Process Machinery Handbook E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Wissenschaft und neue Technologien
• Sprache: Englisch

Seitenzahl: 1135

Veröffentlichungsjahr: 2025

Beschreibung

Process Machinery Handbook: For Field Personnel, Decision Makers, and Students equips newcomers and seasoned professionals with essential insights into the diverse world of process machinery, empowering them to understand unique performance characteristics, common failure modes, and effective strategies for enhancing reliability in their operations.

Any professional working at a production site for any length of time knows that process machinery comes in a wide range of designs and sizes, but not all process machines are considered equal. Some machines are more critical to the process than others, some are small, some are very large, some spin fast, and some turn relatively slowly. The great diversity in their construction and application can be daunting to those new to the industry and sometimes even challenge machinery veterans. There are many common concepts that apply to all equipment types, but each equipment category has its own unique application and performance characteristics, including cavitation in liquid handling pumps, surging in centrifugal gas compressors, rotor instability in high-speed centrifugal compressors, and the effect of the compression ratio on a reciprocating compressor’s the discharge temperature. It is also essential for users to understand how and why different types of machinery fail, keeping in mind that the common failure modes differ greatly between rotating machinery types. We know that by addressing the common types of failure modes associated with each machine type, we can achieve significant improvements in their reliability.

The first step in organizing an effective machinery reliability program is committing to performing failure analyses and gathering failure statistics. These activities will help users learn how and why their machines are failing. The next step is to continuously modify machines, processes, and methods to avoid common failures. Process Machinery Handbook: For Field Personnel, Decision Makers, and Students gives students and professionals alike the tools they need to understand the fundamentals of working with rotating machinery.

Leseprobe

Table of Contents

Cover

Table of Contents

Series Page

Title Page

Copyright Page

Dedication Page

Preface

Acknowledgements

1 Overview of Rotating Machinery

Unspared versus Spared Machine Trains

Driven-Process Machines

Critical Machine Components

Bearing Life

Process Machinery

Pumps

Vertical, Multistage Centrifugal Pumps

Positive Displacement (PD) Pumps

Rotary Positive Displacement Pumps

Screw Pumps

Comparison of Centrifugal and PD Pumps

Compressor Types

Multi-Staging

Drivers

Electric Motors

Steam Turbines

Speed Control

Gas Turbines

Natural Gas Engines

Closing

Part I: FLUID MOVERS

2 Positive Displacement Pumps

What is a Positive Displacement Pump [1]?

Rotary Positive Displacement Pumps

Screw Pumps

Rotary Pump Design Limits

Safety Concerns

Reciprocating Positive Displacement Pumps

Classification of Reciprocating Pumps

Calculating the Required by a Reciprocating Pump Horsepower [2]

Some Reciprocating Pumps Advice [3]

Some Words of Caution

Pulsation and Surge Control

Comparison of Centrifugal and PD Pumps

Troubleshooting PD Pumps [3]

References

3 Centrifugal Pumps: Part 1

Head Versus Pressure

Centrifugal Pump Performance

Basic Centrifugal Pump Construction

Types of Centrifugal Pumps

Fixed Speed Versus Variable Speed Operation

Pumping Systems

The Importance of System Head Curve

Summary

Reference

4 Centrifugal Pumps: Part 2

Can I Use a Centrifugal Pump? [1]

Net Positive Suction Head - NPSH

Summary

Reference

5 Sealless Centrifugal Pumps

Magnetic Drive Centrifugal Pumps

Bearings for Magnetic Drive Pumps

Internal Flush Flow

Advantages and Disadvantages of Mag Drive Pumps

Canned Motor Pumps

Comparing Canned Motor Pumps and Mag Drive Pumps

Monitoring Advice for Sealless Pumps [3]

Monitoring Can Motor Pumps

References

6 Compressors

Commonly Used Compressor Flow Terms

Ideal Gas Law

Example of How to Convert from SCFM to ACFM

Visualizing Gas Flow

Compressibility Factor (Z)

Sizing Compressors

Compression Processes

Polytropic Compression

An Overview of Process Compressors

Compression Basics

Defining Gas Flow

Compressor Types

Multi-Staging

Key Reliability Indicators

Centrifugal Compressors

Centrifugal Compressor Piping Arrangements

Start-Up Configuration

Centrifugal Compressor Horsepower

How Process Changes Affect Centrifugal Compressor Performance

Baseball Pitcher Analogy

How Gas Density Affects Horsepower

Theory Versus Practice

How to Read a Centrifugal Compressor Performance Map

The Anatomy of a Compressor Map

Design Conditions

Keeping Your Centrifugal Compressor Out of Harm’s Way

Compressor Operating Limits

Compressor Flow Limits

Critical Speeds

Horsepower Limits

Temperatures

Reciprocating Compressors

Reciprocating Compressor Installations

Screw Compressors

Oil Injected Screw Compressors

Screw Compressor Modulation

Pressure Pulsation Issues

Troubleshooting Screw Compressors

Reference

Part II: DRIVETRAINS, FOUNDATIONS, AND PIPING

7 Introduction to Process Drivers and Drivetrains

Drivers, Speed Modifiers, and Driven Machines

Drivers

Selection Factors

Sizing

Signs of a Driver Problem

Closing Thoughts

References

8 Machinery Foundation and Baseplate Design Recommendations

Foundations

Foundation Rules of Thumb

Grouted Baseplates

Foundation Design Details

Grouting

Epoxy Pre-Filled Base Plates [4]

Understanding the Importance of Machine Bases

Anchor Bolt Spacing

Bolt Preload

Foundation Design and Installation Standards

References

9 Process Piping Design and Installation Best Practices

Thermal Expansion

Effects of Piping Strain

Piping Flexibility

Elbows and Expansion Loops

Expansion Loop and Expansion Joint

Piping Installation Checks [2]

Pump Piping Best Practices

Monitoring Pipe Stress While Bolting Up

Steam Turbine Piping [3]

Dial Indicator Checks

Hot Alignment Checks

Final Advice

References

10 AC Induction Motors

Theory of Operation [1]

Electric Motor Selection [2]

Electric Motor Driver Enclosures

Open Drip Proof (ODP)

Totally Enclosed Fan Cooled (TEFC)

Totally Enclosed Air Over (TEAO)

Totally Enclosed Non-Ventilated (TENV)

Totally Enclosed Force Ventilated (TEFV)/Totally Enclosed Blower Cooled (TEBC)

Weather Protective 1 (WP1)

Weather Protective 2 (WP2)

Totally Enclosed Air to Air Cooled (TEAAC)

Totally Enclosed Water to Air Cooled (TEWAC)

Explosion Proof (XP)

Motor Reliability Concerns [4]

Controls

Instrumentation

Electrical Safety

The Effects of Voltage Unbalance [1]

Insulation Classes & Their Thermal Ratings

Chapter 10, Addendum A: Reasons Why Motors Fail [6]

Chapter 10, Addendum B: Using VFDs to Minimize Centrifugal Pump Power Usage [4]

Flow Control Techniques

Energy Savings by Variable Frequency Drives

When VFDs Don’t Make Sense

VFD Advances

Chapter 10, Addendum C

References

11[1] General Purpose Back Pressure Steam Turbines

Single-Stage Back Pressure Steam Turbine

Steam Flow Path

Mechanical Components in General Purpose Back-Pressure Steam Turbines

Bearing Lubrication

Force Lubrication Systems

Bearing Housing Seals

Lip Seals

Labyrinth Seals

Steam Packing Rings and Seals

Steam Turbine Speed Controls and Safety Systems

Speed Controls

Governor Classes

Overspeed Trip System

Overpressure Protection

Parting Advice

Reference

12 Gas Turbine Drivers [6]

Overview

Theory of Operation [2]

Two Shaft Gas Turbine Design Details

Typical Conditions Inside an Industrial Gas Turbine

Effect of Atmospheric Conditions

Protection

Fuel and Fuel Treatment

Gas Fuels

Degradation and Water Washing

Advanced Materials for Land Based Gas Turbines [4]

Condition Monitoring Approaches

Gas Turbine Maintenance Inspections [5]

Final Words of Advice

References

13 Natural Gas Engine Drivers

Natural Gas Engines [1]

2 Stoke Engines versus 4 Stoke Engines

The 4-Stroke Engine Cycle [3]

The Differences Between 2-Stroke and 4-Stroke Engines

Turbochargers [2]

Emissions Control

Rich versus Lean Burn Engines [1]

Mechanical Condition Monitoring Techniques

Natural Gas Engine Lubrication and Oil Analysis [4]

Engine Manufacturers’ Lubricant Recommendations

Maintenance and Reliability Recommendations

Oil Filtration [6]

Engine Cooling Systems

Ensuring Engine Reliability

References

14 Turboexpanders for Gas Processing

Introduction

Turboexpanders in Gas Processing

The Benefits of a Turboexpander Over a J-T Valve

Preliminary Sizing of a Turboexpander

Basic Design and Special Features

Rotor

Bearings

Seals

Inlet Guide Vanes (IGVs)

Casings

Spare Parts

Potential Operating Issues

Control

Compressor Surge Control

Automatic Thrust Balancing System

Maintenance Requirements

Common Troubleshooting

Industry Specifications

Capacity Rerates

Inlet Guide Vane Open Area

Expander Wheel Outlet Area

Compressor Wheel Inlet Area

Bearings

Frame Size Increase

Repairs

Turboexpander Best Practices [3]

Importance of Logging Field Data

Sample Data Log Sheet

Addition Information

Takeaway

References

Part III: GEARBOXES, COUPLINGS, AND SEALS

15 Gears and Gearboxes

Gears [1]

Industrial Gearing Advice [3]

Ways to Increase the Reliability of a Gearbox [4]

Temperature of the Gear Teeth

Micro-Geometry of the Gear Teeth

Alignment

Surface Finish

Dynamic Loads

Vibration Analysis in Gearboxes [5]

Other Predictive Technologies

Final Words

References

16 Industrial Drive Couplings

Misalignment Concerns

Misalignment Results in Power Losses Across a Coupling

How Vibration Affects Bearing Life [3]

Types of Flexible Couplings [4, 5]

Elastomeric Couplings

Tire Coupling

Gear Couplings

Gear Coupling Periodic Maintenance

Grid Couplings

Grid Couplings Periodic Maintenance

Disc Coupling

Operational Disc Coupling Inspection

Diaphragm Coupling

Couplings Design Considerations

Some Advantages of Diaphragm and Disc Coupling Designs [6]

Advantages and Disadvantages of Gear Couplings

Advice for Users of Medium Horsepower Couplings

References

17 Seals

Mechanical Seal Configurations and Flush Plans [1]

Practical Ways to Improve Mechanical Seal Reliability [2]

Process Compressor Seals [3]

References

Part IV: BEARINGS AND LUBRICATION

18 Rolling Element Bearings

Bearing Element Bearings

Ball Bearings

Gear Drives

Notes

References

19 Hydrodynamic Bearings

API Mechanical Equipment Standards for Refinery Service

Bearings

Hydrodynamic Lubrication

Tower’s Experiments

Reynolds Equation

Journal Bearings

Babbitt

Current and Future Work

References

20 Introduction to Machinery Lubrication

Lubrication Regimes

References

Part V: CONDITION MONITORING

21 Machinery Vibration Monitoring

Vibration Measurements and Monitoring Systems [1]

Velocity Guidelines

When Spectral Content is Known

Monitoring Critical Machinery with Fluid Film Bearings

Runout Concerns

Grounding and Noise

Shaft Orbits [2]

General Machinery Monitoring Recommendations [3]

Should You Use One or Two Probes?

Vibration Guidelines for Displacement Measurements in Fluid Film Bearings [1]

For Other Centrifugal Machines, Such As Motors, Pumps, etc.

Rule of Thumb for Field Evaluations

Alternate Guidelines for Fluid Film Bearings

ISO 7919 Part 3 Shaft Vibration Guidelines

Managing Site Vibration Data

References

22 Centrifugal Pump Monitoring, Troubleshooting, and Diagnosis Using Vibration Technologies

Nomenclature

Introduction

Conclusions

Acknowledgments

References & Bibliography

23 Optimizing Lubrication and Lubricant Analysis

Introduction

Noria Corporation

Bibliography

24 Troubleshooting Temperature Problems

Temperature Assessments

How Do Infrared Thermometers Work?

Compressor Discharge Temperature Assessments [3]

Why Compression Ratio Matters

Summary

References

Part VI: MACHINERY RELIABILITY

25 Machinery Reliability Management in a Nutshell [1]How to Think Like a Machinery Reliability Professional

Criticality

Environmental Consequences

Safety Consequences

Equipment History

Safeguards

Compressor Operating Limits

Critical Speeds

Horsepower Limits

Temperatures

Layers of Machinery Protection

Machinery Reliability Assessment Example

Background

History

Safeguards

Conclusion

Closing Remarks

Reference

26 Useful Analysis Tools for Tracking Machinery Reliability [1]

Commonly Used Metrics for Spared Machinery (Figure 26.3)

Additional Reliability Assessment Tools for Spared Machines

Cumulative Failure Trends

Metrics for Critical Machines

Availability

An Alternative Means of Determining Availability is as Follows

Critical Machine Events

Process Outage Trends

Process Outage Related to Machinery Outages

Planned Maintenance Percentage (PMP)

Reliability Analysis Capabilities of Your CMMS Software

Reference

27 Improving the Effectiveness of Plant Operators

Items that will be covered in this chapter are the following

Look, Listen, and Feel

Applying Look, Listen, and Feel Techniques to Troubleshooting

Why the Operator’s Input is Important to the Troubleshooting Process

Operator Tools

Understanding the Equipment – Pumps, Seals, and Sealing Support Systems

Centrifugal Pump Relationships to Remember

Positive Displacement Pumps Relationships to Remember

Mechanical Seals

Capital Projects

Writing Quality Work Request

Procedures (Procedures and Decision Trees)

Must Give Operators Feedback

Must Be Required to Use Their Training

Discipline

Conclusion

References

28 Improving Machinery Reliability by Using Root Cause Failure Analysis Methods

Introduction

What is a Root Cause Failure Analysis?

Root Cause Failure Analysis Example #1: Ill-Advised Bearing Replacement

Root Cause Failure Analysis Example #2: Reciprocating Compressor Rod Failure [1]

RCFA Steps

Identifying the Physical Root Cause of the Primary Failure

Fatigue Example: Fin-Fan Cooler Shaft Failures

Preserving Machine Data

Five Why RCFA Example

Cause Map Example #2

Cause Mapping Steps

Inhibitors to Effective Problem Solving [3]

When is a Root Cause Failure Analysis Justified?

Closing Thoughts

References

Index

Also of Interest

End User License Agreement

List of Tables

Chapter 1

Table 1.1 Common types of process machinery elements.

Table 1.2 Comparison between rolling element and fluid film bearings.

Table 1.3 Differences between dynamic and positive displacement pumps.

Table 1.4 Compressor coverage table (English Units).

Table 1.5 Compressor coverage table (Metric Units).

Table 1.6 Allowable compression ratio ranges.

Chapter 2

Table 2.1 Rotary pump limits.

Table 2.2 Differences between dynamic and positive displacement pumps.

Table 2.3 Comparison of the various pump types.

Chapter 3

Table 3.1 Typical centrifugal pump performance data.

Table 3.2 Guidelines for stable pump operation.

Chapter 4

Table 4.1 Comparison of various fluid viscosities.

Table 4.2 Comparison of expected centrifugal pump efficiency various viscositi...

Table 4.3 NPSHa example #1.

Table 4.4 NPSHa example #2.

Table 4.5 NPSHa example #3.

Chapter 6

Table 6.1 Gas conditions as gas flow moves from point A to point D.

Table 6.2 Compressibility factors for natural gas.

Table 6.3 Compressor coverage table (English Units).

Table 6.4 Compressor coverage table (Metric Units).

Table 6.5 below contains k values for some common gases.

Table 6.6 Compression ratio ranges.

Table 6.7 The weights and weight ratios (ball weight/foam ball weight) of vari...

Table 6.8 How gas conditions affect centrifugal compressor performance.

Table 6.9 How process conditions affect reciprocating compressor performance. ...

Table 6.10 How process conditions affect screw compressor performance. Note: T...

Chapter 7

Table 7.1 Common types of process machinery elements.

Chapter 8

Table 8.1 Machine base flatness guidelines.

Table 8.2 Recommended anchor bolt lengths.

Table 8.3 Recommended target torque values for low-alloy steel bolting (target...

Chapter 10

Table 10.2 The effect of load on induction motor.

Table 10.3 Voltage unbalance guidelines.

Table 10.4 Recommended thermal ratings for insulation classes*.

Table 10.A.1 Voltage unbalance examples.

Table 10.A.2 Insulation temperature ratings.

Chapter 11

Table 11.1 The table lists governor specifications as percentages of maximum c...

Table 11.2 Trip settings as a percentage of maximum continuous speed.

Chapter 12

Table 12.1 Typical conditions inside a gas turbine (see Figure 12.17).

Table 12.2 Recommended sensor configurations for gas turbines.

Table 12.3 Hypothetical gas turbine inspection and replacement schedule.

Chapter 13

Table 13.1 Oil analysis condemning limit chart for typical natural gas engines...

Chapter 14

Table 14.1 Turboexpander best practices.

Chapter 15

Table 15.1 Gearbox calculation results.

Table 15.2 Comparison of single- and double-helical gears.

Table 15.3 Case-hardened versus through-hardened teeth.

Table 15.4 Example of gear teeth common factors.

Table 15.5 Common failures in gearboxes detectable by vibration analysis.

Chapter 16

Table 16.1 Coupling comparison table.

Chapter 17

Table 17.1.1 Common mechanical seal flush plans.

Table 17.2.1 Centrifugal pump MTBF statistics.

Table 17.2.2 MTBF targets for mechanical seals in refinery services.

Table 17.2.3 Roles and responsibilities matrix for bad actor team.

Chapter 18

Table 18.1 Notes: a) For bearings with a width/section ratio < 1, use the “nar...

Table 18.2 Rolling element bearing temperatures guidelines (in Celsius).

Table 18.3 Rolling element bearing temperatures guidelines (in Fahrenheit).

Chapter 20

Table 20.1 Sample data set example.

Table 20.2 ISO range codes.

Table 20.3 Typical base cleanliness targets for various machine types.

Chapter 21

Table 21.1 Recommendations for frequency spans and applications for various vi...

Table 21.2 Accelerometer mounts and useful frequency limits. (EDI stands for E...

Table 21.3 Recommended minimum analysis frequency span for various machine ele...

Table 21.4 Signal processing windowing options.

Table 21.5 ISO evaluation standard.

Table 21.6 Commercial standards (DLI machinery vibration severity chart) in En...

Table 21.7 Commercial standards (DLI machinery vibration severity chart) in me...

Table 21.8 [4] Where proximity probes and seismic sensors are best used.

Chapter 22

Table 22.1 ISO vibration evaluation zones.

Table 22.2 ISO vibration velocity limits, units of mm/s RMS, for centrifugal p...

Table 22.3 Motion-magnified video characteristics.

Table 22.4 ODS vs. motion-magnified video.

Chapter 23

Table 23.1 The optimum reference state avoids waste and excess.

Table 23.2 Possible sources for common elements.

Table 23.3 Assigning particles ISO codes.

Table 23.4 Example oil analysis report [1].

Table 23.6 Acronym list.

Chapter 24

Table 24.1a Bearing temperature guidelines,

in Celsius.

Table 24.1b Bearing temperatures guidelines,

in Fahrenheit.

Table 24.2 Dropping points for various greases.

Table 24.3 The ratio of specific heats.

Table 24.4 The effect of discharge pressure on the theoretical discharge tempe...

Table 24.5 Discharge valve temperature valves.

Chapter 25

Table 25.1 Economic consequence ratings of process losses related to machinery...

Table 25.2 Summary of potential failure consequences of interest.

Table 25.3 Severity versus frequency of occurence table for process machinery.

Table 25.4 Risk matrix for machinery reliability assessment example.

Chapter 26

Table 26.1 A hypothetical table of pump failures across a processing facility.

Table 26.2 A forced ranking of pump failures in a hypothetical Cat Cracking un...

List of Illustrations

Chapter 1

Figure 1.1 An electric motor coupled directly to a six-throw, reciprocating co...

Figure 1.2 An electric motor coupled to a centrifugal pump.

Figure 1.3 Elastomeric couplings.

Figure 1.4 Disc pack type couplings.

Figure 1.5 A turbo-expander consists of a compressor and expander on the same ...

Figure 1.6 A natural gas fired engine (on the right) drives a reciprocating co...

Figure 1.7 An electric motor driving a forces draft (FD) fan.

Figure 1.8 An electric motor drives a gearbox, which in turn drives an axial c...

Figure 1.9 This is a cross section of a centrifugal gas compressor. Notice tha...

Figure 1.10 Rolling element bearings is a bearing that carries a load by placi...

Figure 1.11 A journal bearing consists of a smooth shaft rotating inside a cyl...

Figure 1.12 Mechanical seals are often used to prevent atmospheric leakage in ...

Figure 1.13 This tandem, dry-gas seal is one example of a containment seal use...

Figure 1.14 Mag-drive centrifugal pump.

Figure 1.15 Types of pumps.

Figure 1.16 Single stage, centrifugal pump.

Figure 1.17 Basic working principle of a volute-type centrifugal pump.

Figure 1.18 Typical centrifugal pump curve. Notice that as the flow increases,...

Figure 1.19 Vertical, multistage centrifugal pumps.

Figure 1.20 Reciprocating PD pump.

Figure 1.21 (a) Gear pump (b) Lobe pump (c) Internal gear pump (d) Vane pump.

Figure 1.22 Screw pump with timing gears.

Figure 1.23 Single screw pump.

Figure 1.24 Types of gas compressors.

Figure 1.25 Cross section of a reciprocating compressor.

Figure 1.26 Rotary screw compressor.

Figure 1.27 Centrifugal process compressor.

Figure 1.27 Multistage centrifugal compressor.

Figure 1.28 Exploded view of an induction motor.

Figure 1.29 Single-stage impulse steam turbine.

Figure 1.30 Mechanical-hydraulic governor used on a general-purpose steam turb...

Figure 1.31 Single shaft gas turbine.

Chapter 2

Figure 2.1 Types of pumps.

Figure 2.2 Types of rotary positive displacement pumps.

Figure 2.3 Screw pump with timing gears.

Figure 2.4 Single screw pump.

Figure 2.5 Electric motor driven triplex reciprocating pump.

Figure 2.6 Reciprocating positive displacement piston pump.

Figure 2.7 Stuffing box and packing are required to prevent atmospheric leakag...

Figure 2.8 Standard non-lubricated stuffing box designs with two different typ...

Figure 2.9 Diaphragm pump: suction and discharge stroke sequences.

Figure 2.10 Flow characteristics of a duplex reciprocating pump.

Figure 2.11 Flow characteristics of a triplex reciprocating pump.

Figure 2.12 Suction and discharge pulsation dampeners (vertical orange cylinde...

Figure 2.13 Three reciprocating pumps in the field, each with their own dedica...

Figure 2.14 Cross sectional view of a gas charged pulsation dampener. (a) P

o

a...

Chapter 3

Figure 3.1 Single stage, overhung, centrifugal pumps, similar to those seen he...

Figure 3.2 A centrifugal pump takes suction from an overhead process vessel an...

Figure 3.3 Centrifugal pump impeller and volute.

Figure 3.4 Pressure gauges at the bottom of three different liquid columns.

Figure 3.5 Typical pump curve.

Figure 3.6 The best efficiency point of a centrifugal pump curve is where the ...

Figure 3.7 Centrifugal pump cross section.

Figure 3.8 Types of impellers: 1. A closed impeller (far left image) is enclos...

Figure 3.9 Close-coupled centrifugal pump: A close coupled centrifugal pump is...

Figure 3.10 Back pull-out, overhung centrifugal pump: This is a back pull-out ...

Figure 3.11 Multistage centrifugal pump: By installing multiple impeller stage...

Figure 3.12 Vertical, multistage centrifugal pump: These pumps are typically u...

Figure 3.13 As a pump speed increases its developed head increases, therefore ...

Figure 3.14 Typical flow control arrangement for a fixed speed pump. Flow is c...

Figure 3.15 Fixed speed flow control: When the discharge control valve stem pa...

Figure 3.16 Typical flow control arrangement for a pump driven by a variable s...

Figure 3.17 The darker gray area in this figure represents the energy savings ...

Figure 3.18 Typical pumping system.

Figure 3.19 System head curve example.

Figure 3.20 Pump discharging into a pressurized system.

Figure 3.21 Types of pumping system curves.

Figure 3.22 Pump and system interaction curve.

Chapter 4

Figure 4.1 Effect of vapor on centrifugal pump performance.

Figure 4.2 Effect of viscosity on performance.

Figure 4.3 Pump with a flooded suction.

Figure 4.4 Pump with a suction lift. Notice that the liquid level is below the...

Figure 4.5 Pump curve with NPSHr curve.

Figure 4.6 NPSHr versus flow for various impeller designs.

Figure 4.7 NPSHr versus flow for various impeller designs in log-log format.

Figure 4.8 How impeller geometry is related to specific speed (N

S

).

Figure 4.9 How efficiency varies with specific speed and flow.

Chapter 5

Figure 5.1 Mag-drive centrifugal pump cutaway.

Figure 5.2 Figure (a) shows the end view of a typical sealless centrifugal pum...

Figure 5.3 This photo shows the main sealless pump, drive components. The oute...

Figure 5.4 Part of the flow exiting the impeller travels between the inside ma...

Figure 5.5 Canned motor centrifugal pump.

Figure 5.6 Cutaway of a canned motor pumps. Arrows show the paths of cooling f...

Chapter 6

Figure 6.1 Centrifugal compressor in a petrochemical facility.

Figure 6.2 Hypothetical compressor piping system.

Figure 6.3 The three main categories of gas compressors: screw, reciprocating,...

Figure 6.4 The ideal gas laws cannot be used to predict compressor performance...

Figure 6.5 Reciprocating compressors thermodynamic performance closely can be ...

Figure 6.6 Pressure versus stroke diagram for a reciprocating compressor.

Figure 6.7 Centrifugal compressors’ performance can be approximated using poly...

Figure 6.8 Basic compressors designs.

Figure 6.9 During the gas compression process, a volume of gas decreases to in...

Figure 6.10 Compressor schematic.

Figure 6.11 Cross section of a reciprocating compressor.

Figure 6.12 Rotary screw compressor.

Figure 6.13 Multistage centrifugal compressor.

Figure 6.14 Centrifugal compressor cutaway.

Figure 6.15 Compressor rotor inside of a split casing. Notice that impeller ex...

Figure 6.16 Labyrinth seals are used to minimize gas leakage between stages.

Figure 6.17 Cross section of centrifugal compressor.

Figure 6.18 Centrifugal compressor performance curve. There is a performance c...

Figure 6.19 Typical single stage compressor piping arrangement.

Figure 6.20 Pitcher throws a baseball towards the batter’s box.

Figure 6.21 Cross section of a centrifugal compressor showing the impeller and...

Figure 6.22 Technically, the creation of gas pressure inside a compressor is b...

Figure 6.23 A cutaway of a centrifugal compressor showing the rotor and diffus...

Figure 6.24 Generalized high-pressure compressor map.

Figure 6.25 Typical high-pressure compressor map.

Figure 6.26 Typical centrifugal compressor surge control system.

Figure 6.27 Multistage centrifugal compressor rotor.

Figure 6.28 Centrifugal compressor operating limits. This compressor curve rep...

Figure 6.29 Typical centrifugal compressor surge control system.

Figure 6.30 Here is a typical predicted forced response plot. The upper plot i...

Figure 6.31 Reciprocating compressor cylinder cross section.

Figure 6.32 A crankshaft is a sub-component of a reciprocating compressor that...

Figure 6.33 The upper plot, comprised of points A, B, C, D, shows how the pres...

Figure 6.34 There are many different types of reciprocating compressor valves....

Figure 6.35 Finger type unloaders hold a valve open to prevent the valve from ...

Figure 6.36 A volume unloader increases the volumetric efficiency of a cylinde...

Figure 6.37 Valve unloaders can be used to partially unload or fully unload a ...

Figure 6.38 Multistage reciprocating compressor piping arrangement.

Figure 6.39 Typical screw compressor rotors.

Figure 6.40 Flow and pressure range comparison of screw, reciprocating, and ce...

Figure 6.41 Screw compressor compression process.

Figure 6.42 Types of screw compressors.

Figure 6.43 Oil-flooded screw compressor.

Figure 6.44 Oil flooded screw compressor package.

Figure 6.45 An internal slide valve is used to modulate screw compressor flow.

Figure 6.46 Combination silencer.

Chapter 7

Figure 7.1 Small process machinery train comprised of an electric motor (left)...

Figure 7.2 Induction motor driving a centrifugal pump.

Figure 7.3 Steam turbine blades.

Figure 7.4 Natural gas reciprocating engine.

Figure 7.5 Gas turbine (left) directly coupled to a centrifugal compressor (ri...

Figure 7.6 Single shaft gas turbine.

Figure 7.7 A schematic of a two-shaft gas turbine (on the left) driving a cent...

Figure 7.8 A reciprocating natural gas engine (at the far left) is driving a c...

Figure 7.9 High quality air filtration system for a gas turbine.

Chapter 8

Figure 8.1 A motor driven, centrifugal pump is shown here atop a foundation an...

Figure 8.2 Three electric motor-centrifugal pump sets supported by baseplates ...

Figure 8.3 General overview of a typical equipment foundation which will suppo...

Figure 8.4 Notice the installation of the anchor bolt, mounting plate, rebar, ...

Figure 8.5 Typical Soleplate. Notice that all the corners have a radius (round...

Figure 8.6 Typical grouting installation of soleplate.

Figure 8.7 Machinist levels should be used to ensure all baseplate pads are le...

Figure 8.8 Machinist levels should be used to check the baseplate level in lon...

Figure 8.9 Cross sectional view of the foundation with a grouted in sole plate...

Figure 8.10 Typical mounting plate arrangement for baseplate mounted equipment...

Figure 8.11 Underside of a base plate after a prime coat has been applied. It ...

Figure 8.12 Flatness and level measurements determine if the now machined pre-...

Figure 8.13 Epoxy pre-filled base plate fully manufactured by a specialty comp...

Chapter 9

Figure 9.1 Multiple complex piping systems in a processing unit. Notice the el...

Figure 9.2 Nozzle load limits are often defined by industry standards and manu...

Figure 9.3 API 618 recommends that piping near reciprocating machinery is desi...

Figure 9.4 A rigid pipe support on top of a concrete pier.

Figure 9.5 Clevis (rigid) pipe hanger and spring hanger are used support hot p...

Figure 9.6 Constant load spring hanger.

Figure 9.7 A combination piping restraint and guide. This type of support prev...

Figure 9.8 Piping alignment guidelines.

Figure 9.9 One method to check for excessive pipe strain on machinery is with ...

Figure 9.10 Centrifugal pump mounted on centerline supports. The other support...

Figure 9.11 Foot mounted pump casing.

Chapter 10

Figure 10.1 AC induction motors driving centrifugal pumps.

Figure 10.2 Induction motor have stationary windings (stator) and rotor with m...

Figure 10.3 Flange mounted electric motor.

Figure 10.4 Totally enclosed fan cooled (TEFC) electric motor.

Figure 10.5 Electric motor with a weather protective enclosure.

Figure 10.6 Explosion proof electric motor.

Figure 10.B.1 A friction only system curve superimposed on a series of centrif...

Figure 10.B.2 Flow control using a control valve.

Figure 10.B.3 Pump and piping systems without throttling and with throttling.

Figure 10.B.4 Variable speed dontrol. Notice the discharge control valve is mi...

Figure 10.B.5 Variable speed operation.

Figure 10.B.6 Basic types of system curves.

Chapter 11

Figure 11.1 General purpose back pressure steam turbine.

Figure 11.2 Inlet screen to steam turbine upstream of the trip valve.

Figure 11.3 View of the trip valve and governor valve.

Figure 11.4 Single-stage steam turbine cross section.

Figure 11.5 View of nozzle ring which is typically bolted to the inside of the...

Figure 11.6 Complete nozzle ring.

Figure 11.7 Comparison of impulse-type and reaction-type steam turbines.

Figure 11.8 The purpose the non-moving blades or fixed blades serve to redirec...

Figure 11.9 Rotating blades attached to a solid disk.

Figure 11.10 Notice the large exhaust flange exit on the lower left portion of...

Figure 11.11 Hand valves allow users to control the amount of steam flow suppl...

Figure 11.12 A hydrodynamic or sleeve bearing works by developing an oil wedge...

Figure 11.13 Typical ball bearing designs.

Figure 11.14 Oil ring lubrication showing rings contacting oil sump. Also noti...

Figure 11.15 Location of lube oil rings on top of bearing; bronze or brass mat...

Figure 11.16 Oil rings used for oil ring lubrication.

Figure 11.17 View of constant level oiler with ball bearings contacting oil in...

Figure 11.18 Basic forced lubrication system. Pump, bearings and oil reservoir...

Figure 11.19 Complex forced lubrication system with pumps, reservoir in blue, ...

Figure 11.20 Side view of lip seal with garter spring.

Figure 11.21 Shaft is rotating and labyrinth teeth are stationary in the beari...

Figure 11.22 Labyrinth teeth mounted on the shaft provide an additional barrie...

Figure 11.23 Bearing isolators provide the most effective oil seals for bearin...

Figure 11.24 Labyrinth seal mounted on the housing sealing on the shaft.

Figure 11.25 Three segmented carbon rings with garter or retainer spring and a...

Figure 11.26 Steam steals or packing. Notice the carbon seals and housing.

Figure 11.27 Carbon packing gland.

Figure 11.28 Overview of the general-purpose steam turbine. Notice the locatio...

Figure 11.29 Basic mechanical governor.

Figure 11.30 Mechanical-Hydraulic governor details.

Figure 11.31 Woodward mechanical-hydraulic governor. One of the most common ty...

Figure 11.32 The overall governor system and its linkage from the mechanical-h...

Figure 11.33 Magnetic speed sensor used in electronic governors. Each pass of ...

Figure 11.34 Double-seated trip valve.

Figure 11.35 Spring-loaded pin or weight. 1. Body, 2. Pin, 3. Spring, 4. Lock ...

Figure 11.36 Typical mechanical-hydraulic governor arrangement. Notice linkage...

Figure 11.37 Steam turbine with a sentinel valve on top of the exhaust casing.

Chapter 12

Figure 12.1 This is a schematic diagram of a two-shaft gas turbine (on the lef...

Figure 12.2 Single shaft gas turbine cross section. Notice that the gas produc...

Figure 12.3 Cross section of a two-shaft gas turbine. Notice that the gas prod...

Figure 12.4 Schematic of a two-shaft gas turbine. HP is the high-pressure expa...

Figure 12.5 Gas turbine view showing the inlet air volute on the left, air com...

Figure 12.6 On the far left is a typical gas turbine configuration. In the mid...

Figure 12.7 Inside the air compressor, air moves through a series of stationar...

Figure 12.8 Close-up of axial compressor blades, which rotate between sets of ...

Figure 12.9 Gas turbine combustor.

Figure 12.10 Gas turbine transition piece.

Figure 12.11 Single-stage gas turbine. Notice the three rows of expansion turb...

Figure 12.12 Gas turbine firing temperature trend.

Figure 12.13 Cross section of the hot section of a gas turbine. Flow arrows (b...

Figure 12.14 Gas producer blades and power turbine blades in a two-shaft gas t...

Figure 12.15 Power turbine wheel.

Figure 12.16 Locations listed in Table 12.1 are defined (with number labels) i...

Figure 12.17 How temperature and pressure change inside a gas turbine. The loc...

Figure 12.18 Gas turbine control variables.

Figure 12.19 High quality air filtration system for a gas turbine.

Figure 12.20 Hot corrosion on first stage power turbine nozzle.

Figure 12.21 Combustion inspections are required to inspect combustion liners ...

Figure 12.22 Some common inspection findings during a major inspection. (a) Ai...

Figure 12.23 Industrial gas turbine in the field.

Chapter 13

Figure 13.1 Typical skid mounted, engine driven, natural gas reciprocating com...

Figure 13.2 Natural gas engine being installed in a gas processing facility.

Figure 13.3 A six-throw gas compressor (right) driven by a natural gas engine ...

Figure 13.4 Two stroke engine cycle.

Figure 13.5 Four stroke compression cycle.

Figure 13.6 Internal combustion engine turbocharger schematic.

Figure 13.7 Emissions of CO, HC, and NO

x

versus lambda (air-to-fuel-ratio).

Figure 13.8 SCR flow diagram for gas engine system.

Chapter 14

Figure 14.1 A mechanic installs the mechanical center section (MCS) of a turbo...

Figure 14.2 Typical natural gas liquefaction process.

Figure 14.3 A disassembled turbo-expander showing the compressor and expander ...

Figure 14.4 Cross section of a turboexpander showing the rotor.

Figure 14.5 Fixed geometry thrust bearing.

Figure 14.6 Rocker back journal bearing.

Figure 14.7 Mechanical center section (MCS), which includes the rotor and bear...

Figure 14.8 Schematic of a typical ATB system on an oil-bearing turboexpander.

Figure 14.9 Expander wheel.

Figure 14.10 Compressor wheel.

Chapter 15

Figure 15.1 A partially disassembled industrial gearbox showing the pinion and...

Figure 15.2 Spur gear.

Figure 15.3 Helical gear.

Figure 15.4 Double-helical gear.

Figure 15.5 Bevel gears.

Figure 15.6 Worm gear.

Figure 15.7 Hypoid gear.

Figure 15.8 Gear arrangement for Example #2.

Figure 15.9 Gear nomenclature (side view).

Figure 15.10 Gear nomenclature (gear close-up).

Figure 15.11 Gear backlash.

Figure 15.12 Industrial gearbox made up of double-helical gears.

Figure 15.13 Gearbox using double-helical gears.

Figure 15.14 Type of gear misalignment.

Figure 15.15 Typical gear tooth contact patterns: (a) aligned and (b) misalign...

Figure 15.16 Backlash and slack in a gear system.

Chapter 16

Figure 16.1 Flexible spacer coupling. The combination of flexible elements and...

Figure 16.2 Close-coupled pump. Notice that there is no flexible coupling betw...

Figure 16.3 A coupling like the spacer coupling shown here can allow the remov...

Figure 16.4 Types of misalignment.

Figure 16.5 Alignment methods. Today, a laser alignment system is considered t...

Figure 16.6 How misalignment shortens the service life of typical bearings. Te...

Figure 16.7 A large disc pack coupling used between an 8000-HP electric motor ...

Figure 16.8 Jaw coupling.

Figure 16.9 Wood’’s style coupling using an elastomeric flex element.

Figure 16.10 Elastomeric flex coupling used on a vertical can pump.

Figure 16.11 Tire style coupling.

Figure 16.12 Gear couplings. They have a high power density, i.e., they can de...

Figure 16.13 Cross section of a gear coupling showing the internal and externa...

Figure 16.14 Grid coupling.

Figure 16.15 Disc coupling.

Figure 16.16 Disc pack coupling (by FlexElement Texas, Inc., Houston, TX). Thi...

Figure 16.17 Diaphragm coupling is shown here with a tapered bore, no keyways....

Figure 16.18 Single diaphragm coupling developed by Bendix in the early 1960s(...

Figure 16.19 Multiple diaphragm coupling (FlexElement Texas, Inc., Houston, TX...

Chapter 17

Figure 17.1.1 Cross section of a single mechanical seal. Notice that this seal...

Figure 17.1.2 The red curve is a vapor pressure curve for a hypothetical liqui...

Figure 17.1.3 Centrifugal pump with double mechanical seals and an external co...

Figure 17.1.4 API flush Plan 11.

Figure 17.1.5 API seal flush Plan 21.

Figure 17.1.6 API seal flush Plan 12.

Figure 17.1.7 API seal flush Plan 32.

Figure 17.1.8 API seal flush Plan 52.

Figure 17.1.9 API seal flush Plan 53A.

Figure 17.1.10 API seal flush Plan 62.

Figure 17.1.11 The reliability performance of a pump’s mechanical seal tends t...

Figure 17.2.1 Mechanical seal reliability performance has a profound effect on...

Figure 17.2.2 A failure growth plot showing a constant failure trend.

Figure 17.2.3 Multiple failure growth plots.

Figure 17.2.4 Maximum inspection variations (TIR) allowed in the stuffing box.

Figure 17.2.5 Guidelines for seal support reservoir systems.

Figure 17.2.6 Seal cooler guidelines.

Figure 17.2.7 API seal flush Plan 32.

Figure 17.2.8 Cross section of a pusher-type mechanical seal.

Figure 17.2.9 API flush Plan 11.

Figure 17.2.10 API seal flush Plan 12.

Figure 17.2.11 Duplex filters can be used for applications with large volumes ...

Figure 17.2.12 Piping Plan 21.

Figure 17.2.13 Detail of seal piping Plan 23.

Figure 17.3.1 Compressor labyrinth seals control gas leakage by providing a to...

Figure 17.3.2 Impeller eye labyrinth seals and shaft labyrinth seals are used ...

Figure 17.3.3 Oil bushing seal.

Figure 17.3.4 To prevent process gas from leaking, the seal oil pressure must ...

Figure 17.3.5 Compressor face seal.

Figure 17.3.6 Dry gas compressor seal.

Figure 17.3.7 Typical reciprocating compressor packing box.

Chapter 18

Figure 18.1 Various rolling element bearings.

Figure 18.2 Rolling element bearings are commonly used to support induction mo...

Figure 18.3 Exploded view of ball bearing.

Figure 18.4 Rolling element bearings come in all shapes and sizes. They can be...

Figure 18.5 Angular contact ball bearing.

Figure 18.6 Rotor free body diagram.

Chapter 19

Figure 19.1 Journal and thrust bearing typical locations

Figure 19.2 Tower’s experimental setup

Figure 19.3 Towers pressure map

Figure 19.4 Projected area.

Figure 19.5 Journal bearing pressure development.

Figure 19.6 Stribeck curve.

Figure 19.7 Two axial groove journal bearing.

Figure 19.8 Two axial groove journal bearings.

Figure 19.9 Multi-lobe bearings(courtesy: Miba Industrial Bearings).

Figure 19.10 Pressure dam journal bearing

Figure 19.11 Pressure dam bearing pressure profiles

Figure 19.12 Pressure dam bearing with relief track pressure profiles

Figure 19.13 Sleeve bearing terminology

Figure 19.14 Journal bearing terminology

Figure 19.15 Preload in an elliptical bore journal bearing.

Figure 19.16 Single-degree-of-freedom system

Figure 19.17 Oil film pressure distribution

Figure 19.18 Examples of tilting pad journal (TPJ) bearings

Figure 19.19 Shaft centerline plots

Figure 19.20 Schematic of tilting pad journal bearing

Figure 19.21 Tilt pad journal bearing nomenclature

Figure 19.22 Preload in a TPJ.

Figure 19.23 Fly cutting a journal pad

Figure 19.24 Line contact pivot.

Figure 19.25 Rocker back journal pads

Figure 19.26 Rocker back journal pad being ground to size

Figure 19.27 Rocker back journal pad

Figure 19.28 Rocker back journal pads installed in an outer shell

Figure 19.29 Rocker back pivot wear.

Figure 19.30 Pad and outer shell wear due to misalignment.

Figure 19.31 Peak oil film pressures.

Figure 19.32 Hertzian contact pivot.

Figure 19.33 Orion pivot.

Figure 19.34 Orion bearing with Orion pivot.

Figure 19.35 Ball-and-socket pivot.

Figure 19.36 Ball and socket TPJ.

Figure 19.37 Waukesha bearings flexure pivot

®

tilt pad journal bearing

Figure 19.38 Elliott “key back” pivot design.

Figure 19.39 Fluid Pivot® JS tilting pad journal bearing

Figure 19.40 Tilt pad journal bearing - flooded lubrication.

Figure 19.41 TPJ with floating end seals

Figure 19.42 Flooded TPJ.

Figure 19.43 With spray nozzles

Figure 19.44 Directed lubricated tilting pad journal bearings

Figure 19.45 TPJ pads with leading edge oil supply pockets.

Figure 19.46 TPJ oil flow

Figure 19.47 Fixed geometry thrust bearing.

Figure 19.48 Fixed geometry thrust bearings of various sizes.

Figure 19.49 Taper land thrust bearing.

Figure 19.50 Tilting pad thrust bearing (TPT).

Figure 19.51 Misaligned thrust plate

Figure 19.52 Self-equalizing TPT.

Figure 19.53 TPT-equalizing action

Figure 19.54 Thrust pad pivots.

Figure 19.55 Directed lube-equalized TPT.

Figure 19.56 Oil churning (drag) losses with a TPT

Figure 19.57 Directed lubrication TPT

Figure 19.58 Directed lube thrust bearings

Figure 19.59 Thrust bearing and large thrust pad

Figure 19.60 Tinned ring ready for babbitting

Figure 19.61 Rough machined babbitted ring being inspected

Figure 19.62 TPJ with polymer-lined pads

Figure 19.63 Assumed linear starvation boundary (Watson-Kassa, 2021).

Chapter 20

Figure 20.1 This illustration shows boundary, mixed-, and full-film lubricatio...

Figure 20.2 The rotation of a journal within a journal bearing creates a wedge...

Figure 20.3 The film thickness developed by elastohydrodynamic lubrication is ...

Figure 20.4 Double-shielded bearing with grease-metering plate facing grease r...

Figure 20.5 Splash lubrication arrangement.

Figures 20.6 a and b Two different constant-level lubricator styles, both are ...

Figure 20.7 Pressure-balanced constant-level lubricator

Figure 20.8 Lip seals (left and top right) tend to wear and have typically onl...

Figure 20.9 Advanced hybrid bearing protector seal.

Figure 20.10 Dual-face magnetic bearing protector seal.

Figure 20.11 Schematic of an oil mist generator.

Figure 20.12 Example of a pure mist application.

Figure 20.13 Axial cutaway of a plain (journal) bearing and shaft. Notice the ...

Figure 20.14 Bearing housing using an oil ring to deliver oil to journal beari...

Figure 20.15 Types of fluid film bearing.

Figure 20.16 Tilting pad bearing.

Figure 20.17 Schematic of a typical compressor lube oil system.

Figure 20.18 Closed-loop lubrication system for a centrifugal compressor in th...

Chapter 21

Figure 21.1 If ignored, machinery vibration can lead to premature failures.

Figure 21.2 Process machines exhibit unique vibration signatures that vary bas...

Figure 21.3 Monitoring system schematic.

Figure 21.4 Complex dynamic waveform decomposed into sine wave components.

Figure 21.5 Trend examples.

Figure 21.6 Misalignment generates 1x, 2x, and 3x vibration components.

Figure 21.7 Technician collecting machine data in the field.

Figure 21.8 Comparison of peak-to-peak, zero-to-peak, average, and rms vibrati...

Figure 21.9 The vibration technician is collecting field vibration data using ...

Figure 21.10 Bearing housing vibration measurement locations.

Figure 21.11 Vibration caused by imbalance, looseness, gear defects, and bad b...

Figure 21.12 A Fourier analysis can break down a complex vibration waveform in...

Figure 21.13 Typical spectrum related to a condition of severe looseness.

Figure 21.14 The barrel-type, centrifugal gas compressor shown here is a typic...

Figure 21.15 A vertical (x) and a horizontal (y) probe, oriented 90 degrees ap...

Figure 21.16 Proximity probe calibration curve. On this plot, we can see that ...

Figure 21.17 A centrifugal barrel compressor like the one shown here is an exa...

Figure 21.18 (a) Allowable shaft vibration in turbomachinery (English units), ...

Figure 21.19 Example of an orbit with a 45-degree offset. The length of the ma...

Figure 21.20 Example of vibration trending upward.

Chapter 22

Figure 22.1 The cyclic nature of vibration, considered as a waveform.Courtesy ...

Figure 22.2 How vibration vs. time can be related to vibration vs. frequency.C...

Figure 22.3 Illustration of the common forms in which vibrational motion is qu...

Figure 22.4 Types and locations of instrumentation in high-value centrifugal p...

Figure 22.5 Typical uniaxial (left) and triaxial (right) accelerometers, appro...

Figure 22.6 Typical eddy current proximity probe construction and implementati...

Figure 22.7 Rolling element bearing defect frequencies.

Figure 22.8 Illustration of the Lomakin effect stiffness KL in an annular seal...

Figure 22.9 Acoustic modes in constant diameter piping. The conventional speed...

Figure 22.10 Common vibration frequencies and their sources.Courtesy Mechanica...

Figure 22.11 Illustration of natural frequency “fn” resonance and effects of d...

Figure 22.12 Impact test exciters and principle: A brief impact force excites ...

Figure 22.13 Using a Campbell diagram to predict resonance problems.Courtesy M...

Figure 22.14 Typical excitation force sources in a centrifugal pump.Courtesy M...

Figure 22.15 Pictorial description of the reason for imbalance and the 1x RPM ...

Figure 22.16 Imbalance example of orbit and FFT.Courtesy Mechanical Solutions,...

Figure 22.17 Illustration of angular and offset misalignment.Courtesy Mechanic...

Figure 22.18 Misalignment example of shaft orbit and FFT spectrum.Courtesy Mec...

Figure 22.19 Vane pass vibration.Courtesy Mechanical Solutions, Inc.

Figure 22.20 Effect on vibration on Off-BEP operation.Courtesy Mechanical Solu...

Figure 22.21 Subsynchronous vibration.Courtesy Mechanical Solutions, Inc.

Figure 22.22 Example of field data (waterfall plot) from the inboard proximity...

Figure 22.23 Fluid whirl/whip example: Data from a multistage turbomachine.Cou...

Figure 22.24a A negative pressure amplitude clipped off below vapour pressure ...

Figure 22.24b Acceleration amplitude versus time, for a large axial flow water...

Figure 22.25 Typical torsional critical speeds and typical worst-case per-unit...

Figure 22.26 Vertical pump line shaft rotor behavior example.Courtesy Mechanic...

Figure 22.27 Example of how vibration of equipment depends upon the interplay ...

Figure 22.28 Example of force vs. displacement phase angle.Courtesy Mechanical...

Figure 22.29 Bode and Nyquist plots.Courtesy Mechanical Solutions, Inc.

Figure 22.30 Example of data acquisition locations for an ODS test on a vertic...

Chapter 23

Figure 23.1 Ascend

™

Chart. Note: The 40 factors in this chart will be e...

Figure 23.2 Example of optimum reference state on two identical centrifugal pu...

Figure 23.3 40 Ascend™ factors.

Figure 23.4 Three levels of Ascend™.

Figure 23.5 Circles represent asperity contact during sliding conditions.

Figure 23.6 Sliding and frictional heat

.

Figure 23.7 Holistic approach steps.

Figure 23.8 Machine criticality factor (MCF) (relates to the consequences of m...

Figure 23.9 Sample locations for splash/bath lubricated machines.

Figure 23.10 Graphs in an oil analysis reort can help illustrate notable trend...

Figure 23.11 Moisture trend approaching a level limit.

Figure 23.12 The world’s population growth.

Figure 23.13 Condition monitoring and the time domains of machine failure.

Figure 23.14 Failure detectability technique and inspection periodicity influe...

Figure 23.15 Zone inspections for early problem detection.

Figure 23.16 Modern bottom sediment and water (BS&W) bowl sight glass.

Chapter 24

Figure 24.1 Infrared temperature gun.

Figure 24.2 Typical temperature trend. Notice the temperature of “Bearing C” j...

Figure 24.3 Tilting pad bearing.

Figure 24.4 Recommended location for temperature sensors in a tilting pad thru...

Figure 24.5 The air fin cooler, which is located on the far right of the skid,...

Figure 24.6 Schematic of a two-stage reciprocating compressor with an intercoo...

Figure 24.7 Reciprocating compressor’s performance can be approximated using t...

Figure 24.8 Pressure versus stroke diagram for a reciprocating compressor.

Figure 24.9 Centrifugal compressor’s performance can be approximated using the...

Figure 24.10 Reciprocating compressor.

Figure 24.11 How the discharge pressure affects the compressor’s discharge tem...

Figure 24.12 Typical reciprocating compressor temperature measurement. Note: M...

Figure 24.13 Hypothetical compressor valve temperatures.

Chapter 25

Figure 25.1 Managing the risk associated with a site’s process machinery is a ...

Figure 25.2 Machinery failure modes distributions.

Figure 25.3 Machinery failure modes can be broken down into those that are rea...

Figure 25.4 Centrifugal compressor operating limits. This compressor curve rep...

Figure 25.5 Typical centrifugal compressor surge control system.

Figure 25.6 Here is a typical predicted forced response plot. The upper plot i...

Figure 25.7 A set of safeguards is designed to prevent major events from occur...

Figure 25.8 Reciprocating gas compressor cylinders.

Chapter 26

Figure 26.1 Machinery reliability metrics are essential to ensure a site’s rel...

Figure 26.2 Main and spare pump arrangement is used to ensure reliable pumping...

Figure 26.3 The ultimate goal of machinery reliability metrics is to provide r...

Figure 26.4 Pareto chart of total pump failures over the last 12 months for va...

Figure 26.5 Reliability growth plot of pump failures in an operating area.

Figure 26.6 A hypothetical trend plot of the plantwide mean time between repai...

Figure 26.7 Hypothetical machine history. Green (solid) arrows indicate that t...

Figure 26.8 A trend of machinery outage cost will tell you the magnitude of th...

Figure 26.9 A Pareto of production losses across a site. This Pareto indicates...

Figure 26.10 Pareto of causes of production losses over the last 12 months. Th...

Figure 26.11 Pareto of machinery RCFA findings related to process outages. Thi...

Chapter 27

Figure 27.1a Black mark on tank.

Figure 27.1b Indication that the hose is rubbing on the tank.

Figure 27.2 Note that the size of the temperature measuring area gets larger a...

Figure 27.3 Basic centrifugal pump performance curve.

Figure 27.4 Typical centrifugal pump head versus flow, power versus flow, and ...

Figure 27.5 Here is a portion of the decision tree that operators can use to m...

Chapter 28

Figure 28.1 Premature machinery failures result in higher maintenance costs an...

Figure 28.2 Ductile failure (by Bradley Grillomn at the English Wikipedia, CC ...

Figure 28.3 Fatigued hold-down bolt caused by excessive piping vibration.

Figure 28.4 All the fan drive-shaft failures occurred at a 45-degree angle, wh...

Figure 28.5 Close-up view of the fracture surface. The location of the crack o...

Figure 28.6 Example of Shaft fretting.

Figure 28.7 Compressor upset trend plot showing multiple surge events.

Figure 28.8 Causal chain depicting the events leading to a catastrophic bearin...

Figure 28.9 The 5-Why RCFA method requires the investigator to keep asking “wh...

Figure 28.10 A simple cause map explaining the events that led to a hypothetic...

Figure 28.11 Journal failure due to wire-wooling.

Figure 28.12 Cause map of catastrophic compressor failure.

Figure 28.13 Breaking the chain of events.

Figure 28.14 Consequence versus failure frequency.

Figure 28.15 Typical risk matrix.

Guide

Cover Page

Table of Contents

Series Page

Title Page

Copyright Page

Dedication Page

Preface

Acknowledgements

Begin Reading

Index

Also of Interest

Wiley End User License Agreement

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Scrivener Publishing100 Cummings Center, Suite 541JBeverly, MA 01915-6106

Publishers at ScrivenerMartin Scrivener ([email protected])Phillip Carmical ([email protected])

Process Machinery Handbook

For Field Personnel, Decision Makers, and Students

Edited by

Robert X. Perez

This edition first published 2025 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© 2025 Scrivener Publishing LLCFor more information about Scrivener publications please visit www.scrivenerpublishing.com.