SECOND EDITION Practical Machinery Management for Process Plants Volume 3 Turbomachinery Overhauls . Foundations and Repairs . Mechanical Seals . Machinery Components Grouting . Alignment and Balancing Pump Shaft Heinz P. Bloch . Fred K. Geitner Practical Machinery Management tor Process Plants Volume 3, Second Edition Machinery Component Maintenance and Repair Gulf Publishing Company Houston. Texas Practical Machinery Management for Process Plants Volume 3, Second Edition Machinery Component Maintenance and Repair Heinz P. Bloch and Fred K. Geitner This edition was reviewed by the authors and reprinted in 1999. I I Practical Machinery Management for Process Plants Volume 3, Second Edition Machinery Component Maintenance and Rerair Copyright 0 1985, 1990 by Gulf Publishing Company, Hous- ton, Texas. All rights reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced without permission of the publisher. Gulf Publishing Company Book Division P.O. Box 2608 0 Houston, Texas 77252-2608 10 9 8 7 6 5 4 3 Library of Congress Cataloging-in-Publication Data Machinery component maintenance and repairlHeinz P. Bloch and Bloch, Heinz P., 1933- Fred K. Geitner 1st ed. p. cm (Practical machinery management for process plants; v. 3) Includes index. 1. Machinery-Maintenance and repair. 2. Industrial equipment- Maintenance and repair. 1. Geitner, Fred K. 11. Title. 111. Series: Bloch, Heinz P., 1933 Practical machinery management for process plants; v. 3. TJIS3.BS83 1990 670‘ .28’8-d~20 90-3579 CIP ISBN 0-87201-781-8 Series ISBN 0-87201-675-7 Note: The reader is reminded that many of the techniques and procedures de- scribed herein are of a general nature and may have to be modified or adapted to be directly applicable to the specific machinery in his plant. In casc of con- flict, observe the manufacturer’s instructions or ask the manufacturer to assist in resolving any differences. Printed on Acid-Free Paper (co) iv Contents Foreword viii Acknowledgments ix Part I: Background to Process Machinery Maintenance Programming 1 1 Machinery Maintenance: An Ovaview 3 2 Maintenance Organization and Control for Multi-Plant Corporations 12 Type of Operation. Manager’s Role. Central Control System. Planning Turbo- machinery Overhauls. Assignment of Qualified Personnel. Specific Prepara- tion and Planning. Inspection. Cleaning. Reassembly. Documenting What You’ve Done. 3 Machinery Foundations and Grouting 65 What’s An Epoxy? Epoxy Grouts. Proper Grout Mixing is Important. Job Plan- ning. Conventional Grouting. Methods of Installing Machinery. Pressure-In- jection Regrouting . Foundation Repairs. Pump Baseplate Installation and Ep- oxy Grouting. Baseplate Leveling Procedures. Baseplate Preparation. New Concrete Preparation. Old Concrete Preparation. Anchor Bolts. Grout Forms. Epoxy Grout Placement. Appendix 3-A-Detailed Checklist for Rotating Equipment: Horizontal Pump Baseplate Checklist. Appendix 3-B-Specifica- tion for Portland Cement Grouting of Rotating Equipment. Appendix 3-C-De- tailed Checklist for Rotating Equipment: Baseplate Grouting. Appendix 3-D- Specifications for Epoxy Grouting of Rotating Equipment. 4 Process Machinery Piming 142 Fundamentals of Piping Design Criteria. Piping Design Procedure. Flange Jointing Practices. Primary Causes of Flange Leakage. Proper Gasket Selec- V tion. Controlled Torque Bolt-Up of Flanged Connections. Recommendations for the Installation, Fabrication, Testing, and Cleaning of Air, Gas, or Steam Piping. Appendix 4-A-Checklist for Rotating Equipment: Machinery Piping. Appendix 4-B-Specifications for Cleaning Mechanical Seal Pots and Piping for Centrifugal Pumps. Appendix 4-C-Detailed Checklist for Rotating Equip- ment: Pump Piping. Part II: Aliflnment and Balancing 16s 5 Machinery Alignment 171 Prealignment Requirements. Choosing an Alignment Measurement Setup. Checking for Bracket Sag. Face Sag Effect-Examples. Interpretation and Data Recording. Graphical Techniques. Reverse Indicator Method Using Crossover Brackets. Horizontal Movement by Vertical Adjustment. Thermal Growth- Eleven Ways to Correct for it. Thermal Growth Estimation by Rules of Thumb. 6 Balancing of Machinery Components 238 Definition of Terms. Purpose of Balancing. Units of Unbalance. Types of Un- balance. Motions of Unbalanced Rotors. Balancing Machines. Centrifugal Bal- ancing Machines. Measurement of Amount and Angle of Unbalance. Classifi- cation of Centrifugal Balancing Machines. Maintenance and Production Balancing Machines. Supporting the Rotor. Balancing Keyed End-Drive Adapters. Balancing Arbors. Testing Balancing Machines. Test Procedures. Balance Tolerances. Balance Errors Due to Rotor Support Elements. Com- puter-Aided Balancing. Field Balancing Overview. The Vector Diagram. Ap- pendix 6-A-Balancing Terminology. Appendix 6-B-Balancing Machine No- menclature. Appendix 6-C-Balancing and Vibration Standards. Appendix 6-D-Critical Speeds of Solid and Hollow Shafts. Part 111: Maintenance and Repair of Machinery Components 349 7 Ball Bearing Maintenance and Replacement 351 Engineering and Interchangeability Data. Cleanliness and Working Conditions in Assembly Area. Removal of Shaft and Bearings from Housing. Cleaning the Bearing. Shaft and Housing Preparation. Checking Shaft and Housing Mea- surements. Basic Mounting Methods. Hints on Mounting Duplex Bearings. Preloading of Duplex Bearings. Importance of the Correct Amount of Preload. Assembly of Bearings on Shaft. Cautions to Observe During Assembly of Bear- ings into Units. Mounting with Heat. Checking Bearings and Shaft After Instal- lation. Testing of Finished Spindle. Maintain Service Records on All Spindles. vi 8 Repair and Maintenance of Mechanical Seals and Rotating Equipment Components .430 Mechanical Seal Installation, Repair, and Maintenance. Lapping and Seal Face Flatness. Installation of Stuffing Box Packing. Welded Repairs to Pump Shafts and Other Rotating Equipment Components. How to Decide if Welded Repairs are Feasible. Case Histories. High Speed Shaft Repair. Shaft Straightening. Straightening Carbon Steel Shafts. Casting Salvaging Methods. 9 Centrifugal Compressor Rotor Repair 487 Compressor Rotor Repairs. Impeller Manufacture. Compressor Impeller De- sign Problems. Impeller Balancing Procedure. Rotor Bows in Compressor and Steam Turbines. Clean Up and Inspection of Rotor. Disassembly of Rotor for Shaft Repair. Shaft Design. Rotor Assembly. Shaft Balancing. Rotor Thrust in Centrifugal Compressors. Managing Rotor Repairs at Outside Shops. Mount- ing of Hydraulically Fitted Hubs. Dismounting of Hydraulically Fitted Hubs. 10 Protecting Machinery Parts Against loss of Surface 51 8 Basic Wear Mechanisms. Hard Surfacing Techniques. Special Purpose Materi- als. The Detonation Gun Process. Selection and Application of 0-Rings. Cas- ing Joint Compounds. Sealing Compounds. Index 586 vii [...]... Why How -and sometimes Who-of most maintenance and repair activities around petrochemical process machinery We ask however, that our readers never lose sight of the total picture What then is the total picture? 3 4 Machinery Component Maintenance and Repair It is the awareness that true cost savings and profitability can only be achieved by combining machinery reliability, safety, availability, and maintainability... of machinery maintenance problems 6 Machinery Component Maintenance and Repair placement or overhaul After maintenance the future trend in operating cost is known or at least anticipated Such a deterministic situation is illustrated in Figure 1-3 In probabilistic or indeterminate component life problems, the timing and result of maintenance may depend on chance In the simplest situation a piece of machinery. .. accomplish for the reader: Find new and better ways to do our jobs, broaden our perspective as engineers, and contribute to a fund of knowledge which-if properly tappedwill bring benefits to everyone Heinz I? Bloch Fred K Geitner X Part I Background to Process Machinery Maintenance Programming Chapter 1 Machinery Maintenance: An Overview Maintenance and repair of machinery in a petrochemical process... of machinery maintenance and repair These companies or individuals have earned our respect and gratitude for allowing us to use, adapt, paraphrase or otherwise incorporate their work in Wume 3: W J Scharle (Multi-Plant Maintenance) , J A Trotter (Computer-Based Maintenance) , J D Houghton (Planning lhtmnachinery Overhauls), E M RenfdAdhesive Services Company (Major Machinery Grouting and Foundation Repair) ,... Installation, Repair, Maintenance) , H A Scheller (Pump Packages) T Doody (Welded Repairs to Pump Shafts etc.) H A Erb (Repair Techniques for Machinery Rotor and Case Damage), Byron Jackson Pumps (Field Machining Procwiures) %rry Washington, In-Place Machining Company (Metal Stitching Techniques), Barney McLaughlii, Hickham Industries, Inc and W E Nelson (Compressor Rotor and Component Repairs, Sealing... preventive maintenance action while repair is strictly reserved for maintenance of an item that has reached a defined failed state or defect limit? Replucemenr should be understood in our context as a broad term that includes the replacement of components, operating fluids and charges, as well as of complex machinery and systems Finally, we understand organizational srrucrure problems in machinery maintenance. .. report to and work solely under the guidance of the individual plant manager in order not to confuse the chain of command Thus, a decentralized system of giving the plant manager responsibility for general operations, cost performance, and maintenance performance, but with a strong centralized ap- 14 Machinery Component Maintenance and Repair proach to all aspects of monitoring plant performance and providing... ON-LINE INSPEC CLEANING pn (SERYICIBILITY) MINIMIZE HAXIMIZE ON-LIHE CONDITION/ PERFOMNEE MONITORING AND - LIGHTING SPECIAL T W L S SHELTER ACCESSIBILITY OTHER Figure 1-4 Process machinery maintainability components f44XIMIZE ECONOllICALLV INSURAHCE SPARE PARTS Machinery Component Maintenance and Repair 8 dicted and its consequence reduced by perhaps continuous or daily surveillance 3 Select PM task 4 Determine... factors and maintenance costs One cannot be separated from the other Any system, therefore, must account for how cheaply maintenance can be performed from an organizational setup, and also what must be done and how often The ability to update maintenance requirements and improved planning based on experience at a group of plants has a large bearing on overall maintenance costs Other than breakdown maintenance, ... limited experience of plant personnel However, the demand for plant operation attention often prevents timely maintenance performance Another defect is that it lacks uniformity and does not provide compliance reports to home office management And, there is often no effective way to compare the PM performance at similar 16 Machinery Component Maintenance and Repair plants or equipment at different locations . SECOND EDITION Practical Machinery Management for Process Plants Volume 3 Turbomachinery Overhauls . Foundations and Repairs . Mechanical Seals . Machinery Components Grouting Practical Machinery Management tor Process Plants Volume 3, Second Edition Machinery Component Maintenance and Repair Gulf Publishing Company Houston. Texas Practical Machinery. Edition Machinery Component Maintenance and Repair Heinz P. Bloch and Fred K. Geitner This edition was reviewed by the authors and reprinted in 1999. I I Practical Machinery