Improving Machinery Reliability docx

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 [...]... 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 assurance and maintenance cost reduction All of these phases are important; they are intertwined... employed to gain these results are no longer necessary For the past several years, reliability has been the primary focus of maintenance professionals However, as most are aware, reducing load and the rate of production increases reliability But is reduced production an option? If not, perhaps reliability is not the final objective Reliability xiii is a maintenance-oriented objective and the means to an end-but... 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 But an experienced engineer knows that this is... critically examined and have led to substantially improved reliability and maintenance efficiencies Adoption of applicable techniques and procedures at your plant is certain to result in similar benefits In the quest for increased reliability, multiple dimensions must be considered The first is whether maximum profitability for a given enterprise and maximum reliability are one and the same Recent interviews... Investment to optimize reliability and reduce the need for maintenance is imperative From a strategic perspective, maintenance cost reduction is a result-not an action Optimized practices such as pre-procurement equipment reliability audits, installation reviews, and condition-directed or predictive maintenance have been in use since the 1960s All have proven highly effective toward improving availability... Barringer, whose work on life cycle costing and reliability assessment is truly unique; Lou Bewig for some excellent work on benchmarking; Gary Bostick (Woodward Governor) for a concise writeup on modern turbomachinery controls; R Ellis and M Galley (Dow) for documenting task descriptions used in best-of-class maintenance; Galen Evans (Ludeca) for quantifying the reliability impact of laseroptic alignment... this valuable objective is called MIMOSA, the Machinery Information Management Open Systems Alliance.'o I I In summary, gaining maximum value from process, production, and manufacturing equipment requires a comprehensive, value-oriented process that begins at design and extends through operation Vital ingredients include continuing, well-planned machinery reliability enhancement, maintenance optimization,... purchase, install, operate, and maintain process plant machinery only if we invest time and money up front in reading and learning about best available practices That, of course, is what this book is all about Many of my colleagues in process plants, machinery manufacturing facilities, or in the consulting field are practitioners of the various reliability improvement or assurance approaches And for... 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... surveillance and housekeeping problems resulting from a reluctance to get near the “screamer,” let alone get inside the enclosure Alternative solutions are often available and should be explored 4 Improving Machinery Reliability PAOE CENTRIFUGAL COMPRESSOR DATA SHEET CUSTOMARY UNITS 1 6 NO ITEM NO R R C H ORDER -o N -Y OF 1 ~ DATE BY NO DATE u.nT :OR 1i-E B E R M NO iERVlCE NO REOURED 0 0 CONTMOUS 0 NERMlTTENT . Practical Machinery Management for Process Plants VOLUME d THIRD EDITION Improving Machinery Practical Machinery Management for Process Plants: Volume 1: Improving Machinery Reliability, . 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. 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