening, Bainite Hardening, Case
Hardening and surface Hardening.

Case-hardening is used for large heavily loaded bearings subjected to shock loads.
Chromium-nickel and manganese-chromium alloyed steels; with a carbon content of
approximately 0.15 percent are the case-hardening steels most commonly used for
rolling bearings.

Bearings in pumps:
All types of bearings have been used in centrifugal pumps. In horizontal pumps with
bearings on each end, the bearings are usually designated by their location as inboard,
or drive end, and outboard, or non-drive end. Inboard (drive end) bearings are located
between the casing and the coupling. Pumps with overhung impellers have both
bearings on the same side of the casing so that the bearing nearest the impeller is called
inboard and the one farthest away outboard. In a pump provided with bearings at both
ends, the thrust bearing is usually placed at the outboard end and the line bearing at the
inboard end. The bearings are mounted in a housing that is usually supported by brackets
attached or integral to the pump casing.
The housing also serves the function of containing the lubricant necessary for
proper operation of the bearing. Because of the heat generated by the bearing or the heat
in the liquid being pumped, some means other than radiation to the surrounding air must
occasionally be used to keep the bearing temperature within proper limits. If the
bearings have a force-fed lubrication system, cooling is usually accomplished by
circulating the oil through a separate water-to oil or air-to-oil cooler. Otherwise, a jacket
through which a cooling liquid is circulated is usually incorporated as part of the
housing.

Single row angular contact bearing

Deep groove ball bearing
Double row angular contact bearing
Self aligning spherical bearing

Positive Displacement Pumps

Positive Displacement pumps displace a known quantity of liquid with each revolution
of the pumping elements (i.e., gears, rotors, screws, vanes). Positive Displacement
pumps displace liquid by creating a space between the pumping elements and trapping
liquid in the space. The rotation of the pumping elements then reduces the size of the
space and moves the liquid out of the pump. Positive Displacement pumps can handle
fluids of all viscosities up to 1,320,000 cSt / 6,000,000 SSU, capacities up to 1,150
M3/Hr / 5,000 GPM, and pressures up to 700 BAR / 10,000 PSI.

ROTARY PUMPS
Rotary pumps are self-priming and deliver a constant, smooth flow, regardless of
pressure variations.
Types of rotary pumps—
Gear pumps:

 Internal Gear - Internal gear pumps carry fluid between the gear teeth from the
inlet to outlet ports. The outer gear (rotor) drives the inner or idler gear on a
 stationary pin. The gears create voids as they come out of mesh and liquid flows
into the cavities. As the gears come back into mesh, the volume is reduced and
the liquid is forced out of the discharge port. The crescent prevents liquid from
flowing backwards from the outlet to the inlet port.
 External Gear - External gear pumps also use gears which come in and out of
mesh. As the teeth come out of mesh, liquid flows into the pump and is carried
between the teeth and the casing to the discharge side of the pump. The teeth
come back into mesh and the liquid is forced out the discharge port. External
gear pumps rotate two identical gears against each other. Both gears are on a shaft
with bearings on either side of the gears.

Vane: The vanes - blades, buckets, rollers, or slippers - work with a cam to draw fluid
into and force it out of the pump chamber. The vanes may be in either the rotor or
stator. The vane-in rotor pumps may be made with constant or variable displacement
pumping elements.

Lobe: Fluid is carried between the rotor teeth and the pumping chamber. The rotor
surfaces create continuous sealing. Both gears are driven and are synchronized by
timing gears. Rotors include bi-wing, tri-lobe, and multi-lobe configurations.

Screw: Screw pumps carry fluid in the spaces between the screw threads. The fluid is
displaced axially as the screws mesh. Single screw pumps are commonly called
progressive cavity pumps. They have a rotor with external threads and a stator with
internal threads. The rotor threads are eccentric to the axis of rotation.

Internal gear External gear Vane pump Lobe pump Screw

pump

Screw Pumps:
Screw pumps are a special type of rotary positive displacement pump in which the flow
through the pumping elements is truly axial. The liquid is carried between screw threads
on one or more rotors and is displaced axially as the screws rotate and mesh. In all other
rotary pumps, the liquid is forced to travel circumferentially, thus giving the screw pump
with its unique axial flow pattern and low internal velocities a number of advantages in
many applications where liquid agitation or churning is objectionable. The applications
of screw pumps cover a diversified range of markets including navy, marine, and
utilities fuel oil services; marine cargo; industrial oil burners; lubricating oil services;
chemical processes; petroleum and crude oil industries; power hydraulics for navy and
machine tools; and many others. The screw pump can handle liquids in a range of
viscosities, from molasses to gasoline, as well as synthetic liquids in a pressure range
from 50 to 5000 lb/in2 (3.5 to 350 bar) and flows up to 8000 gal/min (1820 m3/h).
Because of the relatively low inertia of their rotating parts, screw pumps are capable of
operating at higher speeds than other rotary or reciprocating pumps of comparable
displacement. Some turbine-attached lubricating oil pumps operate at 10,000 rpm and
even higher. Screw pumps, like other rotary positive displacement pumps, are self-
priming and have a delivery flow characteristic, which is essentially independent of
pressure, provided there is sufficient viscosity in the liquid being pumped. Screw pumps
are generally classified into single- or multiple-rotor types. The latter is further divided
into timed and untimed categories. The single-screw or progressive cavity pump has a
rotor thread that is eccentric to the axis of rotation and meshes with internal threads of
the stator (rotor housing or body). Alternatively, the stator is made to wobble along the
pump centreline. Multiple-screw pumps are available in a variety of configurations and
designs. All employ one driven rotor in a mesh and one or more sealing rotors. Several
manufacturers have two basic configurations available: single-end and double-end
construction, of which the latter is the better known.

Fig. :Diagram of screw and gear elements , showing(a) axial and (b) circumferential flow

As with every pump type, certain advantages and disadvantages can be found in a
screw pump design. These should be recognized when selecting the best pump for a
particular application.

The advantages of a screw pump design are as follows:

• A wide range of flows and pressures.
• A wide range of liquids and viscosities.
• High speed capability, allowing the freedom of driver selection.
• Low internal velocities.
• Self-priming, with good suction characteristics.
• A high tolerance for entrained air and other gases.
• Low mechanical vibration, pulsation-free flow, and quiet operation.

The disadvantages are as follows:

• A relatively high cost because of close tolerances and running clearances
• Performance characteristics sensitive to viscosity changes.
• High pressure capability requires long pumping elements.

RECIPROCATING PUMPS

Reciprocating pump is a hydraulic machine which converts the mechanical energy

into hydraulic energy. It does this work by sucking liquid into a cylinder containing a
reciprocating piston which exerts a thrust force on the liquid and increases its
hydraulic energy (pressure energy of liquid). It is a type of positive displacement
pump which consists of piston or plunger. Piston is present in a cylinder in which it
does reciprocating motion. It is used at a place where relatively small amount of water
is to be delivered at higher pressure.
The main parts of a reciprocating pump is as follows:
1. A cylinder with piston, piston rod, connecting rod and a crank - Cylinder is used to
suck water and delivers it to the desired location. The piston executes reciprocating
motion (back and forth motion) within the cylinder. Piston is connected to the
crankshaft through connecting rod. An external power source is used to drive the
piston within the cylinder. As the piston moves backward it sucks the liquid in the
cylinder and when it moves forward it delivers the water from the cylinder to the
required location.
2. Suction Pipe - As its name indicates, it is used to suck the water from the water
reservoir to the cylinder. It connects the inlet of the pump with water tank.
3. Delivery Pipe - It is a pipe which is used to deliver the water from the cylinder to
the desired location. It connects the outlet of the pump to the tank where the water is
to be delivered.
4. Suction Valve - It is a valve whIch is present at the suction side of the pump. It
opens during suction of water from the tank to the cylinder and remains closed during
compression of the liquid.
5. Delivery Valve - It is a valve which is present at delivery side and opens during
compression of the liquid and remains closed when the water is sucked from the water
tank.
6. Air Vessels - Air vessels in the reciprocating pump is used to get uniform discharge
rate. It is provided on both suction and delivery side and connected to suction and
delivery pipe.

TYPES OF RECIPROCATING PUMP:

1. Single Acting Reciprocating Pump - In this, only one side of the piston engages to
displace the liquid. Eg : piston syringe.

2. Double Acting Reciprocating Pump - In this, both sides of the piston engages to
displace the fluid. In each stroke of the piston, two process i.e. suction and discharge
carried at the same time. It consists of two inflow and two outflow pipes.

 Simplex, Duplex, triplex, Quintuplex Pumps: Many reciprocating type pumps

are simplex(one), duplex (two) or triplex (three) cylinder. Duplex pumps are
usually used where the two pumps can be used alternatively. Such pumps are
commonly used in oil-line pumping, mine de-watering, and chemical and
petroleum products transfer, but has many more applications. A triplex pump
consists of three plungers, with the aim of reducing the pulsation of a single
reciprocating pump. Quintuplex pumps are designed with a gear case that assists
in a high-pressure task. Common applications of which are in cement slurries,
sand-laden fluids, crude oil, acids, mud and other oil well-servicing fluids. Well
Known manufacturers for these types of pumps are National, Gardner Denver,
FMC, SPM, Oilwell, Kerr, Union, Gaso, Emsco, Aplex, and Wheatley.

WORKING PRINCIPLE:

1) SINGLE ACTING RECIPROCATING PUMP

During suction stroke, the piston moves backward and this opens the suction valve
making the water enter into the cylinder. During suction the delivery valve remains
closed and no water is discharged through it.
After suction stroke, the piston moves forward, delivery valve gets open and
suction valve come into close position. As the piston moves forward it exerts thrust
force on the liquid and it starts escaping out of the cylinder through delivery pipe.
The water from the delivery pipes reaches to its required destination
 2) DOUBLE ACTING RECIPROCAING PUMP

As the piston moves to the right hand side as shown in the fig below. The following
process takes place at left and right side.

At left side: The suction valve opens and delivery valve gets closed. The water from
the water reservoir is sucked into the cylinder.

At right side: The suction valve is gets closed and delivery valve gets open. the water
sucked in the previous stroke is discharges out of the cylinder.

In the same way as the piston moves to left hand side, the discharge of the liquid takes
place at left side and suction takes at the right side. And in each stroke of the piston,
both suction and discharge of liquid takes place at the same time. If suction is taking
place at right side than discharge takes place at left and vice-versa.

ADVANTAGES:

1. High pressure is obtained at the outlet.

2. Priming process is not needed in this pump.
3. It provides high suction lift.
4. It is also used for air.
DISAVANTAGES:

1. It requires high maintenance because of more wear and tear of the parts.
2. Low flow rate i.e. it discharges low amount of water.
3. They are heavy and bulky in size.
4. High initial cost.

MAJOR APPLICATION:

Reciprocating positive displacement pumps are highly effective, where a high degree
of accuracy and reliability under different ranges of conditions that are required.
Reciprocating pumps with very high efficiency are often available in a wide range of
hydraulic, mechanical, and material options. They are widely used across industries
such as chemical, petrochemical, refinery, pharmaceutical, cosmetic and water
treatment. Typically, these types of pumps are used for applications such as Salt Water
Disposal, Well Services, Descaling, Hydraulic Fracturing, and Oil & Gas Pipelines.
All types of reciprocating pumps are easily available in the market to meet the diverse
demands, as per different processes and applications. Piston pumps are widely used in
applications such as Energy Recovery, Steam Recovery and hazardous area pumping
and are available with manufacturers such as Union, Gardner Denver, Worthington,
and Wilson Snyder.

COMPARISION OF REPROCATING PUMP Vs CENTRIFUGAL PUMP

S SPECIFICATION RECIPROCATIG CENTRIFUGAL PUMP

NO. PUMP

1 WEIGHT Greator weight Light weight

2 EFFICIENCY Independent of Q/H ratio Affected by Q/H ratio

3 DISCHARGE Pulsating output upto Speadly no output limit

200m³/hr

4 MAINTENANCE More Less

5 SPEED Low ( reducing gear High ( direct coupling
required) with drive)

6 SLURRY Not recommended OK

SERVICE

7 STARTING High torque required Less torque required

8 HEAD high Low ( higher with multi

stage)
 CONCLUSION

As an undergraduate of the MNNIT ALLAHABAD , I would like to say that this

training is an excellent opportunity for me to get to the ground level and experience
the things that we would have never gained through going straight into a job. I am
grateful to the GAIL PATA for giving me this wonderful opportunity.

The main objective of the industrial training is to provide an opportunity to

undergraduates to identify, observe and practice how engineering is applicable in the
real industry. It is not only to get experience on technical practices but also to observe
management practices and to interact with fellow workers.

It is easy to work with sophisticated machines, but not with people. The only chance
that an undergraduate has to have this experience is the industrial training period. I
feel I got the maximum out of that experience. Also I learnt the way of work in an
organization, the importance of being punctual, the importance of maximum
commitment, and the importance of team spirit.

From what I have undergone, I am hundred percent agree that the industrial training
program have achieve its primary objective. It is the platform to prepare for the
students to face to real working life. As a result of the program, I am more confident
to enter the working world and build my future career.

.
REFERENCES
https://en.wikipedia.org/wiki/Pump
http://www.mechanicalbooster.com/2017/08/reciprocating-pump.html
https://www.powerzone.com/resources/glossary/reciprocating-pump
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