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SECOND EDITION Practical Machinery Management for Process Plants Volume 4 Maintenance and Repair... SECOND EDITION Practical Machinery Management for Process Plants Volume 4 Major Pr

SECOND EDITION Practical Machinery Management for Process Plants

Volume 4

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

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

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 n r b i n e 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

13 Vibration and Condition Monitoring .621

Vibration Measurement-Basic Parameters for Predictive

Maintenance on Rotating Machinery Position Measurements

Other Parameters Transducer Types Proximity Probe Velocity

Pickups Accelerometers Generalized Monitoring Recommenda-

tions for Specific Machine Types Steam Turbines Gas Turbines

Hydro-Electric Turbines Electric Motors Compressors Genera-

tors Pumps Gears Fans Centrifuges Pulp Refiners Minimizing

Electrical Runout During Rotor Manufacturing Principles of

Condition Monitoring of Machinery Definition and Objective of

Machinery Condition Monitoring Data Acquisition Unit Period-

“Oiir best thoughts coinefi.oiii or1iei.s”

-Ralph Waldo Enieisori

As in the preceding volumes of our four-part series of books on process machin- ery management we had to depend on the expert input of many individuals and com- pmies to compile this material We extend our thanks and appreciation to these able collaborators and contributors to Volume 4:

Union Pump Company Canada (Horizontal Centrifugal Pumps)

Terry L Henshaw (.Reciprocating Pumps)

Pacific Pumps-Dresser (Centrifugal Pumpsj

Goulds Pumps, Inc (Centrifugal Pumps)

Byron Jackson Pump Division (Vertical Pumps)

John W Dufour (Machinery Installation Guidelines)

Perry C Monroe (Rotating Equipment Checklists)

J.V Picknell and Nash Engineering Co (Liquid Ring Vacuum Pumps)

SIHI (Liquid Ring Vacuum Pumps)

Henry Y Hung and M-D Pneumatics Inc (Positive Displacement Rotary Blowers) Canadian B l o w e r x a n a d a Pumps Ltd (Large Fan Blowers)

Mixing Equipment Co., Inc (Mixers and Agitators)

Cooper Energy Services (Reciprocating Compressors and Gas Engines)

James R Partridge (Lufkin Industries-Power Transmission Gears)

T B Woods Company (V-Belt Drives)

Westinghouse Canada, Inc (Special Purpose Steam Turbines)

S W Mazlack (Break-In of Steam Turbine Carbon Ring Seals)

Elliott Company (General Purpose Steam Turbines j

Rotoflow Corporation (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 for the Electrical Apparatus Sales and Service Industry)

A M Clapp (Lubrication Concepts, Training, Application Methods)

P E Knoeller-Exxon Company USA (Oil Mist, Greases)

Bently-Nevada (Vibration Measurement)

J S Mitchell and J L Frarey (Machinery Condition Monitoring)

H Ambros and Priiftechnik Dieter Busch AG (Machinery Monitoring)

Again, we thank our experienced colleague and friend Uri Sela for unselfishly giving of his personal time to review and improve our work Bill Clark, Sig Zierau, Greg Piegari and especially Art Parente deserve our gratitude for manuscript screen- ing and support in securing Exxon Chemical Company approval to publish As always, we are indebted to our editor, Brad Sagstetter, for his help in getting it all together

Heins P Bloch

Fred K Geitner

Foreword

The readers of the four volumes on “Machinery Management” can be di-

- those who can say: That’s exactly what happened to me back in 19 !

- those who can say: Why didn’t I know this back in 19 ?!

- those who can say: I hope I’ll remember all this when I am in charge!

In other words, those with a lot, a little, and no experience stand to benefit from studying these four volumes Maybe some of the people with a lot of expe- rience could find other ways to solve a particular case, but even they cannot match the knowledge and experience that the authors amassed in these books

In the past, many a good Machinery Manager was “made” through many years of experience, and also through many costly mistakes These “experts” passed on their experience to the people they worked with, but seldom could experience gained in one particular location prepare someone for the multitude

of things that can go wrong It is because of this that the authors must be com- mended for their effort to disseminate not only their experience, but also the lessons they learned from many other experts

Volume 4 complements the first three books by focusing on major equipment installation and repair-foundations, pumps, blowers, turbines, electric motors, and lubrication and storage These four volumes contain a wealth of information

on machinery found in most petrochemical plants, and in their quest for perfec- tion, three principal groups will benefit from this text: Those who design ma-

chinery, those who maintain machinery, and those who operate machinery

As a manufacturer of machinery, I realize that only knowledgeable people can fully utilize our efforts to make the best machines, to give guidelines on how to optimally maintain these machines, and finally how to best operate these ma- chines Used in conjunction with the preceding three volumes or used alone, this book will make the reader a knowledgeable person

vided, in my opinion, into three categories:

Michael M Calistrar Missouri City’ TX

xi

Part I

Chapter 1

Installation, Malntenance, and

The most common centrifugal pump in the petrochemical industry is the horizontal single stage process pump This pump has many different external designs Perhaps the most common is the end suction top dis-

There are many features about this pump that make it adaptable for most applications Designs can be small and inexpensive, or they can

be designs that meet API 601" standards as well as with ANSI**

specifications The top centerline discharge provides excellent stability when subjected to piping stresses and high temperatures Larger pump models incorporate a double volute internal passageway that helps to bal- ance radial loading on the impeller This pump design has a vertical ra- dial split casing with centerline supports and an overhung impeller mounted on a shaft supported by bearings By changing impeller designs this pump can be adapted to all kinds of product applications from light hydrocarbons to slurries

ANSI pumps differ from API* designs as follows: They are chemical

ANSI pumps (Figure 1-2) are generally supplied with open impellers Temperatures are usually limited to 300°F and pressures to 300 psi maximum, depending on the material and flange type Capacity ranges

pellers Often stainless steel is used together with 316 stainless steel shaft

* API = American Petroleum Institute

** ANSI = 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 normally have 150 lb raised face flanges

Mechanical seals provided in ANSI pumps are normally unbalanced, single inside, but single outside seals are also quite common Face mate- rials are often carbon versus ceramic or tungsten carbide Other materi- als can be substituted where applicable Seal flush is usually configured

as recirculation from pump discharge

Motors: TEFC (totally enclosed fan cooled) 460 volt (560 in Canada), three phase at 60 Hertz are standard drivers for North American applica- tions

Base Plates: Normally fabricated from steel plate with smaller base plates cast Pump and motor are mounted on the base plate and connected with a coupling For maintenance and repair work the coupling will have

to be removed and the pump internals can be removed from the pump case without disturbing the piping

ANSI vertical in-line pumps are made in three basic designs: Style “A”

is identified by the rigid spacer coupling which connects the pump stub shaft to the motor shaft This design allows pump mechanical 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 re-

moved without disturbing motor and pip

ing (Courtesy Union Pump (Canada)

Ltd.)