~-SECONIEDITIG~-} 1 I Pracrical Machinery Management for Process Plan@ I I I A 1- - I t VOLUME 4 I :4 r7 m mm II I 0 e SECOND EDITION Practical Machinery Management for Process Plants Volume 4 Major Process Equipment Maintenance and Repair Gulf Publishing Company Houston, Texas SECOND EDITION Practical Machinery Management for Process Plants Volume 4 Major Process Equipment Maintenance and Repair Pumps w Fans and Blowers w Mixers w Compressors Turboexpanders Motors w Turbines Heinz P. Bloch Fred K. Geitner Dedicated with gratitude’ to those who taught us, who inspired us, and who gave us their support and encouragement. Practical Machinery Management for Process Plants Volume 4, Second Edition Major Process Equipment Maintenance and Repair Copyright 0 1985, 1997 by Gulf Publishing Company, Houston, Texas. All rights reserved. Printed in the United States of America. This book, or parts thereof, may not be reproduced in any form 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 2 Library of Congress Cataloging-in-Publication Data Bloch, Heinz P., 1933- K. Geitner. -2nd ed. Includes index. 1. Chemical plants-Equipment and supplies-Maintenance and repair. I. Geitner, Fred K. 11. Title. 111. Series: Bloch, Heinz P., 1933- Prac- tical machinery management for process plants. 2nd ed. ; v. 4 TP157.B56 1996 Major process equipment maintenance and repair / Heinz P. Bloch, Fred p. cm (Practical machinery management for process plants; v. 4) ISBN 0-88415-663-X 660’.283’02884c20 96- 18768 CIP Note: The reader is reminded that many of the techniques and procedures described 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 case of conflict, observe the manufacturer’s instructions or ask the manufac- turer to assist in resolving any differences. iv Acknowledgmen ix Foreword xi Part I: Installation and Repair of Major Process Equipment . . . 1 1 Installation, Maintenance, and Repair of Horizontal Pumps . . - . . . 3 Principles of Installation of Pumps and Drivers. Baseplate and Soleplate Preparation. Grouting Overview. Cement-Based Grouts. Machinery Alignment. Pre-Operational Checks. Pump Preparation for Startup. Shutting Down the Pump. Pump Preventive Maintenance. Calculating the Cost of Your Excess Clearances. Pump Assembly Procedures. Bearing Housing-Sleeve Bearing Construction. Stuffing Box with Mechanical Seal. Reassembling Bearing Housing. How and Why Centrifugal Pumps Continue to Fail. 2 Installation, Maintenance, and Repair of Vertical Pumps , . . . . . . . 72 Types of Wrtical Pumps for Process Plants. Types of Drivers. Deepwell Pump Shaft Adjustment. Maintenance and Repair of Packed Stuffing Boxes. Maintenance and Repair of Pump Bearings. V 3 Reciprocating and Liquid Ring Vacuum Pumps .118 Pump Classification. Liquid-End Components. Packing Main- tenance. Stuffing Boxes. Plunger Material. Drive-End Com- ponents. Maintenance of Liquid Ring Vgcuum Pumps. 4 Positive Displacement and Dynamic Blowers ,142 Maintenance Instructions for Positive Displacement Rotary Blowers. Care and Maintenance of Fans. VBriable Inlet Vanes (VIV’s). Installing Fixed and Floating Pillow Blocks. Stuffing Box Installation. Temperature Detectors. 5 Reciprocating Gas Engines and Compressors .176 Introduction. Compression Cylinder Maintenance. Packing Maintenance. Vglve Breakage. Analyzing Crankshaft Def lec- tion Readings. Determining Bearing Clearances. Reciprocat- ing Compressor Component Overhaul and Repair. Reciprocat- ing Unit Preventive and Predictive Maintenance. Upper PortiodCylinders. Valves. Compressor. Oil System. Routine Checks and Adjustments. Part II: Maintenance for Power Generation and Transmission , . .223 6 Power Transmission Gears ,225 Introduction. Gear Types. Gear Terminology. How Gears Work. Bearings. Basic Installation Procedures. Shaft Operat- ing Positions. Thermal and Mechanical Movement. Tooth Contact Check. Checklist Before Startup. Checklist After Startup. Lubricant Function. Lubricant Selection. Methods of Supplying Lubricant. Lubrication of High Speed Units. Inop- erative Periods. Journal Bearing Maintenance. Rolling Ele- ment Bearing Maintenance. Gear Unit Disassembly and As- sembly. Overheating. Appendix 7A-Helical Gear Formulas, Standard Gearing. Appendix 7B-Typical Gear Unit Arrange- ments. 7 Installation and Maintenance of V-Belt Drives .310 Inspection While Running. Belt and Sheave Gauges. Maintain Proper Belt Tension. Typical Sheave and Bushing Installation Instruction. Typical Sheave and Bushing Removal Instruction. Installation of Belts. Force Deflection Engineering Formulas. vi 8 Steam Turbines and Turboexpanders .329 Special Purpose Steam Turbines. Review of lhrbine Hard- ware. Special Purpose lhrbine Inspection and Repair. Special Purpose Steam nrbine Operation and Maintenance. Proper Break-in of Carbon Rings. Operation of Large Steam Tur- bines. How to Avoid Steam lbrbine Distress. General Purpose Steam lbrbine Maintenance and Repair. Maintenance Over- view. Water-cooled Bearings. Rotor Locating Bearing. Gov- ernor Valve. Steam Turbine Lubrication. Governor Lubrica- tion. Operation and Maintenance of Cryogenic Plant Turboexpanders. Troubleshooting. Disassembling Tbrboex- panders. Inspection and Allowable Wear Data. 9 Gas Turbines .442 Gas Turbine Maintenance Philosophy and Objectives. Spare PartdSpecial Tools. Inspection/Overhaul/Repair. Air Inlet and Compression. Fuel System and Combustion. Turbine and Ex- haust. Controls. Lube Oil System. Maintenance Concepts for Aircraft Derivative Gas Turbines. Inspections. 10 Maintenance of Hydraulic Governors Disassembly .480 11 Maintenance of Electric Motors and Associated Apparatus , , , . ,495 Electric Motor Maintenance. Motor Nameplate Data. Motor Receiving, Handling and Storage. Motor Installation. Preven- tive Maintenance of Nonrotating Apparatus. Appendix 11A- Electrical Machines Maintenance Report. Appendix 11B- EASA Standards for the Electrical Apparatus Sales and Service Industry. Part 111: General Preventive and Predictive Maintenance .543 12 Storage Protection and Lubrication Management .545 Centrifugal and Rotary Pumps. Lubrication Management. Master Lubrication Schedules. Bearing Labyrinth Purge. Gear Coupling Lubrication. Principles of Oil Mist Lubrication. Oil Mist Properties. Principles of Grease Lubrication. Character- istics of Thickeners. Application Limits for Greases. Relubri- cation Frequency Recommended by Manufacturers. Synthetic Lubricants. A Two-Level Monitoring Strategy. VU [...]... American National Standards Institute 3 4 Major Process Equipment Maintenance and Repair Figure 1-1 Horizontal single stage process pump to API (American Petroleum Institute) Standard (Courtesy Byron Jackson.) Figure 1-2 Typical ANSI horizontal process pump with foot mounted casing (Courtesy Byron Jackon.) Installation, Maintenance, and Repair of Horizontal Pumps 5 sleeves Pump suction and discharge will... outweigh the arguments for rim -and- face and other mechanical alignment methods If you or your contractor are unfamiliar with reverse indica- 18 Major Process Equipment Maintenance and Repair tor alignment, get a book and learn, or purchase one of the small hand-held calculators now available that are based on this system 3 Measure and adjust the distance between the driver and the pump shaft ends (D.B.S.E... the equipment If everything checks out properly, the baseplate is ready for grouting 12 Major Process Equipment Maintenance and Repair Grouting Overview’ Epoxy Grout 1 Timing and proper mixing are the keys to successful grouting The grout supplier’s instructions must be followed implicitly Before mixing the various components, everything else should be readysurfaces cleaned and dry, forms completed and. .. construction phase of the installation Many pieces of equipment have been ruined before they had a chance to operate, because of mishandling in the field prior to unit start-up ~ * Source: J W.Dufour, Amoco Oil Company Chicago IL 8 Major Process Equipment Maintenance and Repair A good preinstallation program should accomplish the following: 1 Inspect all equipment upon arrival for any shipping damage 2... grease or with paste wax The exposed bolts should be covered with plastic wrap and the wrap firmly secured with wire 10 Major Process Equipment Maintenance and Repair 2 After the pour, the surface of the foundation should be chipped to remove all laitance and defective or weak concrete Normally, a chipping hammer should be used; sand blasting or using a needle gun is not effective The amount of concrete... made at ambient temperature and "pipefree"-no pipe forces or weight on the equipment (pump and turbine flanges should be unbolted) 7 To eliminate adding mechanical runout to alignment error, indicator readings should be taken by turning the pump and driver shafts together Installation, Maintenance, and Repair o Horizontal Pumps f 19 8 Tighten the equipment hold-down bolts and recheck the alignment;... should be taken when removing and installing rings Axial ring orientation and location as well as the direction of shaft rota- Installation, Maintenance, and Repair of Horizontal Pumps 9 tion is critical Be sure to consult the manufacturer's instruction manual for details 9 Pump mechanical seals are precision components and therefore require special handling during transport and installation When moving... guidelines on how to optimally maintain these machines, and finally how to best operate these machines Used in conjunction with the preceding three volumes or used alone, this book will make the reader a knowledgeable person Michael M Calistrar Missouri City’.TX xi Part I Installation and Repair of Major Process Equipment Chapter 1 Installation, Malntenance, and Repair of Horizontal Pumps The most common centrifugal... (Turboexpanders) Brian Turner (On-Stream Cleaning of Turbomachinery) D H Jacobson and Westinghouse Canada Inc (Gas Turbines) H Henser and GHH-Borsich (Aircraft Derivative Gas Turbines) R S Adamski and Woodward Governor Co (Hydraulic Governors) ix Delta Enterprises (Sarnia) Ltd (Electric Motors and Apparatus) Bob VigndAshland Oil (Electric Motor Repairs) Electrical Apparatus Service Association (Standards... seal and impeller to be removed without disturbing the motor or pump flanges All radial and thrust loads are transferred to the motor bearings This style of pump is shown in Figure 1-3 Figure 1-3 Vertical inline centrifugal pump Rigid coupling, impeller, stuffing box and mechanical seal can be removed without disturbing motor and pip ing (Courtesy Union Pump (Canada) Ltd.) 6 Major Process Equipment Maintenance . Maintenance and Repair Gulf Publishing Company Houston, Texas SECOND EDITION Practical Machinery Management for Process Plants Volume 4 Major Process Equipment Maintenance and Repair. Installation and Repair of Major Process Equipment . . . 1 1 Installation, Maintenance, and Repair of Horizontal Pumps . . - . . . 3 Principles of Installation of Pumps and Drivers National Standards Institute 3 4 Major Process Equipment Maintenance and Repair Figure 1-1. Horizontal single stage process pump to API (American Petroleum Institute) Standard. (Courtesy