I HlHU tUI I IU m Pral II I VOLUME 1 I I I ffl I- Practical Machinery Management for Process Plants VOLUME d THIRD EDITION Improving Machinery Practical Machinery Management for Process Plants: Volume 1: Improving Machinery Reliability, 3rd edition Volume 2: Machinery Failure Analysis and Troubleshooting, 3rd edition Volume 3: Machinery Component Maintenance and Repair, 2nd edition Volume 4: Major Process Equipment Maintenance and Repair, 2nd edition Other Machinery Engineering Texts from the Same Author: Introduction to Machinery Reliability Assessment, 2nd edition Reciprocating Compressors: Operation and Maintenance I Practical Machinery Management for Process Plants I Improving Machinery Reliability Heinz P. Bloch Gulf Professional Publishing is an imprint of Elsevier Science Copyright 0 1982, 1988, 1998 by Elsevier Science (USA). All rights reserved. Originally published by Gulf Publishing Company, Houston, TX. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any fonn or by any means, electronic, mechanical, photocopying, recorchng, or otherwise, without the prior written permission of the publisher. Permissions may be sought directly from Elsevier’s Science & Technology Rights Department in Oxford, UK: phone: (+44) 1865 843830, fax: (+44) 1865 853333, e-mail: pennissions@elsevier.co.uk. You may also complete your request on-line via the Elsevier Science hoinepage (http://mw.elsevier.com), by selecting ‘Customer Support’ and then This book is printed on acid-free paper. ~ ‘Obtaining Permissions’. Library of Congress Cataloging-in-Publication Data Bloch, Heinz P., 1933- Improving machinery reliability / Heinz P. Bloch. - 3‘d ed. Includes bibliographical references and index. p. cm. -(Practical machinery management for process plants; v. 1) ISBN 0-88415-661-3 (alk. paper) 1. Machinery-Reliability. I. Title. II. Series: Bloch, He& P., 1933- Practical machinery management for process plants. 31d ed. ; v. 1. TJ153.B58 1998 621.8’1-dc21 98-26184 CP The publisher offers special discounts on bulk orders of this book. For information, please contact: Manager of Special Sales Elsevier Science 200 Wheeler Road Burlington, MA 01803 Tel: 781-313-4700 Fax: 781-313-4802 For information on all Gulf publications available, contact our World Wide Web homepage at http://www.bh.com/gulf 10 9 8 7 6 5 4 3 2 Printed in the United States of America. Contents Preface x Introduction xx 1 Requirements Specification 1 Industry Standards Available for Major Machinery in Process Plants, 1; How to Deal with the Typical API Data Sheet, 2; Narrative Specifications Lead to Better Machinery, 15; Considering Uprateability and Low Failure Risk, 21; Auxiliary Systems for Turbomachinery: The Systematic Approach, 24; Dealing with Deviations from the Specification, 34; Specifying Machinery Documentation Requirements, 37; Conclusion, 5 1 2 Vendor Selection and Bid Conditioning 53 Selecting Major Machinery Vendors, 53; Applying and Reviewing Machinery Reliability Improvements Derived from Modern Electronics, 54; Selecting a Pump Vendor, 64; Bid Tabulation and Bid Conditioning: An Overview, 76; Reference, 8 1 Audits Versus Reviews, 82; Where to Concentrate Audit and Review Efforts, 82; Rotordynamic Design Audits, 83; Auditing and Reviewing Centrifugal Compressors, 125; Auditing and Reviewing Steam Turbines, 135; Evaluating Major Reciprocating Compressors, 139; Reliability Review for Centrifugal Pumps, 146; Significant Differences in Bearings and Bearing Housings, 156; Marginal Lubrication: A Factor in Pump Failures, 160; Applying Roller Bearings in Centrifugal Pumps, 168; How Much Oil Is Enough?, 171; Bearing Selection Can Make a Difference, 172; Air Cooling Provisions for Bearing Housing-How Good? 173; Stuffing Box Cooling Is Not Usually Effective, 174; Pumps for Handling Entrained Gases, 176; Selection Criteria for Zero Emission Pumps, 178; Design Appraisals for Special-Purpose Gearing, 18 1; Evaluating Cooling Tower Fans and Their Drive Systems, 200; Reliability Reviews in Uprate Situations, 203; Reliable Shaft-Hub Connections for Turbomachinery Couplings, 213; How to Keep Track of Reliability Review Tasks, 224; Machinery Reliability Audits for Existing Plants, 224; References, 238 3 Machinery Reliability Audits and Reviews 82 V 4 Maintenance and Benchmarking Reliability . . . . . . . . 242 Maintenance Measurement, 242; Organize to Manage Reliability, 249; Maintenance Cost vs. Replacement Asset Value: Another Maintenance Spending Benchmark, 257 5 Life Cycle Cost Studies . . . . . . . . . . . . . , . . . . . . . . . . .259 Simplified Life Cycle Cost Estimating, 259; Life Cycle Cost Assessment: The Rigorous Method, 272; Summary, 3 10; References, 3 10 6 Extending Motor Life in the Process Plant Environment . , . . . . . . . . . . . . . . . , . . . . . . . . . . ,313 Squirrel-cage Motors Are Most Prevalent, 3 14; Motor Insulation Systems, 3 14; Insulation Classification, 3 15; Ambient Plus, 3 15; A Bank of Motor Life, 3 17; Running Cooler-A Relative Term, 3 18; Thermal Cushion, 3 19; Enclosures, 3 19; Standard, but Different, 3 19; Learning from Failures, 320; More about Thermal Loading, 320; Economics of Oversizing, 321; Keep Bearings in Mind, 323; Motor Mounting Basics, 325; Motor System Tuneup, 326; Pumping and Piping, 326; Power Points, 326; Over-Current Insurance, 327; Motor Life Insurance Terms, 328; Notes, 328 7 Equipment Reliability Improvement through Reduced Pipestress . . . . . . . , . . . , . . . . . , m . . . . . ,329 Allowable Load, 33 1 ; Excessive Flexibility, 333; Theoretical Restraints, 334; Expansion Joints, 335; Other Practical Considerations, 337; References, 338 8 Startup Responsibilities . . . . . m . . . . . . . . . . . . . . . . .339 Summary of Startup Preparations for Process Plant Machinery, 339; Machinery Startup Review Tasks, 342; Machinery Startup Reporting Structure, 344; Documentation for Effective Tracking of Progress, 348; Vendor Assistance and Outside Facilities, 359; Consultants and Contract Assistance. 359 9 Spare Parts and Their Effect on Service Factors . . . . 361 Spare Parts Philosophies, 361; Spare Parts Storage and Retrieval, 361 ; Spare Parts Documentation, 363 10 Maintenance for Continued Reliability . . . . . , . . . . . . . 365 Modern Maintenance Approaches and when to Apply Them, 365; Maintenance Management Options, 374; Detailed Task Descriptions vi Improve Maintenance Effectiveness, 380; Machinery Turnaround Planning, 394; Turnaround Scope Development through Reliability, Availability, and Maintainability Analysis, 401 ; Effective Maintenance: Preventive or Predictive?, 41 6; Preventive Versus Predictive Maintenance for Typical Centrifugal Pumps, 421; How to Be a Better Maintenance Engineer, 429; The Role of the Maintenance Engineer in the Knowledge Age, 43 I; References, 432 11 Maintenance Cost Reduction .434 Eliminating Cooling Water from General-Purpose Pumps and Drivers, 434; Economics of Dry-Sump Oil-Mist Lubrication for Anti-friction Bearings, 440; Gear Couplings Versus Non-lubricated Couplings, 45 1 ; Elastomeric Couplings, 457; Quantifying the Reliability Impact of Laser Alignment Techniques, 461 ; Quantifying Impact, 470; Why and How to Monitor Centrifugal Pump Condition, 477; References, 483 12 Lubrication and Reliability .485 Methods and Criteria for Lube-Oil Purification, 485; Cost Justification and Latest Technology for the On-Stream Purification of Turbomachinery Lube Oil, 49 1 ; Synthetic Lubricants and Reliability Improvement, 503; Vibration Performance Improved with Synthetics, 5 15; Automatic Grease Lubrication as a Reliability Improvement Strategy, 517; References, 525 13 Providing Safety and Reliability through Modern Sealing Technology ,527 API Standard 682,528; Low-Emission Single Seal Design, 531; Dual Seal Arrangements, 543; Compact Gas Seal Technology for Pumps, 550; The Reliability Impact of Special Seals for Non-Pump Applications, 558; Specialty Seals for Non-Pump Applications, 565; Dry Gas Compressor Seals, 58 1; Warding off Equipment Reliability Setbacks: A Postscript, 593; References, 598 AppendixA 600 Useful and Interesting Statistics AppendixH .609 Common Sense Reliability Models Index 668 vii [...]... debated at the highest levels of management, business forecasts are studied, and thousands of questions are asked and answered before the machinery engineer is given his first opportunity to prepare an inquiry document for major machinery or detailed purchase specification packages for all the machinery in a process plant To the superficial observer, the job of specifying machinery would seem rather routine... required action and recommendations for both Operating and repair action^.^ The timing and length of an optimized production outage, spare parts and personnel requirements are constructed from this information e Benchmark measures such as mean-time-between-repair (MTBR) and availability are valuable management information Information required for executive and financial management includes cost-perunit... should not have to perform manual data gathering The days when time was available to compile information from multiple sources and correlate it manually for management reports is long past Reports must be self-generating, or at least all information must be available for report generation The traditional method of displaying measurements must be improved Begin with a definition of information-it must be... and providing time, materials, and cost information are vital functions of computerized management and information systems Technology is indispensable for condition assessment and for clearly conveying equipment status to operators, maintenance, and production planners Technology also plays a vital role in assembling and communicating planning and performance information, value and benefits to senior... design for reliability and maintainability require best-practice installation identify and correct root-cause deficiencies eliminate chronic problems invest for continuing, value-directed, permanent improvements create value-oriented measures of performance conduct continuing workforce training monitor and test to verify condition and assess and measure results report value gained to senior management. .. interpreted condition information Refined, easily interpreted, actionable information to operations/production planning and maintenance management systems is equally important Contrasted with operators, these users need predictive condition-assessment information for medium and long-term planning Will production assets be available to meet future contractual commitments? The information required includes... sealing technology; John s Mitchell for his always authoritative and equally compelling summary of the direction in which maintenance efforts must be channelled in the twenty-first century; L C Peng for his contribution on pipe stress issues; Jean Revelt (Lincoln Electric) for neatly explaining important reliability aspects of electric motors; R Ricketts (Solomon Associates) for shedding considerable light... benchmarking; and to Paul Smith for his observations on the “knowledge worker” who is certain to be needed to deal with reliability issues from this day on Their contributions and those of others whose personal and/or company names are mentioned in footnotes and captions are gratefully acknowledged Heinz P Bloch, I? E ix Introduction The View of an Advocate for Change* Machinery reliability management in the process... measurements into an easily interpretable form.8 xx Information Exchange This is a vital issue There are three basic alternatives for information exchange Many large corporations implement single-supplier, facility-wide information systems that include accounting, financial, personnel, operations, and maintenance Others accomplish a custom integration to connect information components and practices currently... numerous advantages for enterprise information systems Users can select components that are best for their specific application with assurance of full information exchange System components and information can migrate to best-practice improvements at least cost as experience and technology increase The personal computer model is instructive Low-cost word processing, ready exchange of information between . Practical Machinery Management for Process Plants VOLUME d THIRD EDITION Improving Machinery Practical Machinery Management for Process Plants: Volume 1: Improving Machinery Reliability, . Heinz P., 1933- Improving machinery reliability / Heinz P. Bloch. - 3‘d ed. Includes bibliographical references and index. p. cm. - (Practical machinery management for process plants;. 1) ISBN 0-88415-661-3 (alk. paper) 1. Machinery- Reliability. I. Title. II. Series: Bloch, He& P., 1933- Practical machinery management for process plants. 31d ed. ; v. 1. TJ153.B58