Machinery Component Maintenance P1

Practical Machinery Management tor Process Plants Volume 3, Second Edition Machinery Component... Practical Machinery Management for Process Plants Machinery Component Maintenance and

Grouting Alignment and Balancing Pump Shaft

Practical Machinery Management tor Process Plants

Volume 3, Second Edition

Machinery Component

Gulf Publishing Company

Houston Texas

Practical Machinery Management for Process Plants

Machinery Component

Maintenance and Repair

Heinz P Bloch and Fred K Geitner

This edition was reviewed by the authors and reprinted in 1999

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

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 1 2

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-

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

Foreword

A machinery engineer’s job was accurately described by this ad, which ap-

Personable, well-educated, literate individual with college

degree in any form of engineering or physics to work Job re-

quires wide knowledge and experience in physical sciences, mate-

rials, construction techniques, mathematics and drafting Compe-

tence in the use of spoken and written English is required Must be

willing to suffer personal indignities from clients, professional de-

rision from peers in more conventional jobs, and slanderous in-

sults from colleagues

Job involves frequent physical danger, trips to inaccessible loca-

tions throughout the world, manual labor and extreme frustration

from lack of data on which to base decisions

Applicant must be willing to risk personal and professional fu-

ture on decisions based on inadequate information and complete

lack of control over acceptance of recommendations

peared in the classified section of the New York Times on January 2, 1972:

Well, that was in 1972 Since then, however, the job has not become any sim-

pler The cost of machinery outages and repairs has escalated The prerequisites required to be able to perform as a machinery engineer could even be expanded thus:

A knowledge of stress analysis, measurement techniques, in-

strumentation, vibration analysis, materials, machine shop proce-

dures, fluid flow, rotor dynamics, machinery field erection and

startup procedures, and an understanding of effective maintenance

management

This list is by no means complete And since very few of us feel absolute mas- ter of all of these areas, we seek guidelines, procedures, and techniques that have worked for our colleagues elsewhere Collecting these guidelines for every machinery category, size, type, or model would be almost impossible, and the resulting encyclopedia would be voluminous and outrageously expensive Therefore, the only reasonable course of action has been to be selective and as- semble the most important, most frequently misapplied or perhaps even some of the most cost-effective maintenance, repair, installation, and field verification procedures needed by machinery engineers serving the refining and petrochemi- cal process industries

This is what my colleagues, Heinz P Bloch and Fred K Geitner, have suc- ceeded in doing Volume 3 of this series on machinery management brings us the know-how of some of the most knowledgeable individuals in the field Engi- neers and supervisors concerned with machinery and component selection, in- stallation, 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 or installations in his particular plant environment

Uri Sela Walnut Creek, California

viii

Acknowledgments

It would have been quite impossible to write this text without the help and cooper- ation of many colleagues and friends When we explained our intention to follow up

on Wumes 1 and 2 of this series by assembling pertinent material for hlumes 3 and

4, we struck a responsive chord with professionals who shared our goal of providing

a practical reference text on the subject 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 Scha-

rle (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), M G Murray (Grouting Checklists, Machinery Alignment), C C Fletcher (Machinery Align- ment, Installation, Checkout), Pruekhnik Dieter Busch (Laser Alignment) €? C

M o m (Machinery Installation Checklists), J W Dufour (Machinery Installation Guidelines), W Schmidt (Piping Connection Guidelines), D C Stadelbauer, Schenk Trebel Corporation (Balancing of Machinery Components), MRC Division

of SKF Industries (Bearing Installation and Maintenance), Bill Carpenter, Durame-

t a l k Corporation (Metallic Seal Installation, Repair, Maintenance), H A Scheller (Pump Packages) T Doody (Welded Repairs to Pump Shafts etc.) H A Erb (Re- pair 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 Compounds etc.), M CalistratfKoppers Company (Mounting Hydraulically Fitted Hubs), C R McKinsey and K G Budinski (Hard Surfacing), C R Cooper, h Der Horst Cor- poration (Chrome Plating), Tbrbine Metal Bchnology (Diffusion Alloys) and Na- tional 0-Ring Company (0-Ring Selection and Application)

Three highly qualified machinery engineers D L E Jacobs, W A Clark and Dino Troisi, took care of the appropriate Exxon Chemicals manuscript re- views; their efforts were sincerely appreciated as, of course were those of our close personal friend Uri Sela who devoted so much of his personal time to a detailed review of the entire draft, galleys, and page proofs Uri counseled us on technical relevance spelling, 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 through judicious use of outside contacts, participation in relevant activities of technical societies, and publication of pertinent material we can be sure that our technical productivity will continue to improve The technical per- son will thus be updated on the availability of “state-of-the-art” tools and indi- vidual creativity encouraged

With these sentiments, which so fittingly express our thoughts we conclude

by thanking Exxon Chemical Company for permitting us to tackle this challeng-

ix

ing task on our own It certainly accomplished for us what it is to 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 tapped- will bring benefits to everyone

Preventive

Predictive

Breakdown or demand based

0 “Bad actor” or weak spot management

Machinery maintenance can often be quite costly in a petrochemical

plant operation Prior to the the publication of the first two volumes of this series very few studies were available describing quantitative or ob- jective methods for arriving at the optimization of the four strategies’ Though our readers should not expect detailed contributions to those sub- jects in this volume, we did opt to include an overview section describing the maintenance philosophy practiced in a large multi-plant corporation which makes effective use of centralized staff and computerized planning and tracking methods

What, then, can our readers expect? After a short definition of the ma- chinery maintenance problem we will highlight centralized maintenance planning We will then guide our readers through the world of machinery maintenance procedures by identifying the What, When, Where, 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 pic- ture?

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 il- lustrates this concept Consequently, machinery maintenance cannot be

looked at in isolation It will have to be governed by equipment failure

experience, by our effectiveness in failure analysis and troubleshooting', and by built-in reliability3

Maintenance in a broad definition is concerned with controlling the

condition of equipment Figure 1-2 is a classification of most machinery

maintenance problems

Deterministic or predictive component life problems are those where

no uncertainty is associated with the timing or consequence of the main- tenance action For example, we may have equipment whose components

are not subject to actual failure but whose operating cost increases with time A good illustration would be labyrinths in a centrifugal process compressor To reduce operating cost caused by increasing leakage rate, some form of maintenance work can be done-usually in the form of r e

- inspection 8 Failure Analysis - inspection 8 Failure Analysis

- Inspection (On10ftLine) - Repair - Weak Spot identification 3

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 il- lustrated in Figure 1-3

In probabilistic or indeterminate component life problems, the timing and result of maintenance may depend on chance In the simplest situa- tion a piece of machinery can be described as being “good” or “failed.” From a frequency distribution of the time elapsed between maintenance activity and failure it is possible to determine the variations in the proba- bility of failure with elapsed time These relationships are thoroughly dealt with in Reference 1

Wi: saw from Figure 1-2 that inspection, overhaul, repair and finally

replacement are common to all maintenance strategies The basic pur- pose of inspection is to determine the condition of our equipment All machinery inspection should be based on these considerations:

1 Expected failure experience:

Deterministic

Probabilistic

2 Inspection cost

3 Probability and risk of failure

4 Probable consequences of failure, Le., safety-health, and business

5 The risk that inspection will cuuse a problem4

6 The quality of on-stream condition monitoring results

loss

Figure 1-3 Deterministic trend in costs

Machinery Maintenance: An Overview 7

The terms overhaul and repair are often reserved for maintenance ac-

tions that improve the conditions of an item, but may or may not establish

“good as new” condition In fact, overhaul is often interpreted as a pre- ventive maintenance action while repair is strictly reserved for mainte-

nance 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 or-

ganizational srrucrure problems in machinery maintenance as those con-

cerns that deal with maintainability parameters such as facilities, man- power, training, and tools Figure 1 4 illustrates this point

Most petrochemical process plants have a preventive maintenance (PM) system The authors know of a plant where 95 96 of the maintenance

work orders are turned in by the PM crews and not the operators While this is an extreme-and probably not a very cost effective-way of fail- ure fighting, we can support a moderate approach to machinery PM This moderate approach begins with an attempt to plan all PM actions by following this pattern:

1 Determine what defect, failure, or deterioration mode’ it is you want to prevent from occurring

2 Determine whether the defect, failure, or deterioration mode can be prevented by periodic actions If not, determine how it can be pre-

WINTAINABILITY

MAXIMIZE OWOFF-LINE MTC ACCESSIBILITY MINIMIZE

-

ON-LINE INSPEC CLEANING (SERYICIBILITY)

ON-LIHE CONDITION/ ECONOllICALLV f44XIMIZE

INSURAHCE SPARE PARTS

Figure 1-4 Process machinery maintainability components