Practical Machinery Management 3E pdf

I HlHU tUI I IU m Pral II I VOLUME 1 I I I ffl I- Practical Machinery Management for Process Plants VOLUME d THIRD EDITION Improving Machinery Practical Machinery Management for Process Plants: Volume 1: Improving Machinery Reliability, 3rd edition Volume 2: Machinery Failure Analysis and Troubleshooting, 3rd edition Volume 3: Machinery Component Maintenance and Repair, 2nd edition Volume 4: Major Process Equipment Maintenance and Repair, 2nd edition Other Machinery Engineering Texts from the Same Author: Introduction to Machinery Reliability Assessment, 2nd edition Reciprocating Compressors: Operation and Maintenance I Practical Machinery Management for Process Plants I Improving Machinery Reliability Heinz P. Bloch Gulf Professional Publishing is an imprint of Elsevier Science Copyright 0 1982, 1988, 1998 by Elsevier Science (USA). All rights reserved. Originally published by Gulf Publishing Company, Houston, TX. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any fonn or by any means, electronic, mechanical, photocopying, recorchng, or otherwise, without the prior written permission of the publisher. Permissions may be sought directly from Elsevier’s Science & Technology Rights Department in Oxford, UK: phone: (+44) 1865 843830, fax: (+44) 1865 853333, e-mail: pennissions@elsevier.co.uk. You may also complete your request on-line via the Elsevier Science hoinepage (http://mw.elsevier.com), by selecting ‘Customer Support’ and then This book is printed on acid-free paper. ~ ‘Obtaining Permissions’. Library of Congress Cataloging-in-Publication Data Bloch, Heinz P., 1933- Improving machinery reliability / Heinz P. Bloch. - 3‘d ed. Includes bibliographical references and index. p. cm. -(Practical machinery management for process plants; v. 1) ISBN 0-88415-661-3 (alk. paper) 1. Machinery-Reliability. I. Title. II. Series: Bloch, He& P., 1933- Practical machinery management for process plants. 31d ed. ; v. 1. TJ153.B58 1998 621.8’1-dc21 98-26184 CP The publisher offers special discounts on bulk orders of this book. For information, please contact: Manager of Special Sales Elsevier Science 200 Wheeler Road Burlington, MA 01803 Tel: 781-313-4700 Fax: 781-313-4802 For information on all Gulf publications available, contact our World Wide Web homepage at http://www.bh.com/gulf 10 9 8 7 6 5 4 3 2 Printed in the United States of America. Contents Preface x Introduction xx 1 Requirements Specification 1 Industry Standards Available for Major Machinery in Process Plants, 1; How to Deal with the Typical API Data Sheet, 2; Narrative Specifications Lead to Better Machinery, 15; Considering Uprateability and Low Failure Risk, 21; Auxiliary Systems for Turbomachinery: The Systematic Approach, 24; Dealing with Deviations from the Specification, 34; Specifying Machinery Documentation Requirements, 37; Conclusion, 5 1 2 Vendor Selection and Bid Conditioning 53 Selecting Major Machinery Vendors, 53; Applying and Reviewing Machinery Reliability Improvements Derived from Modern Electronics, 54; Selecting a Pump Vendor, 64; Bid Tabulation and Bid Conditioning: An Overview, 76; Reference, 8 1 Audits Versus Reviews, 82; Where to Concentrate Audit and Review Efforts, 82; Rotordynamic Design Audits, 83; Auditing and Reviewing Centrifugal Compressors, 125; Auditing and Reviewing Steam Turbines, 135; Evaluating Major Reciprocating Compressors, 139; Reliability Review for Centrifugal Pumps, 146; Significant Differences in Bearings and Bearing Housings, 156; Marginal Lubrication: A Factor in Pump Failures, 160; Applying Roller Bearings in Centrifugal Pumps, 168; How Much Oil Is Enough?, 171; Bearing Selection Can Make a Difference, 172; Air Cooling Provisions for Bearing Housing-How Good? 173; Stuffing Box Cooling Is Not Usually Effective, 174; Pumps for Handling Entrained Gases, 176; Selection Criteria for Zero Emission Pumps, 178; Design Appraisals for Special-Purpose Gearing, 18 1; Evaluating Cooling Tower Fans and Their Drive Systems, 200; Reliability Reviews in Uprate Situations, 203; Reliable Shaft-Hub Connections for Turbomachinery Couplings, 213; How to Keep Track of Reliability Review Tasks, 224; Machinery Reliability Audits for Existing Plants, 224; References, 238 3 Machinery Reliability Audits and Reviews 82 V 4 Maintenance and Benchmarking Reliability . . . . . . . . 242 Maintenance Measurement, 242; Organize to Manage Reliability, 249; Maintenance Cost vs. Replacement Asset Value: Another Maintenance Spending Benchmark, 257 5 Life Cycle Cost Studies . . . . . . . . . . . . . , . . . . . . . . . . .259 Simplified Life Cycle Cost Estimating, 259; Life Cycle Cost Assessment: The Rigorous Method, 272; Summary, 3 10; References, 3 10 6 Extending Motor Life in the Process Plant Environment . , . . . . . . . . . . . . . . . , . . . . . . . . . . ,313 Squirrel-cage Motors Are Most Prevalent, 3 14; Motor Insulation Systems, 3 14; Insulation Classification, 3 15; Ambient Plus, 3 15; A Bank of Motor Life, 3 17; Running Cooler-A Relative Term, 3 18; Thermal Cushion, 3 19; Enclosures, 3 19; Standard, but Different, 3 19; Learning from Failures, 320; More about Thermal Loading, 320; Economics of Oversizing, 321; Keep Bearings in Mind, 323; Motor Mounting Basics, 325; Motor System Tuneup, 326; Pumping and Piping, 326; Power Points, 326; Over-Current Insurance, 327; Motor Life Insurance Terms, 328; Notes, 328 7 Equipment Reliability Improvement through Reduced Pipestress . . . . . . . , . . . , . . . . . , m . . . . . ,329 Allowable Load, 33 1 ; Excessive Flexibility, 333; Theoretical Restraints, 334; Expansion Joints, 335; Other Practical Considerations, 337; References, 338 8 Startup Responsibilities . . . . . m . . . . . . . . . . . . . . . . .339 Summary of Startup Preparations for Process Plant Machinery, 339; Machinery Startup Review Tasks, 342; Machinery Startup Reporting Structure, 344; Documentation for Effective Tracking of Progress, 348; Vendor Assistance and Outside Facilities, 359; Consultants and Contract Assistance. 359 9 Spare Parts and Their Effect on Service Factors . . . . 361 Spare Parts Philosophies, 361; Spare Parts Storage and Retrieval, 361 ; Spare Parts Documentation, 363 10 Maintenance for Continued Reliability . . . . . , . . . . . . . 365 Modern Maintenance Approaches and when to Apply Them, 365; Maintenance Management Options, 374; Detailed Task Descriptions vi Improve Maintenance Effectiveness, 380; Machinery Turnaround Planning, 394; Turnaround Scope Development through Reliability, Availability, and Maintainability Analysis, 401 ; Effective Maintenance: Preventive or Predictive?, 41 6; Preventive Versus Predictive Maintenance for Typical Centrifugal Pumps, 421; How to Be a Better Maintenance Engineer, 429; The Role of the Maintenance Engineer in the Knowledge Age, 43 I; References, 432 11 Maintenance Cost Reduction .434 Eliminating Cooling Water from General-Purpose Pumps and Drivers, 434; Economics of Dry-Sump Oil-Mist Lubrication for Anti-friction Bearings, 440; Gear Couplings Versus Non-lubricated Couplings, 45 1 ; Elastomeric Couplings, 457; Quantifying the Reliability Impact of Laser Alignment Techniques, 461 ; Quantifying Impact, 470; Why and How to Monitor Centrifugal Pump Condition, 477; References, 483 12 Lubrication and Reliability .485 Methods and Criteria for Lube-Oil Purification, 485; Cost Justification and Latest Technology for the On-Stream Purification of Turbomachinery Lube Oil, 49 1 ; Synthetic Lubricants and Reliability Improvement, 503; Vibration Performance Improved with Synthetics, 5 15; Automatic Grease Lubrication as a Reliability Improvement Strategy, 517; References, 525 13 Providing Safety and Reliability through Modern Sealing Technology ,527 API Standard 682,528; Low-Emission Single Seal Design, 531; Dual Seal Arrangements, 543; Compact Gas Seal Technology for Pumps, 550; The Reliability Impact of Special Seals for Non-Pump Applications, 558; Specialty Seals for Non-Pump Applications, 565; Dry Gas Compressor Seals, 58 1; Warding off Equipment Reliability Setbacks: A Postscript, 593; References, 598 AppendixA 600 Useful and Interesting Statistics AppendixH .609 Common Sense Reliability Models Index 668 vii [...]... debated at the highest levels of management, business forecasts are studied, and thousands of questions are asked and answered before the machinery engineer is given his first opportunity to prepare an inquiry document for major machinery or detailed purchase specification packages for all the machinery in a process plant To the superficial observer, the job of specifying machinery would seem rather routine... the only way to achieve maximum performance at an affordable cost Asset management and maintenance are not well served by going through the same process There is movement toward open systems in the maintenance and asset management areas The activity accomplishing this valuable objective is called MIMOSA, the Machinery Information Management Open Systems Alliance.'o I I In summary, gaining maximum value... the very top of an enterprise And this likely requires education Education for plant management, senior corporate, and financial management is necessary to illuminate the potential and benefits to be derived from optimized maintenance Education should focus on ways to build the compelling vision of how equipment-asset management can and must contribute to twenty-first century success Profit-centered... Standards Available for Major Machinery in Process Plants Table 1- 1 represents a listing of presently available API (American Petroleum Institute) standards These specifications were developed by panels of user engineers to define petrochemical process plant machinery in a professional fashion Wherever possible, API standards should become the focal point document in machinery specifications for process... Schenk-Trebel, a world-class manufacturer of balancing machinery, major machinery- repair and manufacturing facilities are pursuing selfsufficiency by acquiring at-speed balancing facilities For example, Hickham Industries, Inc., LaPorte/Houston, Texas, began operating an “at-speed” facility in August 1996 Figure 1-4 illustrates the facility’s huge size Turbomachinery rotors are installed and removed by an... spare parts and personnel requirements are constructed from this information e Benchmark measures such as mean-time-between-repair (MTBR) and availability are valuable management information Information required for executive and financial management includes cost-perunit output, return on assets, life cycle costs, and operating profitability These, and other measures, are needed to measure effectiveness,... vital management reports automatically is a crucial requirement of an information system An expert should examine crucial information prior to transmittal and have the opportunity to add interpretation and editorial comments However, the expert should not have to perform manual data gathering The days when time was available to compile information from multiple sources and correlate it manually for management. .. those of others whose personal and/or company names are mentioned in footnotes and captions are gratefully acknowledged Heinz P Bloch, I? E ix Introduction The View of an Advocate for Change* Machinery reliability management in the process industries can be divided into three phases: equipment selection and pre-erection reliability assurance, preparation for effective startup, and post-startup reliability... well-planned machinery reliability enhancement, maintenance optimization, and life-cycle cost justification Within this process, maintenance must be directed toward eliminating problems and safely reducing the need for maintenance Perceptions must change Improving equipment reliability at the very inception of a project, demanding quality during installation, and focusing on lifetime equipment management. .. Maintenance Tasks,” Proceedings; Vibration Institute 19th Anniial Meeting, June 1995, 69-75 5 John Hawkins, “Consolidating Asset Management, ” Minutes o Sixth f MIMOSA Meeting, available on the Internet at: http://www.hsb.com/ pcmlmimosd mimosa.htm1 6 John S Mitchell, “Maintenance and Machinery Information-The Future,” Sound & Vibration, February 1996 7 John S Mitchell, “Condition Monitoring-A Vision for the . I ffl I- Practical Machinery Management for Process Plants VOLUME d THIRD EDITION Improving Machinery Practical Machinery Management for. Compressors: Operation and Maintenance I Practical Machinery Management for Process Plants I Improving Machinery Reliability Heinz P. Bloch Gulf