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 [...]... 135 .5 110.7 95.8 83. 8 78.2 86.4 42 .3 33. 8 27.1 22.9% -12.0 -11.2 -11.8 -5.8 -2.4 -12.7 -7.0 -11.9 2.5 -7.1 4.0 - 13. 2 -8.4 0.7 9.6 -4.5 -11.2 5.9% s 4 5 O 5.8 5.6 8.5 4.8 5 O 6.0 6.5 3. 5 7.9 4.2 6.0 3. 6 11.5 5.1 2.5 10.2% 9.6 9.5 11.4 10.2 14 .3 7.4 11.5 12.0 14.7 5.2 14.4 7.0 14 .3 6.2 20.5 9.9 3. 5 8.0% 7.2 6.1 8.9 7.1 10.9 5.1 9.1 7.8 10.1 3. 3 10.2 4.4 10.7 4.7 12.2 6.6 2.6 -3. 8 -22 .3 -1.5 11.2 -14 .3. .. 5.1 9.1 7.8 10.1 3. 3 10.2 4.4 10.7 4.7 12.2 6.6 2.6 -3. 8 -22 .3 -1.5 11.2 -14 .3 -1.7 8.8 -2.6 -2 .3 -3. 8 -9.4 -3. 1 - 13. 8 -9 .3 -5.5 -10.5 3. 3 5.8 3. 6 7.2 2.5 10.5 5.2 9.1 6.6 7.1 6.0 5.2 6.2 6.8 9.1 6.2 4.9 17.4 5.8 13. 3 4.1 22.4 7.2 17.9 11.1 15.1 9.4 8.4 14.6 13. 1 25.8 12 .3 2.7 6.0 3. 2 7.8 2.6 13. 2 4.2 13. 8 8.1 11.2 6.2 4.8 8.0 8.4 6.2 7.8 Union Carbidc Dow Chemical Monsanto Allied PPG Industries W.R... 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 into a cost-effective total-consistent with the intent of our series of volumes on process machinery management Figure 1-1 illustrates this concept Consequently, machinery maintenance... work force 3 Improved equipment reliability 4 Reduced inventory costs 22 Machinery Component Maintenance and Repair Table 2-1 Maintenance Cost in the Chemical Process Industries, 1982’ Maintenance cost as percent of plant, property and equipment -Historical cost Current Original Depreciated’ cost2 Chemical companies 1982 (million dollars) Change 1981-82 (%) D Pont u $1, 433 . 03 579.0 559.0 37 8.0... doing Volume 3 of this series on machinery management brings us the know-how of some of the most knowledgeable individuals in the field Engineers and supervisors concerned with machinery and component selection, installation, and maintenance will find this an indispensable guide Here, finally, is a long-needed source of practical reference information which the reader can readily adapt to similar machinery. .. syntax and other concerns Last but not least we are indebted to our editor, Brad Sagstetter As we put the finishing touches on the simultaneously released companion Volumes 3 and 4 in our series on Practical Machinery Management for Process Plants, ” we are reminded of some important remarks made by Exxon Chemical Technology Vice President W.J Porter, Jr in early 1984 Mr Porter expressed the helief that... cost system also may be designed to provide input for other systems It can generate equipment cost transactions for a preventive maintenancekquipment records system, for example, or can provide summarized accounting entries for a general ledger system In summary, work order cost systems provide cost information in a form that is fully usable by maintenance management in identification and definition of... Programming Chapter 1 Machinery Maintenance: An Overview Maintenance and repair of machinery in a petrochemical process plant was defined in a preceding volume as simply “defending machinery equipment against deterioration.” Four strategies within the failurefighting role of maintenance were defined: 0 Preventive Predictive Breakdown or demand based “Bad actor” or weak spot management Machinery maintenance... program for his facility In some plants, this is being done with individual check sheets or production boards using equipment manufacturers’ recommendations and the 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. .. Department This allows mechanical and process specialists to make the key cost decisions on what kind and how often maintenance should be accomplished at all affiliate plants by coupling it to an electronic data processing monitoring system This will serve as a management tool in evaluating conformance to the maintenance system Thus, the plant manager is made responsible for efficiently executing the PM . Title. 111. Series: Bloch, Heinz P., 1 933 Practical machinery management for process plants; v. 3. TJIS3.BS 83 1990 670‘ .28’8-d~20 90 -35 79 CIP ISBN 0-87201-781-8 Series ISBN. Geitner Practical Machinery Management tor Process Plants Volume 3, Second Edition Machinery Component Maintenance and Repair Gulf Publishing Company Houston. Texas Practical Machinery. SECOND EDITION Practical Machinery Management for Process Plants Volume 3 Turbomachinery Overhauls . Foundations and Repairs . Mechanical Seals . Machinery Components Grouting