Machinery Component Maintenance and Repair Part 5 pdf

Design Pressure Loads The pressure at the most severe condition of coincident internal or external pressure and temperature expected during normal operation. Weight Loads • Dead weight loads including pipe components, insulation, etc. • Live weight loads imposed by service or test fluid, snow and ice, etc. Dynamic Loads • Design wind loads exerted on exposed piping systems • Earthquake loads must be considered for piping systems where earthquake probability is significant • Impact or surge loads typically due to water hammer, letdown, or discharge of fluids • Excessive vibration arising from pressure pulsations, resonance caused by machinery excitations or wind loads Thermal Expansion/Contraction Effects • Thermal and friction loads due to restraints preventing free thermal expansion • Loading due to severe temperature gradients or difference in expan- sion characteristics Effects of Support, Anchor, and Terminal Movements • Thermal expansion of equipment • Settlement of equipment foundations and/or piping supports The When, Who, What, and How of Removing Spring Hanger Stops Associated with Machinery Initial Tasks Prior to Machinery Commissioning • Align machinery without pipe attached • Adjust pipe for proper fit-up and make connection 150 Machinery Component Maintenance and Repair • Observe alignment of machinery with pipe being attached. If excessive movement is noted, the pipe is to be disconnected and modified until misalignment is brought within the limits permitted. • If the pipe is greater than 8 in. NPS, one may need to add sandbags or similar weights to the pipe at the hanger adjacent to machinery to simulate the operating condition of the pipe. • Pull stops on all system hangers • Check to determine that no hanger travel indicator moves out of the “ 1 / 3 total travel” cold setting zone. If travel is excessive, refer imme- diately to the design contractor for modifications of support. • Adjust the hanger to return travel marker to the “C” position • Record alignment of machinery • Reinstall piping system hanger stops Final Check, Immediately Prior to Machinery Operation • Disconnect or dismantle piping as necessary • Flush and/or steam blow • Repipe and realign • Weight the hanger adjacent to the machinery • Pull system pins, check “C” settings and fine tune hangers. If travel is excessive (out of the 1 / 3 total “C” zone) contact the designated piping engineer for resolution. Flange Jointing Practices These steps can be written up in checklist format allowing field per- sonnel to use piping-related guidelines in an efficient manner, as shown in the appendices at the end of this chapter. The importance of getting flanged joints right the first time cannot be overemphasized if trouble-free performance during startup is desired. In order to obtain an adequate joint the first time we must assure ourselves that the contractor, subcontractor, and the working crews appreciate the importance of quality workmanship needed during each stage of the flange joint building process. This includes materials handling and storage oper- ations, piping prefabrication, erection, and bolting-up procedures. Time spent in covering preventive measures, supervision and crew guidance, and/or training (if needed), and assuring adequate quality control will pay dividends. Process Machinery Piping 151 Primary Causes of Flange Leakage Several common causes of flange leakage are hereby outlined to create an awareness of the effects of poor inspection procedure or materials: Uneven Bolt Stress. Flanges bolted up unevenly cause some bolts to be nearly loose while others are so heavily loaded that they locally crush the gasket. This causes leaks, particularly in high-temperature service where the heavily-loaded bolts tend to relax with subsequent loosening of the joint. Improper Flange Alignment. Unevenly bolted joints, improper alignment, and especially lack of parallelism between flange faces can cause uneven gasket compression, local crushing, and subsequent leakage. Proper cen- terline alignment of flanges is also important to assure even compression of the gasket. See Figure 4-2 for general guidance. Improper Centering of Gasket. A gasket which is installed so that its centerline does not coincide with the flange centerline will be unevenly compressed, thereby increasing the possibility of subsequent leakage. Spiral-wound and double-jacketed high-temperature gaskets are provided with a centering ring or gasket extension to the ID of the bolt circle to facilitate centering of the gasket. Even so, the gasket should be centered with respect to the bolt circle. Certain asbestos replacement gaskets should be cut so that the OD extends to the ID of the bolt circle. Dirty or Damaged Flange Faces. These are obvious causes for leakage since damage or dirt (including scale) can create a leakage path along the 152 Machinery Component Maintenance and Repair Figure 4-2. Dimensional variations permitted for piping and flanges are independent of pipe size. flange face. Damage includes scratches, protrusions (e.g., weld spatter) and distortion (warpage) of the flange. Excessive Forces in the Piping System at Flange Locations. This can occur because of improper piping flexibility design, or by excessive application of force to attain flange alignment. Improper location of temporary or per- manent restraints or supports will also cause high flange bending moments and forces. The Importance of Proper Gasket Selection The following discussion covers some of the more important factors relating to gasket size and type. Flanges are designed to accommodate specific sizes and types of gaskets (Figure 4-3). When the gasket does not meet the requirements necessary to ensure good seating, or is crushed by the bolt load, leakage will result. Heat exchanges girth flanges are more closely tailored to one specific gasket than are piping flanges per ANSI B16.5. Therefore, somewhat greater latitude is possible with the latter. Gasket Width The width of a gasket is considered in the design of a flange. For a given bolt load, a narrow gasket will experience a greater unit load than a wide gasket. It is, therefore, important to determine that the proper width gasket has been used. • For piping gaskets made of an asbestos-replacing material consult ANSI B16.5 • For double-jacketed, corrugated gaskets consult API 601 • For spiral-wound gaskets consult API 601 • For heat exchanger girth flanges, consult the exchanger drawings A common reason for gasket leakage is the use of gaskets which are too wide because of the erroneous impression that the full flange face must be covered. This is not true. The above standards should always be followed. Gasket Thickness Gasket thickness determines its compressibility and the load required to seat it. The thicker the gasket, the lower the load necessary for seating. Process Machinery Piping 153 154 Machinery Component Maintenance and Repair Figure 4-3. Principal flange configurations. All piping flanges are designed to take 1 / 16 in. thick asbestos- replacement gaskets. The 1 / 16 in. thickness assures sufficient compressibil- ity to accommodate slight facing irregularities while having a sufficiently high seating load to prevent blowout. One-sixteenth in. thick gaskets should always be used with ANSI B16.5 flanges unless a specific design check has been made to verify another thickness. Spiral-wound and double-jacketed gasket thickness should comply with API 601. Flange Types and Flange Bolt-Up* Factors Affecting Gasket Performance A gasket is any deformable material that, when clamped between essen- tially stationary faces, prevents the passage of media across the gasketed connection (Figure 4-4). Process Machinery Piping 155 * Major portions contributed by Garlock Sealing Technologies, Palmyra, New York 14522. Figure 4-4. Forces acting on a gasket. Compressing the gasket material causes the material to flow into the imperfections of the sealing areas and effect a seal. This bond prevents the escape of the contained media. In order to maintain this seal, suffi- cient load must be applied to the connection to oppose the hydrostatic end force created by the internal pressure of the system. Gasket performance depends on a number of factors, including: 1. Gasket metal and filler material: The materials must withstand the effects of: a. Temperature: Temperature can adversely affect mechanical and chemical properties of the gasket, as well as physical character- istics such as oxidation and resilience. b. Pressure: The media or internal piping pressure can blow out the gasket across the flange face. c. Media: The gasket materials must be resistant to corrosive attack from the media. 2. Joint design: The force holding the two flanges together must be suf- ficient to prevent flange separation caused by hydrostatic end force resulting from the pressure in the entire system. 3. Proper bolt load: If the bolf load is insufficient to deform the gasket, or is so excessive that it crushes the gasket, a leak will occur. 4. Surface finish: If the surface finish is not suitable for the gasket, a seal will not be effected. Spiral Wound Gaskets Manufactured in Accordance with American Society of Mechanical Engineers (ASME) B16.20 Spiral wound gaskets made with an alternating combination of formed metal wire and soft filler materials form a very effective seal when compressed between two flanges. A “V”-shaped crown centered in the metal strip acts as a spring, giving gaskets greater resiliency under varying conditions. Filler and wire material can be changed to accommodate different chemical compatibility requirements. Fire safety can be assured by choos- ing flexible graphite as the filler material. If the load available to compress a gasket is limited, gasket construction and dimensions can be altered to provide an effective seal. A spiral wound gasket may include a centering ring, an inner ring, or both. The outer centering ring centers the gasket within the flange and acts as a compression limiter, while the inner ring provides additional radial strength. The inner ring also reduces flange erosion and protects the sealing element. 156 Machinery Component Maintenance and Repair Resiliency and strength make spiral wound gaskets an ideal choice under a variety of conditions and applications. Widely used throughout refineries and chemical processing plants, spiral wound gaskets are also effective for power generation, aerospace, and a variety of valve and specialty applications. The spiral wound gasket industry is currently adapting to a change in the specification covering spiral wound gaskets. Previously API 601, the new specification is ASME B16.20. These specifications are very similar, and experienced gasket producers follow manufacturing procedures in accordance with the guidelines set forth in the ASME B16.20 specifica- tions. (See Figure 4-5 for markings.) Torque Tables Tables 4-1 through 4-4 are representative of tables that were developed to be used with Garlock spiral wound gaskets. They are to be used only as a general guide. Also they should not be considered to contain absolute values due to the large number of uncontrollable variables involved with bolted joints. If there is doubt as to the proper torque value to use, we suggest that the maximum value be used. (Text continued on page 165) Process Machinery Piping 157 Figure 4-5. Gasket identification markings required by ASME B16.20. 158 Machinery Component Maintenance and Repair Table 4-1 Torque Tables for Spiral Wound Gaskets, ASME B16.5 Class 150 Max. Torque Max. Gsk. Min. Gsk. Minimum Max. Gsk. Nom. Gsk. ID Gsk. OD Gsk. Area No. Size of per Bolts @ Comp. per Comp. Comp. Torque Comp. Prefer’d Pipe Size Contact Contact Contact of Bolts 60 ksi Bolt Bolt @ Available Recomm. per Bolt Recomm. Torque (inches) (inches) (inches) (Sq. in.) Bolts (inches) Stress (ft lb) 60 K (ft lb) (psi) (psi) (ft lb) Avail. (psi) (ft lb) 0.5 0.75 1.25 0.79 4 0.50 60 7,560 38,503 10,000 16 30,000 47 0.75 1.00 1.56 1.13 4 0.50 60 7,560 26,712 10,000 22 26,712 60 1 1.25 1.88 1.53 4 0.50 60 7,560 19,713 10,000 30 19,713 60 1.25 1.88 2.38 1.67 4 0.50 60 7,560 18,119 10,000 33 18,119 60 1.5 2.13 2.75 2.39 4 0.50 60 7,560 12,637 10,000 47 12,637 60 2 2.75 3.38 3.01 4 0.63 120 12,120 16,125 10,000 74 16,125 120 2.5 3.25 3.88 3.50 4 0.63 120 12,120 13,861 10,000 87 13,861 120 3 4.00 4.75 5.15 4 0.63 120 12,120 9,406 9,406 120 9,406 120 4 5.00 5.88 7.47 8 0.63 120 12,120 12,974 10,000 92 12,974 120 5 6.13 7.00 9.02 8 0.75 200 18,120 16,071 10,000 124 16,071 200 6 7.19 8.25 12.88 8 0.75 200 18,120 11,253 10,000 178 11,253 200 8 9.19 10.38 18.25 8 0.75 200 18,120 7,945 7,945 200 7,945 200 10 11.31 12.50 22.21 12 0.88 320 25,140 13,584 10,000 236 13,584 320 12 13.38 14.75 30.37 12 0.88 320 25,140 9,933 9,933 320 9,933 320 14 14.63 16.00 33.07 12 1.00 490 33,060 11,995 10,000 408 11,995 490 16 16.63 18.25 44.51 16 1.00 490 33,060 11,884 10,000 412 11,884 490 18 18.69 20.75 63.88 16 1.13 710 43,680 10,940 10,000 649 10,940 710 20 20.69 22.75 70.36 20 1.13 710 43,680 12,415 10,000 572 12,415 710 24 24.75 27.00 91.45 20 1.25 1,000 55,740 12,190 10,000 820 12,190 1,000 Process Machinery Piping 159 Class 300 Max. Torque Max. Gsk. Min. Gsk. Minimum Max. Gsk. Nom. Gsk. ID Gsk. OD Gsk. Area No. Size of per Bolts @ Comp. per Comp. Comp. Torque Comp. Prefer’d Pipe Size Contact Contact Contact of Bolts 60 ksi Bolt Bolt @ Available Recomm. per Bolt Recomm. Torque (inches) (inches) (inches) (Sq. in.) Bolts (inches) Stress (ft lb) 60 K (ft lb) (psi) (psi) (ft lb) Avail. (psi) (ft lb) 0.5 0.75 1.25 0.79 4 0.50 60 7,560 38,522 10,000 16 30,000 47 0.75 1.00 1.56 1.13 4 0.63 120 12,120 43,079 10,000 28 30,000 84 1 1.25 1.88 1.55 4 0.63 120 12,120 31,319 10,000 38 30,000 115 1.25 1.88 2.38 1.67 4 0.63 120 12,120 28,994 10,000 41 28,994 120 1.5 2.13 2.75 2.38 4 0.75 200 18,120 30,517 10,000 66 30,000 197 2 2.75 3.38 3.03 8 0.63 120 12,120 31,983 10,000 38 30,000 113 2.5 3.25 3.88 3.53 8 0.75 200 18,120 41,110 10,000 49 30,000 146 3 4.00 4.75 5.15 8 0.75 200 18,120 28,139 10,000 71 28,139 200 4 5.00 5.88 7.52 8 0.75 200 18,120 19,287 10,000 104 19,287 200 5 6.13 7.00 8.97 8 0.75 200 18,120 16,166 10,000 124 16,166 200 6 7.19 8.25 12.85 12 0.75 200 18,120 16,925 10,000 118 16,925 200 8 9.19 10.38 18.28 12 0.88 320 25,140 16,502 10,000 194 16,502 320 10 11.31 12.50 22.24 16 1.00 490 33,060 23,782 10,000 206 23,782 490 12 13.38 14.75 30.25 16 1.13 710 43,680 23,102 10,000 307 23,102 710 14 14.63 16.00 32.94 20 1.13 710 43,680 26,520 10,000 268 26,520 710 16 16.63 18.25 44.36 20 1.25 1,000 55,740 25,133 10,000 398 25,133 1,000 18 18.69 20.75 63.78 24 1.25 1,000 55,740 20,975 10,000 477 20,975 1,000 20 20.69 22.75 70.25 24 1.25 1,000 55,740 19,044 10,000 525 19,044 1,000 24 24.75 27.00 91.40 24 1.50 1,600 84,300 22,135 10,000 723 22,135 1,600 Tables are based on the use of bolts with a yield strength of 100,000 psi. [...]... 0. 75 1.00 1. 25 1 .56 1.88 2.31 2. 75 3.63 4.63 5. 63 6. 75 8 .50 10 .50 12. 75 14. 25 16.00 18. 25 20. 25 24. 25 1. 25 1 .56 1.88 2.38 2. 75 3.38 3.88 4. 75 5.88 7.00 8. 25 10.13 12. 25 14 .50 15. 75 18.00 20 .50 22 .50 26. 75 0.79 1.13 1 .53 2 .51 3.18 4. 75 5. 85 7.40 10.31 13.63 17.67 23.77 31.27 37. 45 35. 34 53 .41 68.48 75. 55 100.14 4 4 4 4 4 8 8 8 8 8 12 12 12 16 16 16 16 16 16 0. 75 0. 75 0.88 0.88 1.00 0.88 1.00 1.13 1. 25. .. 1 .51 5 1.744 2.049 2.300 7 ,50 0 psi Torque Compression (ft lbs) (lbs) 1 2 3 5 8 12 15 25 40 62 98 137 183 219 300 390 52 5 56 3 203 338 51 0 698 9 45 1,2 15 1 ,51 5 2,2 65 3,143 4,133 5, 190 6,6 75 7,9 05 9,7 05 11,363 13,080 15, 368 17, 250 15, 000 psi Torque Compression (ft lbs) (lbs) 2 4 6 10 15 23 30 50 80 123 1 95 273 3 65 437 600 7 75 1, 050 1,1 25 4 05 6 75 1,020 1,3 95 1,890 2,340 3,030 4 ,53 0 6,2 85 8,2 65 10,380 13, 350 ... lb) 0. 75 1.00 1. 25 1.88 2.13 2. 75 3. 25 4.00 4. 75 5.81 6.88 8.88 10.81 12.88 14. 25 16. 25 18 .50 20 .50 24. 75 1. 25 1 .56 1.88 2.38 2. 75 3.38 3.88 4. 75 5.88 7.00 8. 25 10.38 12 .50 14. 75 16.00 18. 25 20. 75 22. 75 27.00 0.79 1.13 1 .55 1.67 2.38 3.03 3 .53 5. 15 9.43 11.97 16.27 22.68 30.92 40 .56 41 .56 54 .17 69.33 76.39 91.40 4 4 4 4 4 8 8 8 8 8 12 12 16 20 20 20 20 24 24 0 .50 0.63 0.63 0.63 0. 75 0.63 0. 75 0. 75 0.88... Prefer’d Torque (ft lb) 0. 75 1.00 1. 25 1.88 1.13 2. 75 3. 25 3. 75 4. 75 5.81 6.88 8. 75 10.88 12. 75 14.00 16. 25 18. 25 20 .50 24. 75 1. 25 1 .56 1.88 2.38 2. 75 3.38 3.88 4. 75 5.88 7.00 8. 25 10.13 12. 25 14 .50 15. 75 18.00 20 .50 22 .50 26. 75 0.79 1.13 1 .53 1.67 2.39 3.01 3 .50 6.68 9.39 11. 95 16.33 20.38 24.97 37. 45 40.89 47.07 68.48 67 .54 80.90 4 4 4 4 4 8 8 8 8 8 12 12 16 20 20 20 20 20 20 0. 75 0. 75 0.88 0.88 1.00 0.88... 4,400 5, 920 7,720 3,780 4,860 6,060 9,060 12 ,57 0 16 ,53 0 21,840 27,870 34, 650 42, 150 50 ,400 59 ,400 69,120 79 ,56 0 102,690 128,760 157 ,770 189,720 45 68 90 150 240 368 53 3 750 1,020 1,200 1, 650 2, 250 3,000 3,300 4,770 6,600 8,880 11 ,58 0 5, 670 7,290 9,090 13 ,59 0 18, 855 24,7 95 32,760 41,8 05 51,9 75 63,2 25 75, 600 89,100 103,680 119,340 154 ,0 35 193,140 236, 655 264 ,58 0 60 90 120 200 320 490 710 1,000 1,360 1,600... 1. 25 1 .50 1.38 1.63 1.88 2.00 2. 25 2 .50 2. 75 3.00 3 .50 200 200 320 320 490 320 490 710 1,000 1,600 1,360 2,200 4,000 4,400 6,360 8,800 11,840 15, 440 26,000 18,120 18,120 25, 140 25, 140 33,060 25, 140 33,060 43,680 55 ,740 84,300 69,300 100,800 138,240 159 ,120 2 05, 380 257 ,52 0 3 15, 540 379,440 52 5,000 92,284 64,024 65, 555 40,021 41,606 42,376 45, 182 47,222 43, 258 49,464 47, 059 50 ,886 53 , 052 67,9 75 92,997... per Bolt (ft lb) Prefer’d Torque (ft lb) 0. 75 1.00 1. 25 1 .56 1.88 2.31 2. 75 3.63 4.63 5. 63 6. 75 8 .50 10.63 12 .50 1. 25 1 .56 1.88 2.38 2. 75 3.38 3.88 4. 75 5.88 7.00 8. 25 10.13 12. 25 14 .50 0.79 1.13 1 .53 2 .51 3.18 4. 75 5. 85 7.40 10.31 13.63 17.67 23.77 29.19 42.41 4 4 4 4 4 8 8 8 8 8 8 12 12 12 0. 75 0. 75 0.88 1.00 1.13 1.00 1.13 1. 25 1 .50 1. 75 2.00 2.00 2 .50 2. 75 200 200 320 490 710 490 710 1,000 1,600... 25, 140 33,060 43,680 33,060 43,680 55 ,740 84,300 118,800 159 ,120 159 ,120 257 ,52 0 3 15, 540 92,284 64,024 65, 555 52 ,629 54 ,971 55 ,7 25 59,696 60,260 65, 423 69,708 72,0 35 80,323 1 05, 849 89,280 10,000 10,000 10,000 10,000 10,000 10,000 10,000 10,000 10,000 10,000 10,000 10,000 10,000 10,000 22 31 49 93 129 88 119 166 2 45 430 611 54 8 831 1,326 100 100 160 279 387 264 357 50 0 800 1 ,50 0 2,200 2,200 4,400 5, 920... 5, 580 Machinery Component Maintenance and Repair Table 4 -5 Torque to Stress Bolts /2 /16 5 /8 4 /3 7 /8 1 9 0.400 0. 454 0 .50 7 0.620 0.731 0.838 0.963 1.088 1.213 1.338 1.463 1 .58 8 1.713 1.838 2.088 2.338 2 .58 8 2.838 0.126 0.162 0.202 0.302 0.419 0 .55 1 0.728 0.929 1. 155 1.4 05 1.680 1.980 2.304 2. 652 3.423 4.292 5. 259 6.324 30 45 60 100 160 2 45 355 50 0 680 800 1,100 1 ,50 0 2,000 2,200 3,180 4,400 5, 920... 10,380 13, 350 15, 810 19,410 22,7 25 26,160 30,7 35 34 ,50 0 Torque (ft lbs) 4 8 12 20 30 45 60 100 160 2 45 390 54 5 730 8 75 1,200 1 ,55 0 2,100 2, 250 30,000 psi Compression (lbs) 810 1, 350 2,040 2,790 3,780 4,860 6,060 9,060 12 ,57 0 16 ,53 0 20,760 26,700 31,620 38,820 45, 450 52 ,320 61,470 69,000 Machinery Component Maintenance and Repair Table 4 -5 cont’d Torque to Stress Bolts Process Machinery Piping 1 75 (Text continued . lb) 0 .5 0. 75 1. 25 0.79 4 0. 75 200 18,120 92,284 10,000 22 100 0. 75 1.00 1 .56 1.13 4 0. 75 200 18,120 64,024 10,000 31 100 1 1. 25 1.88 1 .53 4 0.88 320 25, 140 65, 555 10,000 49 160 1. 25 1 .56 2.38 2 .51 4. lb) 0 .5 0. 75 1. 25 0.79 4 0. 75 200 18,120 92,284 10,000 22 100 0. 75 1.00 1 .56 1.13 4 0. 75 200 18,120 64,024 10,000 31 100 1 1. 25 1.88 1 .53 4 0.88 320 25, 140 65, 555 10,000 49 160 1. 25 1 .56 2.38 2 .51 4. 18.69 20. 75 63.78 24 1. 25 1,000 55 ,740 20,9 75 10,000 477 20,9 75 1,000 20 20.69 22. 75 70. 25 24 1. 25 1,000 55 ,740 19,044 10,000 52 5 19,044 1,000 24 24. 75 27.00 91.40 24 1 .50 1,600 84,300 22,1 35 10,000 723