Maintenance, Reliability and Troubleshooting in Rotating Machinery E-Book
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- Herausgeber: John Wiley & Sons
- Kategorie: Fachliteratur
- Sprache: Englisch
Maintenance, Reliability and Troubleshooting in ROTATING MACHINERY This broad collection of current rotating machinery topics, written by industry experts, is a must-have for rotating equipment engineers, maintenance personnel, students, and anyone else wanting to stay abreast with current rotating machinery concepts and technology. Rotating machinery represents a broad category of equipment, which includes pumps, compressors, fans, gas turbines, electric motors, internal combustion engines, and other equipment, that are critical to the efficient operation of process facilities around the world. These machines must be designed to move gases and liquids safely, reliably, and in an environmentally friendly manner. To fully understand rotating machinery, owners must be familiar with their associated technologies, such as machine design, lubrication, fluid dynamics, thermodynamics, rotordynamics, vibration analysis, condition monitoring, maintenance practices, reliability theory, and other topics. The goal of the "Advances in Rotating Machinery" book series is to provide industry practitioners a time-savings means of learning about the most up-to-date rotating machinery ideas and best practices. This three-book series will cover industry-relevant topics, such as design assessments, modeling, reliability improvements, maintenance methods and best practices, reliability audits, data collection, data analysis, condition monitoring, and more. Volume one began the series by focusing on design and analysis. Volume two continues the series by covering important machinery reliability concepts and offering practical reliability improvement ideas. Best-in-class production facilities require exceptional machinery reliability performance. In this volume, exceptional machinery reliability is defined as the ability of critical rotating machines to consistently perform as designed, without degradation or failure, until their next scheduled overhaul. Readers will find this volume chock-full of practical ideas they can use to improve the reliability and efficiency of their machinery. Maintenance, Reliability and Troubleshooting in Rotating Machinery covers, among many other topics: * General machinery reliablity advice * Understanding failure data * Design audits and improvement ideas * Maintenace best practices * Analyzing failures
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List of Illustrations
Chapter 1
Figure 1.1 Managing the risk associated with a site’s process machinery is a key...
Figure 1.2 Machinery failure modes distributions.
Figure 1.3 Machinery failure modes can be broken down into those that are readil...
Figure 1.4 Centrifugal compressor operating limits. This compressor curve repres...
Figure 1.5 Typical centrifugal compressor surge control system.
Figure 1.6 Here is a typical predicted forced response plot. The upper plot is t...
Figure 1.7 A set of safeguards are designed to prevent major events from occurri...
Figure 1.8 Reciprocating gas compressor cylinders.
Chapter 2
Figure 2.1 Machinery reliability metrics are essential to ensure that a site’s r...
Figure 2.2 Main and spare pump arrangement is used to ensure reliability pumping...
Figure 2.3 The ultimate goal of machinery reliability metrics is to provide reli...
Figure 2.4 Pareto chart of total pump failures over the last 12 months for vario...
Figure 2.5 Reliability growth plot of pump failures in an operating area.
Figure 2.6 A hypothetical trend plot of the plantwide mean time between repairs ...
Figure 2.7 Hypothetical machine history. Green (solid) arrows indicate machine i...
Figure 2.8 A trend of machinery outage cost will tell you the magnitude of the p...
Figure 2.9 A Pareto of production losses across a site. This Pareto indicates th...
Figure 2.10 Pareto of causes of production losses over the last 12 months. This ...
Figure 2.11 Pareto of machinery RCFA findings related to process outages. This c...
Chapter 3
Figure 3.1 (a) Black mark on tank and (b) indication that the hose is rubbing on...
Figure 3.2 Note that the size of the temperature measuring area gets larger as t...
Figure 3.3 Basic centrifugal pump performance curve [2].
Figure 3.4 Typical centrifugal pump head versus flow, power versus flow, and NPS...
Figure 3.5 A portion of the decision tree that operators can use to make better ...
Chapter 4
Figure 4.1 Bearings, seals, impellers are a few examples of rotating machinery s...
Figure 4.2 A small, mag-drive centrifugal pump as shown here may be an example o...
Figure 4.3 Some gas turbine subcomponents in the path of the hot gas, such as in...
Figure 4.4 A complete rotating assembly for a centrifugal compressor, as shown h...
Chapter 5
Figure 5.1 Example of a two out of three (2oo3) centrifugal pump installation in...
Figure 5.2 Voith germany gailroad gearbox.
Figure 5.3 Design to installation to potential failure to failure (D-I-P-F) curv...
Chapter 6
Figure 6.1 Cutaway of an axially split, multistage centrifugal pump. These types...
Figure 6.2 A typical atmospheric distillation column. Notice that the heaviest f...
Figure 6.3 Typical bubble caps used on distillation trays.
Figure 6.4 Hydrocarbon vapors that exit the top of the distillation tower are co...
Figure 6.5 Tower with reboiler and reflux circuits.
Figure 6.6 The red curve is a vapor pressure curve for a hypothetical liquid. To...
Figure 6.7 Typical fractionation train used to produce three liquid common NGL p...
Figure 6.8 Typical pump curve. The BEP flow is 1000 gpm.
Figure 6.9 Cross section of a rerated single-stage centrifugal pump with new cas...
Figure 6.10 Three centrifugal pumps installed in a parallel configuration. Eithe...
Figure 6.11 Two centrifugal pumps in parallel service. Notice that both pumps ar...
Figure 6.12 A constant speed, fixed head pump will generate more differential pr...
Figure 6.13 A comparison of centrifugal pump impellers with different specific s...
Figure 6.14 Typical reflux pump arrangement at the top of a fractionator. Vapors...
Figure 6.15 Vertical turbine centrifugal pump. The distance from the centerline ...
Figure 6.16 NPSHr versus flow for various impeller designs in log-log format. (N...
Figure 6.17 Effect of viscosity on centrifugal pump performance.
Figure 6.18 A hot pump with warm-up piping that allows liquid to bypass the disc...
Chapter 7
Figure 7.1 Mechanical seal reliability performance has a profound effect on the ...
Figure 7.2 A failure growth plot showing a constant failure trend.
Figure 7.3 Multiple failure growth plots.
Figure 7.4 Maximum inspection variations (TIR) allowed in the stuffing box.
Figure 7.5 Guidelines for seal support reservoir systems.
Figure 7.6 Seal cooler guidelines.
Figure 7.7 API seal flush Plan 32.
Figure 7.8 Cross section of a pusher-type mechanical seal.
Figure 7.9 The red curve is a vapor pressure curve for a hypothetical liquid. To...
Figure 7.10 API flush Plan 11.
Figure 7.11 API seal flush Plan 12.
Figure 7.12 Duplex filters can be used for applications with large volumes of so...
Figure 7.13 Piping plan 21.
Figure 7.14 Detail of seal piping plan 23.
Chapter 9
Figure 9.1 Excessive steam leakage was a constant reliability problem. This prom...
Figure 9.2 The outer gland was converted to an integral bushing-lantern ring.
Figure 9.3 General purpose steam turbine.
Figure 9.4 Close-up of steam seal gland.
Figure 9.5 Steam trap configuration required for starting.
Figure 9.6 Split coupling spacer design, installed on 2000 HP, pump-turbine-gear...
Figure 9.7 Field photo of dry flexible metal coupling upgrade with split spacer.
Figure 9.8 Upgraded lube oil system.
Figure 9.9 The original hydraulic-governor & overspeed trip system.
Figure 9.10 Upgraded elliott trip system with pneumatic actuator.
Figure 9.11 Overview of new overspeed protection system.
Figure 9.12 Schematic of new overspeed protection system.
Figure 9.13 New heavy duty outboard bearing housing support flex foot.
Chapter 10
Figure 10.1 Cutting corners during a repair might initially save time and money ...
Figure 10.2 The three most common alignment methods: (a) straight edge method, (...
Figure 10.3 Misalignment shows up as 1x, 2x, and sometimes 3x components in the ...
Figure 10.4 Maximum residual unbalance for industrial rotors (English Units).
Figure 10.5 Maximum residual unbalance for industrial rotors (Metric Units).
Figure 10.6 The classification of different types of fits.
Figure 10.7 Typical spectrum of rotating element looseness.
Chapter 11
Figure 11.1 Example of common mistakes in preventive and corrective work orders.
Figure 11.2 My own research suggests that lack of or ineffective procedures is t...
Chapter 12
Figure 12.1 Every critical component dimension should be measured and double che...
Chapter 13
Figure 13.1 Life cycle inventory analysis (LCIA) flow diagram, per ISO 14040.
Chapter 14
Figure 14.1 Precision maintenance is one of the hallmarks of world-class machine...
Chapter 15
Figure 15.1 Operator inspecting a pump in the field.
Chapter 16
Figure 16.1 Premature machinery failures result in higher maintenance costs and ...
Figure 16.2 Ductile Failure (By Bradley Grillomn at the English Wikipedia, CC BY...
Figure 16.3 Fatigued hold down bolt caused by excessive piping vibration.
Figure 16.4 All the fan drive-shaft failure occurred at a 45-degree angle, which...
Figure 16.5 Close-up view of the fracture surface. The location of the crack ori...
Figure 16.6 Example of shaft fretting.
Figure 16.7 Compressor upset trend plot showing multiple surge events.
Figure 16.8 Causal chain depicting the events leading to a catastrophic bearing ...
Figure 16.9 The 5 why RCFA method requires the investigator to keep asking “why”...
Figure 16.10 Shows a simple cause map explaining the events that led to a hypoth...
Figure 16.11 Journal failure due to wire-wooling.
Figure 16.12 Cause map of catastrophic compressor failure.
Figure 16.13 Breaking the chain of events.
Figure 16.14 Consequence versus failure frequency.
Figure 16.15 Typical risk matrix.
Figure A.1 Think of the sequence of events leadings to a machinery failure as a ...
Figure B.1 Ductile failure (By BradleyGrillo at the English Wikipedia, CC BY-SA ...
Figure B.2 Fatigued hold down bolt caused by excessive piping vibration.
Figure B.3 Impeller erosion.
Figure B.4 Shaft fretting.
Figure B.5 Hot corrosion in GT 1
st
stage nozzle.
Figure B.6 Hot corrosion and blade tip rubbing.
Figure B.7 Damaged jounal bearing.
Figure B.8 Journal bearing damaged by wire-wooling issue.
Figure B.9 Journal bearing, and journal damage caused by wire-wooling issue.
Figure B.10 Cutaway of a rolling element bearing in a housing.
Figure B.11 Mechanical seal components.
Figure C.1 Plugged suction screen on compressor inlet piping.
Figure C.2 Plugged flue nozzles from a gas turbine.
Figure C.3 Impeller worn out due to erosion.
Figure C.4 Expander wheel eroded due to liquids in the inlet gas.
Figure C.5 Pipe clamp bolt fatigued due to high shaking forces.
Figure C.6 Engine connecting rod bolt fatigued due to faulty bolt design.
Figure C.7 Axial compressor blade fatigue due to blade flutter.
Figure C.8 Alternate angle of failed blade.
Figure C.9 A main bearing from reciprocating engine is beginning to fail after t...
Figure C.10 Tapered land thrust bearing beginning to fail due to compressor surg...
Figure C.11 Wire-wooling bearing failure due to high chrome shaft and oil contam...
Figure C.12 Expander wheel on the right shows sign of rubbing due to excessive a...
Figure C.13 Axial air compressor blade fatigues due to tip rubbing.
Chapter 17
Figure 17.1 Fractionator bottom pump.
Figure 17.2 Pump X-section showing rub locations.
Figure 17.3 Frequency analysis of bearing X-Y probes vibration before mechanical...
Figure 17.4 Impeller wear ring clearances larges enough to prevent rubs during s...
Figure 17.5 Casing stationary wear rings can rub on rotating impeller.
Figure 17.6 A laser alignment tool was used to check the driver to driven machin...
Figure 17.7 Warm-up piping modification to top entry line.
Figure 17.8 Frequency analysis: of non-drive bearing using X-Y probes (Nov-14-20...
Chapter 18
Figure 18.1 Water Injection Pump Drive Train: An electric motor (far left) drive...
Figure 18.2 Pump internals.
Figure 18.3 Close-up of pump wear rings.
Figure 18.4 Wear ring geometry with tapered bore.
Guide
Cover
Table of Contents
Title Page
Copyright
Dedication
Preface
Acknowledgements
Begin Reading
About the Editor
About the Contributors
Index
Also of Interest
End User License Agreement
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Scrivener Publishing
100 Cummings Center, Suite 541JBeverly, MA 01915-6106
Publishers at ScrivenerMartin Scrivener ([email protected])Phillip Carmical ([email protected])
Maintenance, Reliability and Troubleshooting in Rotating Machinery
Volume 2
Edited by
Robert X. Perez
This edition first published 2022 by John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA and Scrivener Publishing LLC, 100 Cummings Center, Suite 541J, Beverly, MA 01915, USA
© 2022 Scrivener Publishing LLC
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While the publisher and authors have used their best efforts in preparing this work, they make no representations or warranties with respect to the accuracy or completeness of the contents of this work and specifically disclaim all warranties, including without limitation any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives, written sales materials, or promotional statements for this work. The fact that an organization, website, or product is referred to in this work as a citation and/or potential source of further information does not mean that the publisher and authors endorse the information or services the organization, website, or product may provide or recommendations it may make. This work is sold with the understanding that the publisher is not engaged in rendering professional services. The advice and strategies contained herein may not be suitable for your situation. You should consult with a specialist where appropriate. Neither the publisher nor authors shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages. Further, readers should be aware that websites listed in this work may have changed or disappeared between when this work was written and when it is read.
Library of Congress Cataloging-in-Publication Data
ISBN 9781119631644
Cover image: Pixabay.Com Cover design by Kris Hackerott
Set in size of 11pt and Minion Pro by Manila Typesetting Company, Makati, Philippines
Printed in the USA
10 9 8 7 6 5 4 3 2 1
Dedication
This book series is dedicated to rotating machinery professionals around the globe who have devoted their careers to repairing, evaluating, and optimizing their equipment. It is through their diligence that critical machines are able to operate safely, efficiently, and reliably between scheduled outages.
Preface
Good reliability engineering is not the search for perfection—rather, it is the search for pragmatic solutions to business problems.
H. Paul Barringer, Reliability Consultant
Rotating machinery represents a broad category of equipment, which includes pumps, compressors, fans, gas turbines, electric motors, internal combustion engines, etc., that are critical to the efficient operation of process facilities around the world. These machines must be designed to move gases and liquids safely, reliably, and in an environmentally friendly manner. To fully understand rotating machinery, owners must be familiar with their associated technologies, such as machine design, lubrication, fluid dynamics, thermodynamics, rotordynamics, vibration analysis, condition monitoring, maintenance practices, reliability theory, etc.
The goal of the “Advances in Rotating Machinery Series (3 volumes)” book series is to provide industry practitioners a time-savings means of learning about the most up-to-date rotating machinery ideas and best practices. This three-book series will cover industry-relevant topics, such as design assessments, modeling, reliability improvements, maintenance methods and best practices, reliability audits, data collection, data analysis, condition monitoring, and more.
Volume 1 of the series focused on design and analysis. Volume 2 covers important machinery reliablity concepts and offers practical reliability improvement ideas. Best-in-class production facilities require exceptional machinery reliablity performance. In this volume, exceptional machinery reliability is defined as the ability of critical rotating machines to consistently perform as designed, without degradation or failure, until their next scheduled overhaul.
Specifically, Volume 2 contains the following content adressing machinery reliability:
General Reliablity Advice
Design Audits and Improvement Ideas
Maintenace Best Practices
Analyzing Failures
This volume provides readers with sound advice that can be used to assess and improve the reliablity of a broad range of process machiney, including process pumps and compressors, gas and steam turbines, and mechanical seals and their support systems. I hope readers will find this book to be a useful addition to their technical libraries.
Robert X. Perez, EditorFall 2021
Acknowledgements
I would like to thank all the contributors for their expert advice and their clear and insightful prose. Without them, this book series would not have been possible. I would also like to thank the publisher for believing in me and allowing me to develop this comprehensive book series. Finally, I would like to thank my wife for reviewing my drafts and for her encouragement.
