Improving Machinery Reliability 3 Episode 1 doc

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 [...]... RM 610 N _ DATE - YB 1 2 3 4 6 8 7 8 0 10 I1 12 13 14 15 16 17 in 10 20 21 n 2 3 24 17 CENTRIFUQU coMm FOR DEN REFWERY SERV D R Y B U B WETBUCB MhDOR HAW0 UNlT R E S P O N S I B I W (2.9 .1. 7) .- - SHIPMENT: 14 .4 .1) 0DOMESTIC 0 EXPORT 0 EXPORT B O W 0 REOD 0OUTDOOR STORAGE MORE THAN 6 M O W S I< 4 11 SPARE ROTOR ASSEMBLY PACKAGED FOR (4.4 3. 10 1 O H O R I Z O N T N STORAGE PRNTED N U.S.A D S d 1. .. MMSCFDISCFM (14 .7 PSLA L S d F DRY1 I WElOHT FLOW, llhW (WETI (DRY1 16 17 18 IO m I 2s 27 28 I I I I I I I I I I I I I1 25 I I I 23 24 I I I 22 I 1 2% I I I I 20 Jo 0 Bhp RE-ED 31 0 lRE0IRPMl ESTMATED SUROE I C N (AT SPEED ABOVE1 P O L r n O F i C Hw IFT-CBSIIBI 35 0 0 0 0 36 0 RRFORMWCE C U R E W E E R 32 33 3 (MLLOSSES NCLI POLYfRoRcEFFCENCY (XI OU*RAMEEW 37 PROCESS CONTROL 30 Mm(o0 TO 40 41 42 S E W... Machineiy Reliability Table 1- 1 Principal API Standards for Mechanical Equipment (19 97) Standard 7B- 1 IC Standard Standard Standard Standard Standard Standard Standard 546 610 611 612 6 13 614 Standard Standard Standard Standard Standard Standard Standard 616 617 618 619 670 6 71 672 Standard Standard Standard Standard Standard Standard 674 675 676 677 678 6 81 5 41 Standard 682 Standard 6 83 Standard... 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 0 WACTIRER STu*DBY ORMRTYPEI3 .1. 0 M l M R ll€M NO MODEL 7 8 # (ALLDATA ON PER N IT 10 ems) OTHER CONOITTIONS (3. 1. 2) RATED NORMN A C B D 11 12 13 14 16 0 0 0 M S -0 (ALSO... PEAK1 23 0 MATERIALS INSPECTION REQUIREMENTS (4.2 .3) MATL 0 ROTATION, VIEWED FROM DRIVEN END 2 4 MATL ATSHAFT SEALS ALLOWABLE TEST LEVEL ! 21 2 ( 21 21 0 LABYRINTHS: 0SPECIAL CHARPV TESTING 12 .11 .3) 0RADIOGRNWY REQUIREDFOR 0MAGNETIC PARTICLE REOUIRED FOR 0LIQUID PENETRANT REQUIRED FOR INTERSTAGE TYPE MATERIAL BALANCE FiSTON TYPE MATERIAL 2 ( 0 CASING: 3 ( MODEL 0 SEAL TYPE (2.8 .3 31 CASING S f t i 7 3. .. TwOTlLNO _ PSU 0 VARIABLE M E T 0 SPEED VARUTION 0 QUOE VANES (3. 4.2 .3) - PBU FROM TO Y x DISCH*RGE BLOWOFF TO 0 COOLED BYPASS FROM TO 0 SWRCE l3.4.2 .11 TYPE a u 45 0 SUCFROM 30 0 0 PNEUMATIC ELECTROMC 0 OTHER m a ANll-B~OEBYPASS 48 0 W N OAUrOMATIC 0 NONE 4I 48 REWKS: 40 M RWTEO W U.S.A O S d l 7 - 1 REV 1 1 1 Figure 1- 1 API 617 , data sheet page 1 (Courtesy American Petroleum Institute.) 5 Requirements... CONSTRUCTION: TYPE (SEPARATE 1 N T E G R A L ) ~ S U l T MATERIAL 4 IIN U.S.A DS- 617 -3 _ PAINTED REV 1 Figure 1 -3 API 617 , data sheet page 3 (Courtesy American Petroleum Institute.) n I *I I , I I I I I ID c ,-r , 1; .; 1 - ; ;1 i Figure 1- 4 At-speed balance... 31 CASING S f t i 7 3 ; MATERIAL 3 : THICKNESS (IN.) 0 SETTLING OUT PRESSURE (PSIGJ 0 SPECIAL OPERATtON (2.8 .1) 0 SUPREMENTAL DEVICE REOUIREO FOR CONTACT 3r MAX WORIUNG PRESS PSlG 3 ! MAX DESIGN PRESS PSI0 24 TEST PRESS (PSIG): HELIUM 3i MAX OPER T E M P O F MIN OPER T E M P * 3 1 MAX NO OF IMPELLERSFOR CASING SHAFT SEALS: CORR ALLOW (IN.) 31 Mu( CASING CAPACITY 41 RADIOGRAPHQUALrTy 4 HYDRO ‘ I CASING... PACKAGED FOR (4.4 3. 10 1 O H O R I Z O N T N STORAGE PRNTED N U.S.A D S d 1 7 - 2 0 M R T I C N STORAGE REV l l M Figure 1- 2 PIPI 617 , data sheet page 2 (Courtesy American Petroleum Institute.) 6 Improving Machinery Reliability (text corrfirtrterlf,vrtt page 3 ) On data sheet page 3 (Figure 1 -3) , the specifying engineer must determine whether the critical speed projections made by the vendor are based on... Conference, EPRI, Philadelphia, May 17 -19 , 19 94 8 Edward Tufte, The Visual Displays of Quantitative Information, Graphics Press, Cheshire, CT 9 John S Mitchell, Summarized Minutes of the Seventh MIMOSA Meeting, available on the Internet, 19 98 10 John S Mitchell, “MIMOSA, Building the Foundation for 21st Century Optimized Asset Management,” Sound & Vibration, September 19 95 11 Robert C Baldwin, “The Promise . 0-88 415 -6 61 -3 (alk. paper) 1. Machinery- Reliability. I. Title. II. Series: Bloch, He& P., 1 933 - Practical machinery management for process plants. 31 d ed. ; v. 1. TJ1 53. B58 19 98. . . . . . ,32 9 Allowable Load, 33 1 ; Excessive Flexibility, 33 3; Theoretical Restraints, 33 4; Expansion Joints, 33 5; Other Practical Considerations, 33 7; References, 33 8 8 Startup. 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,