Improving Machinery Reliability 3 Episode 16 pot

Pump Foundation Effects On Costs & Reliability Best Practices For Installation And Use Except For Better Pump Foundation Achieves 91% of Inherent System Life Better Pump Foundation Pra

Pump Foundation Effects On

Costs & Reliability

Best Practices For Installation And Use Except For Better Pump Foundation Achieves 91% of Inherent System Life

Better Pump Foundation Practices = 3.5 Pump System Mass

Pump Foundation Effects On

~~

suction 14" case

loss= 8,706 hours

Best Practices For Installation And Use Except For Good Pump Foundation Achieves 67% of Inherent System Life

Good Pump Foundation Practices = 0.5 Pump System Mass-Stilt Mounted

tJl

0

Foundation Effects On Costs &

u)

0

200% 150%

Foundation Effects On Component

- Best Practices = 5*mass

- Good Practices = 3.5*mass

- Inferior Practices = OS*mass

Grouting Of Pump

BasedFoundations

foundation monolithic to reduce vibrations

Poor grouting allows pump bases to have high

amplitude vibrations which destroy inherent

reliability and yield short MTTF

Good grouting attenuates vibrations and results in

long MTTF

Grouting of pumps to foundations require a void-

free, adhesive attachment between pump base and

concrete foundation with moisture-free materials

that will not crack or allow entrance of moisture

for long periods of time

.9

Grouting Effects On Costs &

Re I i a b i 1 i tv

suction ' 1c' case

Best Practices For Installation And Use Except For Better Grout Achieves 91% of Inherent System Life

Better Grout Practices = Slightly Porous But Adhesive

Grouting Effects On Costs &

suction 14" case

Best Practices For Installation And Use Except For Good Grout Achieves 69% of Inherent System Life

Good Grout Practices = Cementitious & Low Adhesion

Grouting Effects On Costs &

Grouting Effects On

Component Reliability

Impeller life Mtr Starter li

Mtr Winding life

I

Summary Of Best Practices

This is the highest grade for installation and use-little life is lost from these practices

These life results are from a pump survey conducted from expert sources from around the world

Loss Of Inherent Reliability- y f i t s u J = t e l G , f i l , ; r -

-

j each practice Find the lowest

' long-term cost of ownership ~

Best practices is the highest grade for installation and use-little system life is lost

All best practices are used simultaneously to achieve 98% of the inherent system life

rn

0

Summary Of Better Practices

Note the deteriorating effects of the lower grade for installation and use

These life results are from a pump survey conducted from expert sources from around the world

Loss Of I n he re nt Re1 i a b i I i ty -1 Frequently these costly, life

Better Practices consuming are used simultaneously , low-grade practices

Note the substantial loss of system life from the lower grade for installation and use

100 hp pump: 8 discharge * 1 0

suction * 14" case

All better practices are used simultaneously to achieve 60% of the inherent system life

Summary Of Good Practices

This lowest grade for installation and use results in the Ioss of substantial life!

Piping Rotational Foundation

Grouting

UD

Suction Straight Alignment Balance

Multiplier BEP

Design 0.5 Times k0.125 Rough at Equipment Cementitious

Loss Of Inherent Reliability- ,

I

practices used simultaneously Note that nearly all system life is lost from this lowest grade for installation and use

All good practices are used simultaneously to achieve only 4% of the inherent system life

b

3 3

L

F'

Pareto Distributions Of

Severity-I Grade Lower

Resulting System Life When All Practices Are Best

Except The Named Practice Is One Grade Lower (i.e., Better)

LID Intake Rotational Foundation Grout Pump Rotating Piping

Piping Alignment Curve BEP Balance Alignment

P

Pareto Distributions Of

Resulting System Life When All Practices Are Best

Except The Named Practice I Grades Lower (i.e., Good)

How To Correct Short MTTF

Increase equipment strength-larger inherent MTTF

Decrease equipment loads-use better practices to decrease loads or operate the equipment derated Mix and match loaddstrengths for cost effectiveness

- Use life cycle costs to decide loadhtrength mix and match strategy

- Use higher grade equipment/practices as found by life cycle costs

- Train engineering personnel to select and specify both equipment and installation practices, a n d operating practices which are cost effective

- Involve production personnel in maintenance problems to stop equipment abuses which increase loads and reduce life

- Train maintenance personnel to repair equipment correctly with a view toward correcting cost ineffective practices causing decreased reliability

Why Work On Reliability Issues?

Solving reliability problems solves cost problems

Set reliability goals as business items for cost reductions

Solving reliability problems requires new tools and

training to both predict and solve root causes of failures

Reliability problems are often people/procedure problems b

'tt

EL K'

!?

and teamwork helps solve the root cause of the problem

Use reliability engineers as strategic resources to prevent

failures while using maintenance engineers as tactical

failure restorers until problems are permanently resolved

Make reliability improvements pay their way by working

Analytical cost model, 289, 292

Anderson hub clamp, 223

Audits 272-3 10

centrifugal compressor, 125-1 35 independent, 119

machinery reliability, 82-238 steam turbine, 135-139 Automatic grease lubrication,

Autonomous maintenance,

Auxiliary systems, 24-33 Axial preloading, 156 Axial thrust, 194-198

5 17-525

366-367

Babbitt, 9 Back electromotive force, 3 16 Backlash values, 192-193 Balance, 6, 8 , 9

Bank of motor life, 3 17-3 18

Barrier fluid leakage, 572 Barrierbuffer fluid selection,

Bearing 546-549

clearance, 53,95-96 coefficients, 89-90, 104 contamination, 324,447-450

668

Better practices, 660-661 Bid

comparison, 53,74-75 conditioning, 78 requests, 68-69 tabulation, 75-80 372-373

Blowers, 266 Boundary lubricated gas and liquid

Break-even charts, 299,301, 302 Broadband measurements, 480,

Buffer fluid contamination, 576 Buffedbarrier fluid selection,

Cavitation erosion, 75 Centrifugal pump, 26, 39, 122-1 25, 146-155, 168-17 1, 176,266,356-358,421-429, 477-483

Centrifuge seal reliability, 574-575 Centrifuges, 573-574

Chocks, 461-463 Coalescers, 497-498 Compact gas seal technology, Behavioral training, 367 550-558

670 Machineiy Failure Analysis & Troubleshooting

barrier gas consumption, 553

Cost benefit ratios, 272

Cost justification methods, 272

non-lubricated, 45 1-457 non-lubricated metallic disc, 11,

reviewing, 454 spacers, 455 turbomachinery, 2 13 Crew concept, 256 Critical business issues (CBI),

Critical-dimension diagram, 44 Critical speed map, 86-88, 92-94 Cumulative fatigue theory, 114 Cupped oil flinger design, 164, 167

453-454

243-244

Depreciation calculation, 277,278 Depropanizer feed bottoms

Derating, 321 Derating factor, 185

Design appraisals exchanger, 4 1 1-4 12

shortcuts, 182-1 86 special purpose gearing, 181-200

Detecting abnormal parameters, 478-483

Diesel engines, 39 Digital control systems, 55-56, 57 Dimensional records, 3

Disassembly procedures, 44,46 Discount factors, 276

Index 671

Discounted cash flow (DCF), 278

Disposal costs, 297,299

Distributed seal flush, 530

Dodd Bar technique, 463

Downtime, 367

Dry gas compressor seals, 58 1-599

Dry-sump oil-mist lubrication,

See also motor

Electrical power analysis, 410

Equipment tabulation, 35 1, 352 Equivalent daily capacity, 250 Event log, 354

Excessive mist velocity, 444 Exhaust-temperature measurement

Expansion joints, 335-337 External contamination, 447-450

data, 267-269,304 frequencies, 261-263

of components, 417-418

of valve, 418-420 risk, 21-23 statistics, 83 centrifugal compressor,

centrifugal pump, 122-124 gas turbine, 121-122, 124 steam turbine, 120-121 Fan cooled bearing housings, 174 Fire system analysis, 41 1

Flashing hydrocarbon services, 528 Flexibility of pipe, 333-334 Flinger disks, 163, 164 Fluid flow circulation, 545-546 Forced non-synchronous instability, 106 Fretting, 213

119-120

672 Machinery Failure Analysis h Troubleshooting

Friction, 334

Full contract maintenance, 376

Full-fluid film gas and liquid

Fully crowned coupling tooth, 45 1

I

Impeller overspeed test, 20-21 single suction, 148 Impeller and blade response analyses, 1 14-1 16 In-house maintenance, 375-376 Income tax, 277-278

Increasing profits, 371-372 Independent maintenance,

Independent service contractor,

Indikon technique, 463 Interference diagram, 114 Inquiry document, 1

Instability vibrations, 106 Installation completeness checklists, 49-51 Instrumentation analysis, 409-4 10 Insulation classification, 3 15 Insulation systems, 3 14

Index 673

Lateral response analyses, 99-107

gear shaft, 100-104

liquid pump, 99

rotor stability analyses, 104-107

LJD suction straight run

Lean oil contact cooler, 413-414

Life cycle

effects, 632

calculation (governor

options), 262

total cost (LCC total), 261

Life cycle cost

Load distribution factor, 185

Locked rotor current by

piping alignment practice,

rotational alignment practice,

639-640

63 4-6 3 5

Lost gross margin, 297

Low-emission single seal design,

531-543

Lube oil coalescers, 497-498 contamination levels, 485-486 dewatering centrifuges, 495-497 filterddryers, 498

purification, 485-491 ~ 498-499 purification costs and

technologies, 49 1-503 water contamination, 486-491 specifying, example, 24-34 Lube system,

Lubricant viscosity, 436 Lubrication

automatic, 5 17-525 data, 46-48

effect on service life, 424 gear tooth, 45 1

grease, 446447,517-525 marginal, 160-1 68 mesh, 193

motor, 445-446 oil-mist, 440-450 pump failures, 160-168 seal, 56 1-562

synthetic, 503-515 See also

674 Machinery Failure Analysis & Troubleshooting

purpose, 82

rotordynamic design audits,

Machinery reliability reviews,

Machinery review checklist,

Machinery turnaround planning,

Main fractionator tower, 414

Material index numbers, 189

Mean-time between failure

clamping methods, 70-71 failure, 124

gas-lubricated, 75, 76 life expectancies, 266 selection, 67-68

260,261

638-642 344,394-399

Mechanical startup section, 344, 347,348

Mesh lubrication, 193 Metrics, 242-247 Mezzanine, 3 Minimum continuous stable flow Mixer seal reliability problems, Mixers, 568

Monte Carlo simulation Motor

(MCSF), 151-153 568-573

techniques, 307-3 10 ambient temperature, 3 15-3 17 bearings, 323-324

enclosures, 3 19

failure, 3 13

insulation classification, 3 15 insulation systems, 3 14-3 15 life, 3 13-328

life insurance, 328 mounting, 325 oversizing, 321-323

Net positive suction head (NPSH)

influence on service life, 146,

insufficient, solution to, 66

Net present value (NPV), 276,

On-stream lube oil purification,

Operational level maintenance

(OEM) maintenance,

3 7 9-3 7 9 Outage log sheet, 353 Overcurrent insurance, 327 Overhead tank, 30-32,34 Overload factor, 183, 184

Oversizing (motors), 321-323 Overtime, 468-469

Performance deterioration, 59,

Performance optimization, 61-62 Phase displacement technique, 57 Phosphate esters, 508

Pipe flexibility, 333-334 Pipe restraints, 334-335 Pipe stress, 329-338 Piping alignment, 638-642 Piping loads, 330-333 Poseidon pump, 177 Predictive maintenance, 373,

4 16-429 Preload, 156, 172 Pressure thrust force, 336 Pressurized barrier fluid, 549

Pressurized dual seal, 549-550

664-665

97-99

60-6 1

Polyglycols, SO8

676 Machinery Failicre Analysis & Troubleshooting

Process piping assessment, 408

Process plant machinery startup

preparations, 339-342

Procurement costs, 273

Proximity reference system, 463

Published failure data, 267-269

positive displacement, 26 reciprocating, 66

repair costs, 477 seal MTBF, 292 shaft MTBF, 292 single-stage high-speed, 66 Sulzer “Poseidon,” 177 tabulation, 349

upgrading, 27 1 vendor selection, 64-76 vertical deep-well, 66 zero emission, 178-181

characteristics, 618, 620 effects on component

practices, 62 1 responsibilities, 625

Pump curve

characteristic life, 627

Pump foundations, 648-652 Purge mist (wet sump) lubrication, 441-443

Reliability audits, 82-238 See

also Machinery reliability

Reliability reviews See a h

Machinery reliability reviews

Replacement asset base

Replacement asset value (RAV),

sensitivity to bearing clearance,

sensitivity to pedestal and

95-96

foundation flexibility, 97-99

sensitivity to unbalance location, 96-97

stability analyses, 104- B 07 Rotordynamic design audits, 83-125

impeller and blade analyses, lateral critical speed analyses, pulsation analyses, 117-1 19 torsional critical speed analyses, transient torsional analyses,

114-1 17 85-107

107-112 112-SI4

classification, 559, 560 design, 72, 99

dry gas, 581-599

elastomeric lip, 447 face deflections, 532-533

face materials, 535-536 face warpage, 569 face width, 534-535 flush arrangement, 537-540 gas lubricated, 55 1

geometry, 564-567 hermetic, 449

678 Machiizery Failure Analysis & Troubleshooting

vapor pressure margin, 540-542

Seal oil system, specifying, 24-34

Segmented carbon bushings,

Single flinger spool, 168

Single narrative document, 15,20

Society of Automotive Soderberg diagram, 204,205 Sommerfeld number, 88, 89 Spare parts

documentation, 363 Engineers, 273

effect on service factors, identification sheets, 46, 47,364

philosophies, 361 recommended, 362 storage and retrieval, 36 1, 363 Special lateral response analysis

See Lateral response analyse

Specialty seals, 565-581 Specification deviation, 34, 36 Spiral groove gas seal, 582-583 Standardization, 65,68

Startup 361-364

documentation, 348-360 preparations, 339-342 reporting structure, 344-348 responsibilities, 339-360 review tasks, 342-344 Strategic level maintenance measures, 245-248 Stress

alternating, 210-21 1 combined, 206,217 concentration factors, 206, 207,211

pipe, 329-338 torsional, 112, 113,207-208 uniaxial, 206

Tactical level maintenance

Tapered-bore coupling hubs,

critical speed analyses, 107-1 12 excitation, 110

holding, 214-217 natural frequencies, 107-109 stress calculations, 11 1 stresses, 112, 113,207-208 vibrations, 107

Total productive maintenance Total quality management (TQM),

Tracking sheets, 224-229 Trade-off studies, 287 Transducers, 478-479 Transient torsional analysis, Triplshutdown log, 355 Turbines

control systems, 55

efficiency calculation, 59 gas, 3 9 , 6 0 4 1 , 121-122, 124 governors, 55

performance deterioration, 59, steam, 45, 120-121, 135-139,

auxiliary systems, 24-33 control systems, 56

on-stream cleaning methods, 59 performance, 59

rotordynamics, 83 Turnaround documentation, 44-46

680 Machinery Failure Analysis & Troubleshooting

Turnaround management team,

Undamped mode shapes, 92-93

Undamped natural frequencies,

Vacuum oil purifiers, 49 1,

Vane passage frequency, 1 15

Vapor pressure margin, 529-530,

selection, 64-76 Vibration monitoring, 478433 Vibrations, 106

Viscosity selection, 440-441 Viscosit y-temperature

Volatile organic compounds

Watt loss equilibrium, 3 16 Weibull distributions for failures,

Wet sump oil-mist lubrication,

Work process documentation,

294,307-309

44 1-443

384-389