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Forsthoffer’sProven GuidelinesforRotating WilliamE.Forsthoffer
Butterworth-HeinemannisanimprintofElsevier
TheBoulevard,LangfordLane,Kidlington,OxfordOX51GB,UnitedKingdom 50HampshireStreet,5thFloor,Cambridge,MA02139,UnitedStates
Copyright©2022WEForsthoffer.ElsevierInc.Allrightsreserved.
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ThisbookandtheindividualcontributionscontainedinitareprotectedundercopyrightbythePublisher (otherthanasmaybenotedherein).
Notices
Knowledgeandbestpracticeinthisfieldareconstantlychanging.Asnewresearchandexperiencebroadenour understanding,changesinresearchmethods,professionalpractices,ormedicaltreatmentmaybecome necessary.
Practitionersandresearchersmustalwaysrelyontheirownexperienceandknowledgeinevaluatingandusing anyinformation,methods,compounds,orexperimentsdescribedherein.Inusingsuchinformationormethods theyshouldbemindfuloftheirownsafetyandthesafetyofothers,includingpartiesforwhomtheyhavea professionalresponsibility.
Tothefullestextentofthelaw,neitherthePublishernortheauthors,contributors,oreditors,assumeanyliability foranyinjuryand/ordamagetopersonsorpropertyasamatterofproductsliability,negligenceorotherwise,or fromanyuseoroperationofanymethods,products,instructions,orideascontainedinthematerialherein.
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Dedication TomygrandsonBenjaminLeeForsthofferwhoselikesareTheatreOrgan,Piano,andSTEMandhasassistedmewith thisbook
Acknowledgments Thematerialandguidelinescontainedinthisbookaretheresult ofover55yearsofinteractionswithmanydedicatedoperators, millwrights,I&Es,engineers,andmentorsfromendusers,contractors,andmachineryvendors.Foreachchapterofthisbook, IhaveconsultedindustryexpertsIhaveknowntoreviewthe chapteroutlinestoassurethetopicsandguidelinesareespeciallysuitedforentrylevel,midlevelpersonnelandtheirsupervisorsconsideringthepresentplantandindustryenvironment.
IwanttosincerelythankDanHunt,TedPrinciotto,andSab Ribeirowhocontributedtothiscause.
Lastbutcertainlynotleast,mycareerwouldnothavebeen possiblewithoutthesupport,encouragement,andassistance frommywifeDorisof51yearsandourchildrenJennifer,Brian, Eric,Michael,andDara.Aspecialnoteofthankstomyson MichaelandgrandsonBenwhohelpedwiththematerialin thisbook.
Overthelast59yearsinthepositionofarotatingmachinery designer,enduser,andconsultant,Billhashadtheopportunity tobeinvolvedwithalltypesofrotatingmachinery:pumps,compressors,gears,mixers,extruders,meltpumps,steamturbines, gasturbines,centrifuges,spindryers,andtheirassociatedcomponents(rotors,bearings,seals,andsupportsystems).
InvolvementconsistedoftotalcomponentandsystemcentrifugalcompressordesignforDeLaval(Siemens),for
AbouttheAuthor ExxonMobil:Specificationwriting,selectionofalltypesof rotatingequipmentforallmajorvendors,designaudits,shop testing,start-upandtroubleshootingforallmajorgasprocessing chemicalandrefiningcompaniesworldwide.
Theaboveworkscopehascontinuedfrom1990atForsthoffer AssociatesInc.(“FAI”).Thisbackgroundhasresultedinalotof rotatingmachineryDo’sandDon’tsandmanyofthemlearned thehardway!
TheeffectiveuseofthisbookandespeciallyineBookformat willallowyoutoquicklyandoftencontributecost-effective safe,environmentalandreliabilityrecommendationstoyour respectivecompany.Tousethisbookinthemosteffective manner:
•Gototheselectedchapterandconsultthekeyfact topicindex
•Eachtopicisarrangedinthefollowingformat: TheKeyFactstoaddresstheissueinclearand conciseterms
KeyFactAwarenessinformationtoenablethereaderto obtaindetailedinformationforprompt,accurate,and
HowtousethisBook cost-effectiverecommendationsforoptimumsafety, environmentalcontrol,andreliability
Keyfactwebsitesthatprovideusefulinformation
SeetheKeyFactWebsiteQRindexfordirectaccessto websites.
Itisrecommendedthatyoureviewthecontentin Chapters1 through3 firstbeforegoingtotheindividualmachinerytype, componenttypes,andreliabilitychapters.Thisapproachwill establishanawarenessandprocedurebaselinethatcanbeused effectivelywhendealingwiththemachineryspecificdetailsand workingwithyourplantmanagement,contractors,andmachineryvendors.
1.AssessmentandImprovementofYourRotating MachineryKnowledgeBase..... ...............1
1.1WhatKnowledgeDoINeedtoExcelasa MachinerySpecialist?.. .....................2
1.2WorkingWithYourAssociatesandImmediate Supervisor. ...............................4
1.3HowDoIEffectivelyBuildMyKnowledge Base? ...................................5
1.4WhatSpecificationsShouldILocateand Review?.. ...............................5
1.5WhatMachineryBooksConstituteanEffective PublishedKnowledgeBase?.. ................6
1.6HowDoIKeepCurrentWithMyKnowledge Base? ...................................6
1.7HowtoUseThisBookEffectively?.. ...........7
1.8TheVitalImportanceofCrossDiscipline Knowledge ...............................7
1.9TheImportanceofUnderstandingandUsing PFDsP&IDs ...............................8
1.10HowtoUseYourMachineryCalculation ToolboxEffectively ........................10
1.11HowtoAssureThatParameterTrendsAre Accurate.. ..............................12
1.12DoestheConclusionMakeSense?.. ..........13
1.13GetuptoSpeedonNonincendiveWireless MachineryMonitoringInstrumentation ..........13
1.14AskforProjectAssignments.. ...............14
1.15ParticipateinTurnarounds ...................14
2.AssessmentofRotatingMachineryCondition onSite.............. ......................17
2.1RotatingMachineryAssessmentMethods.. .....18
2.2RotatingMachineryConditionMonitoring Methods.. ..............................21
2.3RotatingMachineryVibrationBasics. ..........25
2.4HowtoDefineandIdentifyaMachinery BadActor. ..............................31
2.5IstheBadActoraMachineryType,an Application,orComponentType?... ..........31
2.6MinimizeBadActorRCFAs(RootCauseFailure Analysis)byMonitoringConditionChange BeforeFailure... .........................32
2.7ObtainingKeyBadActorObjectiveFacts.. .....32
2.8HowtoDefineKeyTrendingComponent ConditionParameters.. ....................33
2.9HowtoObtainBadActorCostsandRemedial Savings... ..............................34
2.10HowtoDraftaCost-EffectiveRemedialActionPlan..35
2.11SettingupBadActorPostRemedialCondition Monitoring... ............................35
2.12KeepingManagementInformedofBadActor ConditionChanges. .......................35
3.EliminatingandCorrectingBadActorCostly Safety,EnvironmentalandReliabilityIssues......39
3.1WhatIstheCategoryoftheBadActorCause?...40
3.2IdentifyingandCorrectingProcessChangeand SystemChangeIssues... ..................40
3.3IdentifyingandCorrectingInstallationIssues.....44
3.4IdentifyingandCorrectingOperatingProcedure Issues. .................................46
3.5IdentifyingandCorrectingDesignor ManufacturingIssues .......................46
3.6IsaMachineryRevamp/RerateRequired? .......51
3.7IsaMachineryReplacementRequired?. ........51
3.8EffectiveBidTabulationsforMinimumProject TimeandLifeCycleCost.. ..................54
3.9TheImportanceofthePreawardMeeting .......55
3.10EffectiveVendorCoordinationMeetings (VCMs)Guidelines.. .......................55
3.11EffectiveProjectDocumentReview ............57
3.12AssuringanEffectiveFAT(FactoryAcceptance Test)Program ............................58
4.PumpKeySafety,EnvironmentalandReliability Issues......... ...........................61
4.1UnderstandingPumpTypesand Characteristics ...........................62
4.2UnderstandingthePumpUnit... .............63
4.3CentrifugalPumpTypes.. ..................63
4.4CentrifugalPumpCharacteristics. .............69
4.5PositiveDisplacementPumpTypes ............73
4.6PositiveDisplacementPumpCharacteristics.....75
4.7WhentoUseCentrifugalPumps. .............77
4.8WhentoUsePositiveDisplacementPumps......78
4.9UnderstandingtheConceptofPumpHead (Energy) .................................80
4.10CentrifugalPumpCurves.. ..................84
4.11PumpHydraulicDisturbances... .............85
4.12EROE(EquipmentReliabilityOperating Envelope)GuidelinesforCentrifugalPumps......89
4.13PreselectingPumps .......................91
4.14AccuratelyDefineAllLiquidandHydraulic ConditionsthePumpWillExperience.. ........92
4.15NPSHa,NPSHr,RecirculationandVaporization Guidelines. ..............................94
4.16PumpControlandProtectionGuidelines... .....98
4.17PumpProtectionGuidelines.. ..............102
4.18CentrifugalPumpParallelControlGuidelines ....104
4.19UseVFDsforVariableSpeedPumpControl ....105
4.20ReciprocatingPumpPulsation. ..............106
4.21PumpBearingSelectionGuidelines.. .........107
4.22MechanicalSealandFlushPlanGuidelines. ....112
4.23WhentoRemoveorRetainSuctionStrainers ....115
4.24SparePumpChangeoverGuidelines. .........115
4.25PumpProcessPipingAttachmentGuidelines...116
5.CompressorKeySafety,Environmentaland ReliabilityIssues.............. .............119
5.1UnderstandingCompressorTypesand Characteristics.. ........................120
5.2UnderstandingtheCompressorTrainorUnit ....121
5.3AxialandCentrifugalCompressorTypes... ....122
5.4AxialandCentrifugalCompressor Characteristics.. ........................127
5.5PositiveDisplacementCompressorTypes.. ....130
5.6PositiveDisplacementCompressor Characteristics.. ........................134
5.7WhentoUseAxialandCentrifugal Compressors ............................136
5.8WhentoUsePositiveDisplacement Compressors ............................137
5.9UnderstandingtheConceptofCompressor Head(Energy)... ........................138
5.10ExcessiveBlade/ImpellerHeadPer Blade/Impeller... ........................143
5.11CentrifugalCompressorCurves ..............144
5.12CentrifugalCompressorCurveFlowLimits. ....145
5.13TheCausesofSurge... ...................146
5.14TheCausesofChoke/Stonewall .............149
5.15TheImportanceofGasCompositionSampling andMonitoring.. ........................151
5.16CompressorFoulingPreventionGuidelines. ....151
5.17AvoidUnsparedIntegralGearCompressors inProcessServices .......................156
5.18BewareofIntegralGearCompressor IntercoolerFoulingWhichCanCauseSurging...157
5.19EffectiveAxialandCentrifugalCompressor ControlandProtectionGuidelines... .........158
5.20CentrifugalCompressorMechanical ComponentFunctionOverview ..............161
5.21StationaryandVariableGuideVane Function.. .............................168
5.22Impeller,Blade,andRotorTypesand Function.. .............................169
5.23CentrifugalCompressorDiaphragmFunction andComponents. ........................170
5.24ImpellerandInterstageShaftSealTypesand Function.. .............................171
5.25RotorStiffnessIsKeytoDefiningCritical Speeds... .............................172
5.26CriticalSpeeds—RadialandTorsional .........173
5.27LateralRotorResponseCalculations. .........175
5.28RadialBearingTypes,Function,and ConditionMonitoringGuidelines .............180
5.29RotorAxial(Thrust)ForcesandThrust Balance ................................184
5.30ThrustBearingTypes,Function,andCondition Monitoring... ...........................187
5.31SealTypesandFunctions. .................190
5.32PDCompressorPulsationandPreventive Measures... ...........................191
5.33PositiveDisplacementCompressorInlet Filtration ...............................192
5.34RecipCompressorFrameRunningGearKey InspectionPoint—WebDeflection ............192
5.35RecipDistancePieceand/orPackingBuffering forFlammableandToxicGases. ............194
5.36ReciprocatingCompressorControl Guidelines... ...........................194
5.37ScrewCompressorTypes,Applications, andConditionMonitoring. .................198
6.CouplingandGearKeySafetyandReliability Issues. ..................................211
6.1CouplingFunctionandTypes ................212
6.2ReplacingGreaseandLubricatedCouplings WithDryCouplings.. ......................218
6.3TheCouplingSystemSafetyandReliability Guidelines ...............................218
6.4ProperHydraulicHubAssemblyGuidelines ......220
6.5ProperDiscandDiaphragmCouplingBSE (BetweenShaftEnd)Guidelines... ............222
6.6UseTorquemetersforCriticalSteamTurbine andGasTurbineDriverApplications ...........224
6.7GearTypesandFunctions.. .................224
6.8GearToothContactGuidelines... ............230
6.9HighlyLoadedPinionGearBearingGuidelines...231
7.SteamTurbineKeySafetyandReliabilityIssues..235
7.1SteamTurbineFunctionandTypes ...........236
7.2SingleStageTurbineOptimumReliability Guidelines... ...........................240
7.3CCM(ComponentConditionMonitoring) GuidelinesforSteamTurbines... ............244
7.4CriticalMultistageCondensingTurbine HighThrustTemperatureIssues. ............248
7.5SteamFoulingIssuesandRemedialActions....249
7.6ShaftStiffnessRatioUsedtoDeterminethe NeedforaTurningGear.. .................251
7.7TheNeedtoExerciseTripValvesPeriodically...251
7.8ElectronicGovernorModificationand Advantages—SafeCoupledOverspeedTrips....253
7.9VanePassingFrequenciesCausingDamage toTurbineDiaphragmsandBladesand UnderstandingtheCampbellandGoodman Diagrams ...............................254
7.10UseTorquemeterstoAccuratelyDetermine TurbinePowerinCondensingandExtraction/ AdmissionTurbinesUsedforCriticalPumpand CompressorApplications. .................257
8.GasTurbineKeySafetyandReliabilityIssues....259
8.1FunctionandTypesofGasTurbines ...........260
8.2AeroderivativeTurbineAdvantages ............263
8.3AlwaysConfirmCorrectSiteConditions. .......265
8.4SelecttheTurbinefortheProperPower ServiceFactor ............................267
8.5AssureProperInletFiltrationforthe Application. .............................267
8.6InstallTorquemetersforCompressorandPump ApplicationstoTrendGasTurbineEfficiency. ....269
8.7UnderstandingISOPerformanceRatings ........269
9.LubeandSealOilSystemKeySafetyand ReliabilityIssues...... .....................277
9.1Lube,Seal,andControlOilSystemFunction andTypes. .............................278
9.2Lube,Seal,andControlSystemP&ID UnderstandingandFieldTracingGuidelines ....280
9.3UsingAPI614andLessonsLearnedtoAssure EffectiveSpecificationofSystemDesign... ....282
9.4OilSystemDesignReviewstoAssureProper ComponentSizing ........................286
9.5RequiringEffectiveOilSystemFATs(Factory AcceptanceTests) ........................292
9.6UseCentrifugalPumpsWheneverPossible forHighReliability ........................293
9.7TheNecessityofUsingModulatingType ReliefValvesandHowtoTestThem. .........294
9.8UseDirectOilActuatedControlValvesWith SensingLineSnubbersWheneverPossible. ....294
9.9AlwaysRequireDualAccumulators.. .........296
9.10DoNotUseCottonorPaperFilterCartridges inSystemsThatContainH2OintheOil........299
9.11ProperOperationofTransferValves. .........301
9.12OilRundownTankFunctionandUse. .........302
9.13AuxPumpAutoStartGuidelines .............304
9.14AlwaysMonitorControlValvePosition .........305
9.15DesignOilConsolesforOperatorAccessibility..306
9.16MonitorPumpSuctionStrainerDifferential PressuretoPreventPumpFailure... .........308
9.17EliminatetheUseofMainPumpSteam TurbineDriversIfPossible ..................308
9.18AlwaysSampleOilDownstreamoftheFilters toMonitorFilterEffectiveness. ..............309
9.19BestoftheBestOilFlushingProcedure Guidelines. .............................310
9.20UseFilterDifferentialPressureChangeout FrequencytoMonitorOilReservoir Condition. .............................315
9.21ChecktheOilTemperatureBeforeChanging FilterCartridgesDuringColdWeather Start-Ups. .............................315
9.22CheckAccumulatorFunctionQuarterly ........316
9.23CheckStartAuxiliaryPumpFunctionJust PriortoShutDownforAccurateAssessment oftheFunction.. ........................316
9.24SealOilDrainerTypesandFunction. .........318
9.25CompressorSweetBufferGasSystem FunctionsandGuidelines ..................321
9.26AlwaysMonitorBushingSealOilSystems forGasRelease.. ........................327
9.27AlwaysRequireThattheSealOilSystemIs onBeforeGas(N2 orProcess)IsIntroduced IntotheCase ............................329
9.28MinimumStart-UpPressureintheCase GuidelinesforBushingSealOilSystemsWith SupplySideControlValvesinHighPressure Applications. ...........................330
9.29MonitorDegassingTankEffectiveness.. .......331
10.PumpMechanicalSealKeySafetyand ReliabilityIssues ..........................335
10.1PumpMechanicalSeals’Functionsand Types. ..............................336
10.2APISealFlushSystemTypesand Functions... .........................340
10.3UsingLessonsLearnedtoEliminateSeal BadActors.. .........................348
10.4ThePrimaryCauseofCentrifugalPump SealFailures—NotOperatingWithinthe PumpEROE. .........................352
10.5AssureProperConditionsontheSeal DataSheet.. .........................354
10.6EliminateStrainersorCyclonesintheFlush System ..............................357
10.7UseCartridgeSealsWheneverPossible. .....359
10.8AlwaysMonitorSealChamberPressure. .....360
10.9UseFlowControlValves(Kates,etc.)for APIPlan32ExternalFlushes ..............361
10.10AssureProperSealInstallationProcedures...361
10.11Plan23OperationGuidelines ..............363
10.12APIPlan54/53/52SelectionGuidelines. .....364
10.13BadActorSealSystemInputtoSealVendor Guidelines... .........................367
11.DryGasSealKeySafetyandReliability Guidelines..... ..........................369
11.1DryGasSealSystemFunctionandTypes ....370
11.2DryGasSealSystemDesignOptions.. .....379
11.3UsingBadActorSealLessonsLearnedto ProperlySpecifyDGSSystemDesign.. .....379
11.4GuidelinesforAssuringDryGasSealSystems ofOptimumSafetyandReliability ..........382
11.5PresenttheProposedP&IDtotheOEMin thePre-FEEDProjectPhaseBasedon LessonsLearnedandAllPlantOperating Conditions... .........................383
11.6ReplacingOilSealsWithDGS... ..........383
11.7AssuringThatSealGasPressureIsGreater ThanVent(Flare)Pressure. ...............384
11.8UsingN2 GasBetweenTandemSealsto AssureSealGasFreeAdmissions ..........386
11.9WhenNottoBuffertheSealWithDischarge Gas.................................387
11.10WhentoUseaGasBoosterSystem... .....388
11.11UseBidirectionalSeals... ...............388
11.12MonitorTandemSealSecondaryCondition...388
11.13AlwaysMonitorSecondarySealVentDrains forOilCarryover... ....................389
11.14WhentoUseDoubleDryGasSeals .........390
11.15DoNotUseBoneDryN2 (DewPoints Below 30°C( 22°F))...................390
11.16UseaTandemSealPrimaryVentBypass DeviceinHigh-PressureService. ..........391
11.17ConsiderDualVentTripsinCriticalTandem SealServices(PrimaryandSecondary Vents)... ............................391
11.18NeverConnectBearingHousingVents......392
11.19ConsiderDifferentialPressureControllers forSeparationN2 ControlinTandemSeals...392
11.20Paintand/orLabelDGSSystemsfor OperatorAwareness.. ..................393
11.21CartridgeDryGasSealInstallation ProcedureGuidelines. ..................393
11.22DryGasSealSiteConditionInformation toExchangeWithSealVendors ............394
12.PostshipmentPrecommissioningPM,PDM ConditionMonitoring.......... .............397
12.1MachineryInstallationGuidelines... ........398
12.2ReceivingandPreservingRotating Machinery ............................399
12.3GroutingGuidelines... ..................400
12.4ImplementaSiteMachineryInstrument ConditionExcellenceProgram .............401
12.5BestoftheBestOilFlushingProcedure Guidelines ............................402
12.6ProperProcessPipingAlignmentand FoundationSupportGuidelines ............407
12.7PerformOilSystemTransientTestPriorto ScheduledShutdownandAgainBefore “OnlineOperation” ......................412
12.8MinimizePMProgramsandExtendIntervals byEffectivePDM(ComponentCondition Monitoring) ...........................413
12.9EffectivePumpChangeoverGuidelines. .....416
12.10MaintainStrongOEMVendorContacts. .....417
12.11ConductSite-SpecificTrainingor OEM/ConsultantVideoTrainingforBad ActorIssues. .........................417
12.12PerformRCAImmediatelyWhenCondition ChargesAreNoted—SetSoftAlarms.. .....418
12.13AssureCompleteCCMTrendingforAll CriticalEquipment.. ....................418
13.RootCauseAnalysis“RCA”andRootCause FailureAnalysis“RCFA”Guidelines...........423
13.1TheFiveCausesofFailure. ...............424
13.2EffectiveCCM(ComponentCondition Monitoring).. .........................425
13.3AccuratelyDefiningtheAffected(Potential Failed)ComponentFunction ..............425
13.4AccuratelyDefineAllComponentSystems andSystemComponentFunctions .........427
13.5ObtainOnlyObjectiveFacts(Basedon ResultsandTrends). ....................427
13.6DefineAbnormalConditionsandPotential Causes ..............................429
13.7DetermineEffects,Causes,andRoot Causes ..............................430
13.8ListingRootCauses. ....................430
13.9UsinganEffectiveRCA(RootCauseAnalysis) BeforeaRCFA(RootCauseFailure Analysis) .............................430
13.10DevelopingaCost-Effective ActionPlan.. .........................431
Preface Theobjectiveofthisbook/eBookistoprovideaconcise,easyto access,arrayofKeyRotatingMachineryFacts,detailedinformation,andwebsitereferencesforentrylevelpersonnel,experiencedpersonnel,andtheirsupervisorsthatwillenablethem toimmediatelycontributetotheircompany’ssafety,environmentalconcerns,reliability,andprofits.
SincethepublicationofmyBestPracticehandbookfor RotatingMachineryin2011,muchhaschanged.Rotating Machineryexperiencehasbecomeminimalforoperators,servicepersonnel,millwrights,andengineersforendusers,EP&Cs, andOEMs.Since2015andespeciallynowintheCV-19era, site-specifictrainingforendusersandcrossdisciplinetraining forEP&CsandOEMshavebecomeathingofthepast.Digital “OffPlant”AssetMonitoringhastakenhold.Theneedfor experiencedpersonneltoassessplantmachinerycondition anddeterminewhenandif“OffPlantAssetMonitoring”isjustifiedandcosteffectiveisdemonstratedbythevastnumberof RFCAs(RootCauseFailureAnalysis)wehaveperformed since2016.
IhavethereforecompiledwhatIfeelareKeyFacttopicsthat entrylevelandmidlevelexperiencedpersonnelcanquickly obtainandimplementtoaddressrotatingmachinerycondition changebeforeasafetyissue,environmentalissue,and/orcostly downtimeisexperienced.Thisbookisformattedtoallowall presentandfutureeBooktechnologiestobeusedonalldevices toobtainquickaccuratetextfacts,audiofacts,andsupporting information.
Theformatforeach“KeyFactTopic”isto:
•PresenttheKeyFactstoaddresstheissueinclearand conciseterms
•PresentKeyFactAwarenessinformationtoenablethereader toobtaindetailedinformationforprompt,accurate,andcosteffectiverecommendationsforoptimumsafety,environmentalcontrol,andreliability
•PresenttheKeyFactrelatedwebsitesthatwillshowdetails ofthetopic.PleaserefertotheQRindexforQRcodeswhich willallowquickwebsiteaccess.
Thisbookisarrangedinanorderthatwillallowareaderto firstobtaintheknowledgetoincreasetheirrotatingmachinery effectivenessindeterminingtheplantassetsthatneedimmediateattention,howtocorrecttheirabnormalities,andhowto communicateeffectivelywithplant,EP&C,andOEMpersonnel(Chapters1–3).Theremainderofthechapterswilldeal withaspecifictypeofmachinery,criticalcomponents,effective conditionmonitoring,installationguidelines,androotcause analysiskeyfacts.
Asisthecasewithmypreviousmachineryhandbooks,this textisintendedforeveryoneassociatedwithrotatingequipmentregardlessofeducationalbackground(operators,millwrights,andengineers).
Insummary,itismyintentiontopresentimportantKey RotatingMachineryGuidelinesattainedthroughmy59years intheindustryandover500plantvisitstoanyoneinanycompanythathastheobjectiveofRotatingMachinerySafetyand Excellence.Itismybeliefthatthisbookcanprovideastrong platformfromwhichyoucanelevateyourrotatingmachinery awarenesstoa“BestoftheBest”level.
1AssessmentandImprovementofYourRotating MachineryKnowledgeBase.....
2AssessmentofRotatingMachineryCondition onSite..............
3EliminatingandCorrectingBadActorCostly Safety,EnvironmentalandReliabilityIssues.......39
4PumpKeySafety,EnvironmentalandReliability Issues...............
5CompressorKeySafety,Environmentaland ReliabilityIssues.......
7SteamTurbineKeySafetyandReliability Issues.........
ReliabilityIssues.
ReliabilityIssues. ..........................335 11DryGasSealKeySafetyandReliability Guidelines......
12PostshipmentPrecommissioningPM, PDMConditionMonitoring...................397 13RootCauseAnalysis“RCA”andRootCause FailureAnalysis“RCFA”Guidelines............423
AssessmentandImprovementofYour RotatingMachineryKnowledgeBase 1 Introduction
IamwritingthisbookinJulyof2020inthemiddle oftheCV-19pandemicintheUnitedStateswhich hasenduredapproximately25%ofthereported World-WideCV-19relateddeaths.Thispandemic hasimpactedthemachineryindustrybycausing increasedretirementsofexperiencedpersonnel andminimizingtheamountofexperiencedmachinerypersonnelonsite.However,ithasbeenmyexperiencethateverycatastrophecontainsopportunities. Searchfortheopportunities,identifythem,andtake
Keywords
Processawareness,Thrustbearing,Machineryindustry,Reliability,Safety,Trending
action.Thereforethischapterwillcontainthekey opportunitiesthatIhaveidentifiedinmycareerthat willenablethemachineryspecialisttorapidlyobtain amachineryknowledgebaseandcontributetothe safetyandreliabilityofyourmachineryandimmediatelycontributetotheprofitofyourcompany.The materialinthischapterwouldalsobemosthelpful forthoseconsideringacareerinRotatingMachinery andbeginningthatventureasaninternorCo-Op studentduringtheireducationalyears.
1.1WhatKnowledgeDoINeedto ExcelasaMachinerySpecialist? Keyfacts •Whatarethekeyequipmenttypesonthesite(nonsparedand spared)?
•AmIfamiliarwiththem?Ifnot,wheredoIgetthis information?
•Istherein-housesitespecifictrainingforthisandother specificareas?
•Learnthefunctionofeachofthefivemajorpartsofanytype ofarotatingmachine(see Awarenessinformation later).
•Thefunctionofthesefivepartswillbeessentiallythesame foranytypeofrotatingmachinery.
•Isuggestthatyoustartwithpumpssincetheyarethepredominanttypeofmachineryinplantsandareverysimilarto othertypesintermsoffunction.
•Thisapproachwillenableyoutoeffectivelyusethe conditionmonitoringtoolsavailableforeachtypeofmachinery.
•IhaveprovidedayouTubereferenceintheWebsitereference sectionwhichwillprovidesimplefunctionknowledgefora centrifugalpump.
•Asyouprogressinexperience,establishadatabasefor detailedfunctiondefinitionsofeachmajorcomponentin eachtypeofmachinery.
Awarenessinformation:Themajor machinerycomponents Thinkofallthemachinerythatyouhavebeenassociatedwith andask … Whatarethemajorcomponentsandsystemsthat arecommontoalltypesofrotatingequipment?
▪ Pumps
▪ Steamturbines
▪ Compressors
▪ Motors
▪ Gasturbines
▪ Fans
▪ Etc.
Figure1.1.1 presentsthemajorcomponentclassificationsfor anytypeofmachinery.
Rotor
Radial bearing
Thrust bearing Seal
Auxiliary systems that support the bearings and seals
Fig.1.1.1 • Majormachinerycomponentsandsystems.
Regardlessofthetypeofmachinery,monitorthesecomponentsandyouwillknowthetotalconditionofthemachine.
Componentconditionmonitoring Componentandsystemfunctionsmustfirstbedefinedandthe normalvaluesforeachcomponentlisted.Thesefactsarepresentedin Figure1.1.2.
Define the function of each affectedcomponent
Define the system in which each affected component operates
List the normal parameters for each affected component and system component
Fig.1.1.2 • Componentandsystemfunctions.
Oncethefunctionofeachcomponentisdefined,eachmajor machinerycomponentcanbemonitoredasshownin Figure1.1.3
Define each major component
List condition monitoring parameters
Obtain baseline data
Trend data
Establish threshold limits
Fig.1.1.3 • Componentconditionmonitoring.
Baseline Havingdefinedallconditionparametersthatmustbemonitored,thenextstepinaconditionmonitoringexerciseisto obtainbaselineinformation.Itisimportanttoobtainbaseline informationassoonasphysicallypossibleafterstart-upof equipment.However,operationsshouldbeconsultedtoconfirmwhentheunitisoperatingatratedorlinedoutconditions. Obtainingbaselineinformationwithoutconferringwithoperationsisnotsuggestedsincemisinformationcouldbeobtained andthusleadtoerroneousconclusionsinpredictivemaintenance. Figure1.1.4 statesthebasicsofabaselinecondition.
If you don’t know where you started, you do not know where you are going!
Fig.1.1.4 • Baselinecondition.
Itisamazingtoushowmanytimesbaselineconditionsare ignored.Pleaseremember Figure1.1.4 andmakeitapractice toobtainbaselineconditionsassoonaspossibleafterstart-up.
Trending Trendingissimplythepracticeofmonitoringparameterconditionwithtime.Trendingbeginswithbaselineconditionandwill continueuntilequipmentshutdown.Inmoderndaythought,it isoftenconjecturedthattrendingmustbeperformedbymicroprocessorsandsophisticatedcontrolsystems.Thisisnotnecessary!Effectivetrendingcanbeobtainedbyperiodicmanual observationofequipmentorusingequipmentavailabletous intheplantwhichwillincludeDCSsystems,etc.Theimportantfactistoobtainthebaselineandtrendsofdataonaperiodic basis.Whentrendingdata,thresholdpointsshouldalsobe definedforeachparameterthatistrended.Thismeansthat whentheparameterpreestablishedvalueisexceeded,action mustbetakenregardingproblemanalysis.Settingthreshold valuesastandardpercentageabovenormalvalueisrecommended.Typically,valuesareontheorderof25%–30%above baselinevalues.
Figure1.1.5 presentstrendingdataforahydrodynamicjournalbearing.Alltheparametersnotedin Figure1.1.5 shouldbe monitoredtodefinetheconditionofthisjournalbearing.
Component - bearing (journal)
Parameters
Shaft Vibration (x) (mils)
Shaft Vibration (y) (mils)
Shaft Position (’)
Bearing Pad Temp. (*F) A Pad
Bearing Pad Temp. (*F) B Pad
Oil Viscosity(ssu)
Oil Flash Point Speed (rpm)
Trending data Fig.1.1.5 • Trendingdata.
Specificmachinerycomponentandsystem monitoringparametersandtheirlimits
Onthefollowingpagesiscontainedinformationconcerning whatparametersshouldbemonitoredforeachmajormachinery componenttodetermineitscondition.Inaddition,typical limitsarenotedforeachcomponent.Theselimitsrepresent theapproximatepointatwhichactionshouldbeplannedfor maintenance.Theyarenotintendedtodefineshutdownvalues.
Therotor
Rotorconditiondefinestheperformancecondition(energyand efficiency)ofthemachine. Figure1.1.6 presentsthisvaluefor apump.
Fig.1.1.7 • Conditionmonitoringparametersandtheiralarmlimits— Journalbearing(antifriction).
Journal bearing (hydrodynamic)
Parameter
Limits
1. Radial vibration (peak to peak)2.5 mils (60 microns)
2. Bearing pad temperature 220°F (108°C)
3. Radial shaft position* >30° change and/or 30% position change
4. Lube oil supply temperature 140°F (60°C)
5. Lube oil drain temperature 190°F (90°C)
6. Lube oil viscosity off spec 50%
7. Lube oil particle size >25 microns
8. Lube oil water content below 200 ppm
* Except for gearboxes where greater values are normal from unloaded to loaded
Fig.1.1.8 • Conditionmonitoringparametersandtheiralarmlimits— Journalbearing(hydrodynamic).
Fig.1.1.6 • Pumpperformancemonitoring.
Radialbearings
Figures1.1.7and1.1.8 presentthefactsconcerningantifriction andhydrodynamic(sleeve)radialorjournalbearingcondition monitoring.
Thrustbearings
Figures1.1.9and1.1.10 showconditionparametersand theirlimitsforantifrictionandhydrodynamicthrust bearings.
Thrust bearing (anti-friction)
Parameter Limits
1. Bearing housing vibration (peak) radial .4 in/sec (10 mm/sec) axial .3 in/sec (1 mm/sec)
2. Bearing housing temperature 185°F (85°C)
3. Lube oil viscosity off spec 50%
4. Lube oil particle size nonmetallic >25 microns metallic any magnetic particles with sump
5. Lube oil water content below 200 ppm
Fig.1.1.9
• Conditionmonitoringparametersandtheiralarm limits—Thrustbearing(antifriction).
Thrust bearing (hydrodynamic)
Parameter Limits
1. Axial displacement* >15–20 mils (0.4–0.5 mm)
2. Thrust pad temperature 220°F (105°C)
3. Lube oil supply temperature 140°F (60°C)
4. Lube oil drain temperature 190°F (90°C)
5. Lube oil viscosity off spec 50%
6. Lube oil particle size >25 microns
7. Lube oil water content below 200 ppm
* and thrust pad temperatures >220°F (105°C)
Fig.1.1.10
• Conditionmonitoringparametersandtheiralarmlimits— Thrustbearing(hydrodynamic).
Seals Figure1.1.11 presentsconditionparametersandtheirlimitsfor apumpliquidmechanicalseal.
Pump liquid mechanical seal
Parameter
Limits
1. Stuffing box pressure <25 psig (175 kpa) **
2. Stuffing box temperature Below boiling temperature for process liquid
3. Flush line temperature +/–20°F (10°C) from pump case temp
4. * Primary seal vent pressure (before orifice) >10 psi (70 kpag)
* On tandem seal arrangements only
** Typical limit –there are exceptions (Sundyne Pumps)
Fig.1.1.11
• Conditionmonitoringparametersandtheiralarmlimits— Pumpliquidmechanicalseal.
Auxiliarysystems
Conditionmonitoringparametersandtheiralarmlimitsare definedin Figures1.1.12and1.1.13 forlubeandpumpflush systems.
Figures1.1.6–1.1.13 presentedthetypicalalarmlimitsfora centrifugalpump.Similarlimitscanbeestablishedforalltypes ofmachineryyouwilldealwithusingthissameapproach:Rotor, JournalBearing,ThrustBearing,SealandAuxiliarySystem Parameters.
Lube oil systems
Parameters
Limits
1. Oil viscosity off spec 50%
2. Lube oil water content below 200 ppm
3. Auxiliary oil pump operating yes/nooperating
4. Bypass valve position (P.D. pumps)change > 20%
5. Temperature control valve positionClosed, supply temperature > 130 55°C)
6. Filter ΔP > 25 psid (170 kpag)
7. Lube oil supply valve position change > +/–20%
Fig.1.1.12 • Conditionmonitoringparametersandtheiralarm limits—Lubeoilsystems.
Pump seal flush (single seal, flush from discharge)
Parameter
Limits
1. Flush line temperature+/–20°F (+/–10°C) of pump case temperature
2. Seal chamber pressure< 25 psi (175 kpa)above suction pressure
Fig.1.1.13 • Conditionmonitoringparametersandtheiralarmlimits— Pumpsealflush.
Websitereference Thefollowingwebsiteprovidesinformationforthefunctionof thecentrifugalpumpcomponents: Centrifugalpumpcomponentsexplained.10/10/2018. https://www.youtube.com/watch?v¼3rqnXffrSmc SavRee3D
1.2WorkingWithYourAssociates andImmediateSupervisor Keyfacts •Gettoknowyourofficemates
•Developrelationships
•Discussyourbackgroundwiththeirs
•Offertodoanyworktask!
•Thisactionwillenableyoutoobtainthegreatestamountof information/experience
Awarenessinformation Asanewadditiontoamachinerygroupwhetherinanofficeora plant,youcanfeeloutofplace.Ifyouhavepreviouslyhadacooporsummerinternshipinthisfield,itwillbeeasier.Regardless,donotbeafraidofmeetingyourpeersbothinandoutof work.Afterworkmeetingplacesareagreatassettodiscusstheir background,plans,andevenhousing.Icanremember,believeit ornot—58yearsback,meetingtwoengineersinmyfirstplace ofemploymentandarrangingasummerrentalatthebeach.It presentedanopportunitytolearnoftheirbackground,experience,andapproachestoournewplaceofemployment.Wehave remainedfriendsthruoutourcareers!
Inaddition,frequentlyseeyoursupervisor,perhapsfor morningcoffeemidweekorevenlunch.Makesurethat sheorheisawareofyourinterestinlearningasmuchaspossibleanddonothesitatetoofferfreetimetolearnevenon
theweekends(Cominginforaspecialmeeting,amachinery test,eveninglocallecturesthatpertaintoyourwork). Jointhelocalchapterofyourengineeringdegree(ASME, IEEE,etc.).
Websitereference
Howtomanageyourbosseffectively|PaulRenaud.3/13/2018. www.youtube.com/watch?v¼rTpLuwhUOYk
1.3HowDoIEffectivelyBuild MyKnowledgeBase? Keyfacts Onceyouhavesettledinyourworkenvironmentandhavemet yourcoworkersandsupervisor(6monthsorso),askyoursupervisortoadviseacompetencymaporplanwhichwillidentify:
•Importantspecificationsyouneedtoknow Companyrotatingmachineryspecificationsiftheyexist
API(AmericanPetroleumInstitute)
ASME(AmericanSocietyofMechanicalEngineers)
•Trainingcoursesandpossiblesymposiumsthatwillprovide “basicexperience”thatwillformagreatfoundationforyour knowledgebase.
•Publicationsthatrelatetorotatingmachinery
Awarenessinformation
Wehavenotedasfollowsoursuggestedcompetencymapthat wehaveusedforourclientssincethe1990s.FAIdenotesForsthofferWorkshopsorTitlesofForsthofferMachineryTexts publishedbyElsevier.
Yearsof experienceCompetency Trainingorpublications
0–1
1–5
• FunctionofMachinery TypesPD/Dynamic
• EffectofProcesson MachineryReliability
• FunctionofMajor MachineryComponents
• ComponentCondition Monitoring(CCM)
• Performance CalculationsPumps, Turbines,and Compressors
• VibrationAnalysis
• MechanicalSeal FunctionandMonitoring
• AuxiliarySystem ComponentFunctionand Monitoring
• DetailedUnderstanding oftheLNGProcess
>5
• FAI—PrinciplesofRotating Equipment
• FAI—CCMWorkshop
• FAI—PumpsandSeals
• FAI—Compressors
• FAI—SteamTurbines
• FAI—AuxiliarySystem
• JMCampbell—GC4(2Week Course)
• BentlyNevada—Vibration
• SealVendorTraining
• CompressorControlsCorp.— ControlandProtection
• SurgeandProcess Controls
• ComponentCondition Monitoring(CCM)
• MachineryBestPractices
• ReliabilityOptimization
• Troubleshooting
• TurnaroundPlanning
• TurnaroundChecks
• IndustryMachineryBest PracticeAwareness
Websitereference • FAI—BestPractices
• FAI—ReliabilityOptimization
• TroubleShooting(TapRoot, Aurora,etc.)
• AttendanceandPresentation duringTexasA&M TurbomachinerySymposium
Thiswebsitedetailsthebestmixofcompetency,attitude,and mindsetforapersonnewtoacompany.The3attributesto lookforintoptalent.4/22/2014.
https://www.entrepreneur.com/article/232851
1.4WhatSpecificationsShouldI LocateandReview? Keyfacts •Knowingthespecificationsforthemachinerythatyouwillbe workingwithisamustfor:
Determiningiftheaffectedmachineryneedstobemodifiedtoimprovereliability
Assuringthatnewmachinerypurchasedisinaccordance withspecifications
•Askyoursupervisortolistyourcompaniesandindustry specificationsthatyouwillneedtoknow
•Locateandobtainthesespecifications
•Scheduletimetorevieweachspecificationbeginningwith yourcompany’sspecificationiftheyexist
•Makenotesoneachspecification,filethesenotesinyour machinerydatabase,andaskyourcoworkersandsupervisor anyquestions
Awarenessinformation Myexperienceisthatmajorcompanieshavemachinery specificationsforspecifictypesofmachineryandwilleither referenceAPI(AmericanPetroleumInstitute)orASME(AmericanSocietyofMechanicalEngineers).Isuggestobtainingthe machineryspecificationsforthemachineryyouwillbeworking withfrom:Companyspecifications,API(IfyourcompanypurchasesAPIequipment)orASMEforChemicalPumpServices. Foreachmachineryspecification,therewillbeassociateddata sheetsthatarerequiredtobefilledinbythepurchasertodefine operatingconditions,mechanicalcomponentrequirements,etc. Ihavefoundthatitismostusefultoalsonotespecificrequirementsfortheprojectonthedatasheetsthatwerenotincluded inpastpurchasedmachineryandhavecausedreliabilityissues.
Websitereferences APIStandards.Listingofallmachineryspecificationsfor purchase.8/2/2020.
http://www.rotating.equipment/?page_id¼59
Listofallcodesandstandards|ASME.Listingofallmachinery specificationsforpurchase(Listdesiredtype,i.e.,Centrifugal Pumps,CentrifugalCompressors,SteamTurbines,etc.). 8/2/2020.
https://www.asme.org/codes-standards/find-codes-standards
1.5WhatMachineryBooksConstitute anEffectivePublishedKnowledge Base? Keyfacts •Havingaccesstoorpersonallyowningkeymachinerybooks areessentialtorecommendationsthatcanbemadefor machineryoptimumsafetyandreliability.
•Irecommendthefollowingmachinerybooksformachinery typesandComponents(Viewrecommendedbooksin Websitereferences below):
PumpHandbook—IgorKarassik
ProcessCentrifugalCompressors—KlausHLudtke PracticalGearDesign—Dudley,DarleW ForsthofferMachineryHandbooks
HeinzPBlochMachineryBooks
ThePracticalVibrationPrimer—CharlesJackson DryGasSealsHandbook—JohnStahley
Awarenessinformation Todeterminewhichreferencebooktostartwith,identifythe typeofmachinerythatyouareinvolvedwithorstartwith thetypethatcausesthemostreliabilityissuesifyouworkina plant.Obtainelectronictextorverbalversionifavailableand fititinwithyourworkschedule(i.e.,dailycommute,earlymorningbeforeworking,lunchbreakorbedtimereading!ha,ha).
Websitereferences PumpHandbook:Karassik,Igor,Messina,Joseph,Cooper.12/ 18/2007.
https://www.bing.com/search?q=%09Pump+Handbook% 3A+Karassik%2C+Igor%2C+Messina%2C+Joseph%2C +Cooper+&form=ANSPH1&refig= 760a8903cc19476f8e00a33a1d68d5bb&pc=U531 HandbookofPracticalGearDesign:Dudley,DarleW.1984. https://www.bing.com/search?q=handbook+of+practical +gear+design%3A+dudley%2C+darle+w&form=ANSPH1 &refig=13c4b609685c482aa195fd4833d1f57b&pc=U531 WilliamEForsthofferBooks—ListofbooksbyWilliamE Forsthoffer.
https://www.abebooks.com/book-search/author/ forsthoffer-william-e HeinzPBlochBooks—ListofbooksbyHeinzPBloch.1983. https://www.bing.com/search?q=%09Heinz+P+Bloch +Books%E2%80%94List+of+books+by+Heinz+P
+Bloch&form=ANSPH1&refig= eede2d1311f04171bb74ffd4f5400544&pc=U531 ThePracticalVibrationPrimer:CharlesJackson.1979.
https://www.bing.com/search?q=%09The+Practical +Vibration+Primer%3A+Charles+Jackson&form= ANSPH1&refig=012a214139ed467a94f2abb93529495a& pc=U531
DryGasSealsHandbook:Stahley,John:9781593700621. 2005.
https://www.amazon.com/Dry-Seals-Handbook-JohnStahley/dp/1593700628
1.6HowDoIKeepCurrentWithMy KnowledgeBase? Keyfacts •Machinerydesign,componentfunctionknowledge,instrumentation,controls,andmonitoringareallsubjectto changes;failuretobeawareofthesechangesinhibitsyour abilitytooffercreative,cost-effectivesolutions.
•Irecommendthefollowingperiodicalstokeepcurrentwith machineryandprocessindustryissues:
TurbomachineryMagazine
CompressorTechMagazine
HydrocarbonProcessingMagazine
•Reviewtheearliermentionedpublicationsontheinternetand discusswithyoursupervisorregardingcompanysubscriptions.
•Lastoptionifcompanysubscriptionsdon’twork—purchase oneortwoofthesepublications,itwillbeworthitto maintaincurrentindustryknowledge.
•Asktoattendoneoftheannualmachinerysymposiumsin yourarea
TexasA&Msymposium, Globalrotatingmachinerysymposiumsinyourarea (MiddleEast,Asia,Canada,Europe,etc.).
Awarenessinformation Establishadatabaseforkeypublicationarticlesbasedontypeof machinery(pumps,compressors,etc.)andmachinerycomponents(rotors,bearings,gears,seals,auxiliarysystems,andcontrolsystems).CopyandpastekeyarticlesinyourMachinery PublicationsDatabase accordingtomachinerytypeand componenttype.
Websitereferences TurbomachineryInternationalMagazine. https://www.turbomachinerymag.com/ CompressorTechmagazine. https://compressortech2.com/ HydrocarbonProcessing-Refining,Petrochemical,GasProcessingand https://www.hydrocarbonprocessing.com
TexasA&MUniversity—Turbomachinery&PumpSymposium. https://tps.tamu.edu
1.7HowtoUseThisBookEffectively? Keyfacts •Thisbookisstructuredforquickreference.
•Failuretouseyourdevicesandfiletheinformationobtained willlimityourabilitytoeffectivelycontributetoyourcompany’ssafety,reliability,andprofits.
•Usethetopicindexandgototheselectedchapterforthe informationrequired.
•Ifyourbookiselectronic,accessthisinformation eitherintextorAudiobook,ifthisbookwillbeavailablein Audiobookfortheitemoritemsthatmeetyourneed.
•Readthekeyfactsthengotothesuggestedwebsiteforutube orarticles.
•Afterobtainingthisinformationreadthroughtheawareness informationsectioninyoursparetimeandespeciallywhen preparingamanagementrecommendation.
Awarenessinformation Identifyacoupleofissuesyouwanttoknowabout,gototheindex andreadtheinformation,locatethewebsitereference,andreador heartheawarenessinformation.Createadatabaseandstatethe potentialuseofthisinformationforeasyaccesswhenyourequire itusingkeywords,i.e.,pumplowflow,compressorsurge,etc.
Websitereference Forsthoffer’sProvenGuidelinesforRotatingMachineryExcellence.
https://www.elsevier.com/books/forsthoffers-provenguidelines-for-rotating-machinery-excellence/forsthoffer/ 978-0-323-85433-7
1.8TheVitalImportanceofCross DisciplineKnowledge Keyfacts •Ihavefoundthatapproximately80%oftherootcauseof machineryfailureliesintheprocessandsystemsinwhichthe machineryisinstalled.Theother20%isassociatedwiththe installation,operatingprocedures,design,andmanufacture ofthemachinery.
•Theonlytimecrossdisciplinesbecomeinvolvedisusually duringaRCFA(RootCauseFailureAnalysis).
•Bring“processawareness”intotheprogramtosignificantly increasemachineryreliability.
•Gettoknowakeyprocessengineerandhisfavoriteoperator. Thisactionwill Increaserecommendationimplementationbyhavingprocessandoperationssupport. Minimize“fingerpointing”betweenmaintenanceand operations.
•ManyofourClientshaveintegratedtheirMachineryReliabilityGroupswithOperations,Process,I&E,andMechanicalspecialistswhichresultedinoptimummachinerysafety andreliability(see Awarenessinformation below).
Awarenessinformation Regardlessofthelevelofasitereliabilityoptimizationprogram, itcanbeimproved.Mypersonalexperienceisthat:
•Badactorsa aredefinedbutnotpermanentlysolved.
•Manymaintenanceactivitiesstillarereactive— “Firefighting.”
•Preventativemaintenance(timebased)activitiesare excessive.
•Predictivemaintenance(conditionbased)activitiesstillare minimal.
•Someactionplansforbadactorresolutionhavebeendefined butarenotimplemented.
•Lessonslearned,frombadactors,havenotbecomebest practicesformachineryupgradesand/ornewequipment purchases.
•Thereliabilityeffortismaintenancebasedanddoesnot incorporateothersitedisciplines.
Whyarethesecharacteristicsprevalentinmostplants?The plantmanagementhasnotbeenconvincedoftheopportunities availabletosaveconsiderableoperatingcostsandincrease profitbyreducingdowntimerelatedtoreliabilityissuesand excessivemaintenancetime.Plantmanagementmustbe shownresultsandtheassociatedsavingstoendorseanyplan forreliabilityoptimization.Often,a“salesman”thathasthe earofmanagementisrequired.Ihavefoundthatthisperson isusuallyatrusted,senioroperatororaprocessengineer. Andconsideringthatmostreliabilityeffortsaremaintenance based,thissalesmanisnowheretobefound.
Settingupaneffectivemultidisciplinedsite reliabilityinitiative Inmyexperience,Ihaveworkedwithmanysitereliability efforts,differentnames,differentcultures,anddifferentlevels ofexperience.Intheearlydaysofmyexperiencewiththese efforts(1970sand1980s)therewasbutoneconstant all effortswerestrictlymaintenancebased.Oh,yes,therewas anotherconstant … identifiedopportunitiesforreliability improvementwerenotimplemented.
Theeffortsalsousuallyhadanameandsomeofthose were:thereliabilitygroup,th evibrationmonitoringgroup, thefailureanalysisunit,thefailureanalysisandPMgroup, etc.Regardlessofthename,theeffortwasaimedat improvingsitereliabilityofallequipment,notonlyrotating equipment,andachievedresultsbuttheywereusuallyshort termandproblemsreoccurred.Overtheyears,asisnatural, theeffectivenessoftheprograminacertainplantvariedas personnelenteredandleftthegroup.Thosewholeftusually didsoforhigherpayandthosethatentereddidsofor increasedexperience.
a Abadactorisdefinedasanymachineorstationaryitemthatexperiencesoneor moreESDsperyear(unscheduledshutdownsorfailures).Notethatwhilethis bookisdevotedtorotatingequipment,theprinciplesdiscussedhereareequally applicabletoalltheequipmentinanyplant.
Reviewofthehistoricaleffortsofthesegroupsalsohadan interestingsimilarity.Everygrouporplanteffortusuallyhad identifiedtherootcauseofaproblembutwasunabletogather enoughcontinuedmanagementsupporttoimplementtheidentifiedactionplan.Asacorporateconsultantforamajoroiland chemicalcompanyandlaterasanindependentconsultant, Iwouldbeaskedtoreviewvarioussitereliabilityproblems andrecommendacost-effectiveactionplan.Inmanyofthe cases,myresultwasveryclosetowhathadbeenrecommended priortomystudy.However,thedifferencewasthatmyaction planwasusuallyacceptedandworked(justasthesitegroup’s planwouldhavealsobeensuccessful!).Thisisnotveryencouragingtosomeonewhoworkslonghours,is“oncall,”andmust attendtoreactivemaintenanceissuesattheusualtimes … weekends!!!Incidentally,haveyouevernoticedthatequipment usuallydecidesto“packitin”ontheweekendeverywhereinthe world(Thursday,FridayintheMiddleEast,Saturday,Sunday intheWest,etc.).
Iaskedmyself,whythiswasthecase?Afterobservingthe characteristicsnotedbeforeforseveralyears,theefforts lackedaneffectivesalesprogram.Asaresult,sincethemiddle1990s,Ihavebeenrecommendingthatallsitereliability effortsareintegratedanddefinitelyincludeanoperationrepresentativewhocanbeaprocessengineerorsenioroperator orboth.Thereasonsarebecauseallsiteequipmentreliability dependsupontheprocessrequirementsandthat,let’sfaceit, theplantisrunbyoperationsandifthereisanelementof operationsinthereliabilitygroupwhoagreeswiththegroup’s recommendation;acceptanceandimplementationhavea muchbetterchance.Because thereisnowasalesmanin thereliabilitygroup!
Naturallytheapproachwillbedifferentineachplantand thereareasmanypossiblevariationsasthereareplants. Figure1.8.1 presentssomeofthepossiblestructuresofasite reliabilityinitiative.
Specific, multi-discipline experienced reliability group
A site culture change that makes reliability everyone’s responsibility
Operation, process and instrument reliability group members are on a one-yearrotation assignment
Fig.1.8.1 • Sitereliabilityinitiativeguidelines.
Rotationoftheoperations,process,andperhapsinstrumentationmembersofthereliabilitygrouphasshowntobeavery goodideasincereturningmembersofthegrouptotheirown disciplineswillnaturallyspreadthewordregardingfunction awarenessandtheimportanceoftheprogram.Itamounts toautomaticfunctionawarenesstraining!Selectionofthe membersofthegrouponrotationshouldbemadecarefully. Ihavefoundthatthesepeopleshouldbethe“believablepeople” (experiencedpersonnelwhohavetherespectoftheir coworkers).
Rememberagainthatregardlessofmakeup,the initiativemustbemultidisciplined.Theadvantagesofthis arrangementaremany.Themajoronesarepresentedin Figure1.8.2.
Valuable process information input
Process and operation members are salesmen
Significantly greater degree of function awareness of site equipment among all site disciplines
Higher degree of ownership among all site disciplines
Less finger pointing when problems occur
Fig.1.8.2 • Multidisciplinedreliabilitygroupadvantages.
ItisinterestingtonotethatIhavealwaysobservedthatsmallerremoteplants(Articregion,NewZealand,SouthernChile andPlatforms)haveconsistentlyoutperformedlargerunitsin termsofactionplanimplementation.Intheselocations,they mustworktogether!Andwhentheydo,sinceeveryonelearns somethingregardingotherdisciplineresponsibilitiesandwork scope,theresultsandacceptanceofactionplansflowsmoothly.
Oncethedecisionistakentoincludeoperationsandmaintenance groupsinthereliabilityprogram,considerationshouldbegivento establishing“ownership”inthesegroupsregardingtheprogram.
Websitereference 8keybenefitsofcrossfunctionalteamcollaborationJune27, 2018.
https://www.proofhub.com/articles/benefits-of-crossfunctional-team-collaboration
1.9TheImportanceofUnderstanding andUsingPFDsP&IDs Keyfacts •Failuretoassociatemachinereliabilitywiththeprocessand systemsrendersitdifficulttoidentifytherootcausesof machineryfailure.
•AlwaysobtainandusetheassociatedPFDs(Process flowdiagrams),processP&IDs(ProcessandInstrument Diagrams)andP&IDsforthemachineyouare troubleshooting.
•Iftheissueinvolvesmachineryperformance,walktheprocessinthefieldwiththeseP&IDsstartingattheinlettothe machinerywithaprocessengineerandoperator.
•Iftheissueinvolvesmachinerymechanicalcomponents (bearings,seals,controlsystems)obtaintheappropriate P&IDsandwalkthesystemstartingatthesourcewith aprocessengineerand/oroperatorfamiliarwiththesystem.
Awarenessinformation Thefollowingprocessflowdiagramisanexampleofaschematic orblockflowdiagramanddepictsthevariousunitprocesses withinatypicaloilrefinery.IalwaysfirstrefertothisPFD
Fig.1.9.1 foreachprocessinwhichthemachineryIamconcernedwithislocated.OnceIreviewthePFD,Ithenreference theP&IDforthatprocesswhichcontainsallthedetailed
informationofallcomponentsthatareassociatedwiththe machineryaswellasthemachinerydetailsandinstrumenttypes andfunction.
NotedbelowisatypicalCentrifugalCompressorDryGas SealP&ID.UsuallytheOEM(OriginalEquipmentManufacturer)willnotethesettingson Figure1.9.2
Finished products are shown in blue Sour waters are derived from various distillation tower reflux drums in the refinery
The “other gases’ entering the gas processing unit includes all the gas streams from the various process units
Websitereference
UnderstandingProcessFlowDiagramsandP&IDs. https://panoramaeng.com/process-engineering/ understanding-process-flow-diagrams-and-pids-india/
1.10HowtoUseYourMachinery CalculationToolboxEffectively Keyfacts •Learnwhatfrequentcalculationsyouwillbeperformingfrom yoursupervisorandassociates.
•Obtainthecalculationsandlearnhowtheyfunction.Perform thecalculationbyhandusingtheequation.
•Ifthecalculationisinexcel,doacalculationfirstbyhand identifyingtheparameters.
•Fileallthesecalculationtagsinyourdatabasebycalculated parameter,i.e.,temperaturerise,thermalexpansion,pump head,compressorhead,power,etc.
•The“EngineeringToolbox”Appwillalsobeveryusefulfor quicklyobtainingotherrequiredequations.
Awarenessinformation Notedbelowisourpumpexcelcalculationsheetwhichis availableinUS,SI(bar,kPa,andkg/cm2 ).Werecommend thatyouusethiscalculationbutfirstdeterminethehead andpowerresultsbyhand,convertingtheprogramtoparametervalues
Fig.1.9.2 • TypicalCentrifugalCompressorTandemDryGasSealP&ID.
PumpComponentConditionMonitoring Performance
Item#
Date
Input
P1(psig)
P2(psig)
S.G.
PumpSpeed(RPM)
FlowRate(gpm)
Calculate
Head(ft)
FlowDeterminationa
ControlValvePosition
CVforValveandTrim Typeb
FluidS.G.
ControlValve Δ P
CalculatedValveFlow––––
MotorAmps
Volts
PowerFactor
MotorEff’y
CalculatedPower––––FlowFromPumpCurvec
T1(Deg.F)
T2(Deg.F)
CP(SpecificHeat)
CalculatedHead
CalculatedPumpEff’y––––FlowFromPumpCurvec
PumpMaintenance Requiredd
EROEDetermination
BEPFlowe
EROEMinFlow
EROEMaxFlow
IsPumpinEROE
EROETargetsforOperations
Flow
Amps
Pump Δ T(Measuredon InletandDischargePipes)
aIfaflowmeterisnotavailablepumpflowwillbedeterminedbyoneofthe alternativemethods.Thesealternativemethodsareasfollows:1.Portable UltrasonicFlowmeter,2.ControlValvePositiontocalculateflow,3.MotorAmps tocalculatePower,4.Pump △Ttocalculatepumpefficiency. bTheCVcanbe foundontheValveManufacturerscurveforspecificvalvetypeandtrim.Notethat mostofthemajorvalvemanufacturerspostthesecurvesontheirwebsites. cFlow willbeestimatedusingtheoriginalshoptestcurve.Notethatifthepumpisnotin goodconditiontheseestimateswillnotbeveryaccurate. dPumpMaintenance shouldbeconsiderediftheheadandflow(operatingpoint)whenplottedonthe testcurveisapprox.10%belowtestcurveflowforcalculatedhead. eFlowat HighestEfficiencytakenfromtheshoptestcurveintheSupplementarymanual.
Following,theformulasareshownforonesetofdata,so youcanseetheequationsused.
Item#
Date
Input
P1(psig)
P2(psig)
S.G.
PumpSpeed(RPM)
FlowRate(gpm)
Calculate
Head(ft) ¼IF(ISERROR(((10.2*(B8-B7))/B9)),"-", ((2.311*(B8-B7))/B9))
FlowDeterminationa ControlValvePosition
CVforValveandTrimTypeb
FluidS.G.
ControlValve Δ P
CalculatedValveFlow ¼IF(ISERROR((B18/(SQRT(B19/B20)))),"-", (B18/(SQRT(B19/B20))))
MotorAmps Volts
PowerFactor
MotorEff’y
CalculatedPower ¼IF(((B23*B24*B25*B26*SQRT(3))/ 1000)¼0,"-",(B23*B24*B25*B26*SQRT (3))/746)
FlowFromPumpCurvec
T1(Deg.F)
T2(Deg.F)
CP(SpecificHeat)
CalculatedHead ¼B14
CalculatedPumpEff’y ¼IF(ISERROR((B33)/((367100*B32* (B31-B30))+1)),"-",((B33)/((367100 *B32* (B31-B30))+1)))
FlowFromPumpCurvec
PumpMaintenance Requiredd
EROEDetermination
BEPFlowe
EROEMinFlow ¼IF(0.5*B40 ¼ 0,"-",0.5*B40)
EROEMaxFlow ¼IF(1.1*B40 ¼ 0,"-",1.1*B40)
IsPumpinEROE ¼IF(B11 ¼ 0,"-",IF(B11 < B41,"No", IF(B11 > B42,"No","Yes")))
EROETargetsforOperations
Flow
Amps
Pump △ T(MeasuredonInlet andDischargePipes)
EngineeringToolBox. https://www.engineeringtoolbox.com
1.11HowtoAssureThatParameter TrendsAreAccurate Keyfacts •Commontodayistoberequiredtoobtainmachinery parametertrendswhenmachineryconditionchangesor machineryfails.
•Identifytheaffectedcomponent(rotor,bearings,thrust bearing,sealsorlube,sealorcontrolsystem).
•ObtaintheassociatedP&ID(ProcessforRotor), (machineryforbearingsandseals),(lube,seal,control,etc. forauxiliarysystems)thatshowsthetagnumberfor eachtrend.
•Itisessentialthatyouknowwhatthetrendistellingyou.
•Gotothefieldandseewhereeachinstrumentisthatyouwill trendandwhatitismeasuring!
•Inmanycases,thatinstrumentwillnotgiveaccurateinformationbecauseofitslocationandalocalgageorinstalled magneticbaseinstrument(vibration,temperature,etc.)may berequired.Useintrinsicallysafewirelessinstrumentsif possible,toenableimmediatetrending.
•Besuretomodifythetimebaseeffectivelytoshowallaspects ofthetrendbeforeconditionchangeorfailure.
•Assurethatthesamplerateisadequateforyouranalysis.
•Setthresholdvaluestoassureparameterchangeisnoted(see Awarenessinformation below).
Awarenessinformation Trendingisthepracticeofmonitoringparameterconditionwith time.Trendingbeginswithbaselineconditionandwillcontinue untilequipmentshutdown.Inmoderndaythought,itisoften conjecturedthattrendingmustbeperformedbymicroprocessorsandsophisticatedcontrolsystems.Thisisnotnecessary! Effectivetrendingcanbeobtainedbyperiodicmanualobservationofequipment,intrinsicallysafebluetoothinstruments,or usingequipmentavailableintheplantwhichwillincludeDCS systems,etc.Theimportantfactistoobtainthebaselineand trendsofdataonaperiodicbasis.Whentrendingdata,threshold pointsshouldalsobedefinedforeachparameterthatistrended. Thismeansthatwhentheparameterpreestablishedvalueis exceeded,actionmustbetakenregardingproblemanalysis.Settingthresholdvaluesastandardpercentageabovenormalvalue isrecommended.Typically,valuesareontheorderof25%–30% abovebaselinevalues.
Figure1.11.1 presentstrendingdataforahydrodynamic journalbearing.Alltheparametersnotedshouldbemonitored todefinetheconditionofthisjournalbearing.
Component - bearing (journal)
Parameters
Shaft Vibration (x) (mils)
Shaft Vibration (y) (mils)
Shaft Position (’)
Bearing Pad Temp. (*F) A Pad
Bearing Pad Temp. (*F) B Pad
Oil Viscosity(ssu) Oil Flash Point Speed (rpm)
Fig.1.11.1 • Trendingdata.
Trending data
1.12DoestheConclusion MakeSense? Keyfacts •Askyourselfwhatyouaretryingtocalculateandlookat results
•Checkequationnumeratoranddenominatorparametersand seeifitmakessense
Numeratordecrease,answerdecrease
Denominatordecrease,answerincrease
Exponentwholenumber,answerincrease
Exponentfraction,numberdecrease
Awarenessinformation Asayounggraduateengineer,Iwasassignedmyfirstcentrifugal compressoropenimpellerdesignchallengesometimeinthelate 1960s(see Figure1.12.1).Inthe1960s,compressorimpeller designconsistedofafull-scalelayoutoftwobladesshowing bladethickness.Sectionsofthebladesandflowpathweremade andenteredontoanIBMinputsheetthatwentdowntothe IBM360computerdepartmentformakingcardstobeinserted intothecomputer.Twotothreedayslaterresultswouldbe available.
Sincethebladethicknessdesignwasconstantitwaseasyto measurethebladethicknessonceandinstructthecomputer cardpuncherthatallbladeshadthesamethickness.Theblade stressresultswerereceivedandacceptedbytheexperienced designers.Ihadcompletedmyfirstimpellerdesign,anopen impellerpredictedtodeliver82%PolytropicEfficiencyandlast 20yearsormore!
Approximately6monthslater,IwasbroughtintotheChief Engineer’sofficetohearthatmyimpellerhadbeeninstalledat PacificGasandElectric’sWestCostpipelineandhadtestedat 84%PolytropicEfficiency!Congratulationswereextended andIwastoldIcouldleaveearlysinceitwasaFridayand gotomyrentedsummerplaceatthebeachwhichIsharedwith friends.Whilepackingupandtellingmycoworkersofmysuccess,mybosscameintoourofficeandindicatedIwasneeded inhisoffice.Thesameengineerwasonthephonewho reportedmysuccess,butInoticedthattherewastotalsilence. Thepreviouscallhadtheloudcompressorbackgroundnoise. Mybosspromptedtheengineertotellmethesituation.He simplystated“Wefirstthoughttherewasanearthquakewith thevibration,thenthecompressortripped,andyour84% impellerissomewhereinthepipelinebetweenhereandSan Francisco!
Naturally,Ididnotleaveearlythatday!Findingsshowedthat thefull-scalebladethicknessusedfortheflowpathwhich resultedinimpellerperformanceandefficiencywas1/8ofan inch.However,myinputtothecomputerprogramwas1/4 ofaninch.Lessonlearnedthehardway!Alwayscheckyour resultscarefully!
Websitereference Howtocheckformulasinexcel.August12,2011. https://www.bing.com/search?q=How+to+check +formulas+in+excel.+August+12%2C+2011.&form= ANSPH1&refig=e4cb1a790837407eb0a5cd7407756010& pc=U531
1.13GetuptoSpeedonNonincendive WirelessMachineryMonitoring Instrumentation Keyfacts Exactdimensionsofsectionsoftheflowpathwererequired fortheaerodynamicprogramandthesamewasrequiredforthe bladestressprogram.Theaerodynamicflowpathwasfinally confirmedafternumerousattemptsandconsultationwiththe experienceddesignersinmycompany.
Atthatpointitwasnecessarytoconfirmthemechanical stressoftheimpellerbladesandsupportinghubusingexact dimensionsfromthefull-scalelayout.
•ManywirelessISA100andHARTintrinsicallysafeand nonincendiveinstrumentsareavailabletoday.
•Theycanbeinstalledeasilytomonitormachinerytemperature,pressure,flow,vibrat ion,displacement,andvalve position.
•Ihavefoundtheirbenefitfor Monitoringtroublesomepumps(badactors) Centrifugalcompressorperformance(pressures,temperatures,andflowsfortrendingofefficiencyandoperating point)whereinstrumentationhasnotbeeninstalled
Fig.1.12.1 • Opentypecentrifugalcompressorimpeller.
Awarenessinformation BakerHughesandEmersonHARTofferaprovenlineofwirelessintrinsicallysafeandnonincendiveinstrumentsapprovedby ISA100andAPI6705theditionformonitoringof:
Flow
Pressure
Temperature ValvePosition Vibration
Atthepresenttime,wirelessinstrumentsarenotapproved forprotectivesystems.
Transmissiondistanceswithrepeatersandnetworkconfigurationsallowtransmissiondistancessufficientforcondition monitoringinthecontrolroom.
Consultyourplantmanagementtoassurethattheseinstrumentsmeetsecurityrequirements.
Websitereferences ISA100wirelesstutorial.8/13/2020.
https://www.rfwireless-world.com/Tutorials/ISA100wireless-tutorial.html
Whatisthedifferencebetweennonincendiveandintrinsically safe?8/13/2020.
https://intrinsicallysafestore.com/non-incendive-andintrinsically-safe/ IndustrialWirelessTechnology j EmersonUS.8/18/2020. https://www.emerson.com/en-us/automation/measurementinstrumentation/industrial-wireless-technology RangerProWirelessConditionMonitoring&VibrationSensor. 9/10/2021.
https://www.bakerhughesds.com/bently-nevada/onlinecondition-monitoring/ranger-pro-wireless-sensor-system
1.14AskforProjectAssignments Keyfacts •Becominginvolvedassoonaspossiblewithmachineryprojectswilladdsignificantvaluetoyourcareerintermsof machinerysafetyandreliabilityrequirements.
•Projectassignmentswillexposeyoutocost-effectiveness,daily revenuechallenges,andlifecyclecostanalysisaswellasexposureto theEP&Cs(Engineering,ProcurementandConstructionCompanies)andtheMachineryOEMs(OriginalEquipmentManufacturer)andlearningtheirapplicationlimitsandexperience.
•Youwillbeworkingwithexperiencedmaintenance,operation,andprocesspersonnelandlearnhowthosedisciplines influencethesafetyandreliabilityofrotatingmachinery.
Awarenessinformation Duringthefirstpartofmycareer,Ispentalotoftimeinclient’s plantswhileworkingasacentrifugalcompressordesignengineer. Ibecameawareoftheimpactoftheprocessandinfrastructure (electrical,cooling,steam,air,lubricationandsealingsystems)
onmachinerysafetyandreliability.Whileworkingforamajor chemicalandrefiningcompanyIparticipatedasamachineryspecialistinmanyrefiningandchemicalprojects.Theexperience gainedintheseprojectshasbeenamajorpartofmyknowledge baseintermsoflessonslearnedandmachinerybestpracticesto assuremachinerysafetyandreliabilityisoptimizedforinitial selection,installation,andconditionmonitoringforproactive predictivemaintenanceoftheinstalledmachinerytoenable remedialactionpriortoacostlycriticalmachineryfailure.
Websitereference Professionrotatingequipmentengineer11/05/2021. https://www.123test.com/professions/profession-rotatingequipment-engineer/
1.15ParticipateinTurnarounds Keyfacts •Turnaroundspresentagreatopportunitytoseetheinternals ofthemachinery.
•Theyalsoexposeyoutotheneedforscheduleswhileassuring correctinstallation.
•TheywillexposeyoutoworkingwithOEMfieldspecialists. Helpthemandtheywillhelpyou!
•Theyprovideagreatopportunitytoallowoperatorsandprocess engineerstoseetheinternalsofthemachinery(pumps,compressors,turbines,etc.)sothattheycanlearnaboutthefunction oftheinternalcomponents(rotor,bearings,seals,etc.)andhow importantthetrendstheymonitorareinpreventingmachinery failure.Thatis,beawareofcomponentconditionchangeprior toanalarmand/ortrip.
Awarenessinformation Asnotedbefore,theimportanceofobservingthemajorcomponents,knowingtheirfunction,andthetrendingparametersto determinetheirconditionisessentialtopreventingcriticalmachineryfailuresthatwillimpactsafetyandrevenue.Thefollowingcase historydemonstratesthisimportanceofusingtrendsofthefive majorcomponents(rotor,journalbearings,thrustbearings,seals, andauxiliarysystems)tominimizethelengthsofturnarounds.
Acentrifugalcompressorinalargerefinerywasscheduledfor maintenanceduringtheupcomingturnaround.Maintenance planninghadscheduledbearinginspectionandchangeifnecessary.Duringtheturnaroundwhenthebearingswereinspected, excessiveclearancesandsignsofdeteriorationwerefound.Naturally,thebearingswerereplaced.However,becausethebearings werereplaced,itwasdecidedthattheseals,whicharemoredifficulttoremoveandinspect,bechecked.Uponremoval,theseals werealsoinadistressedconditionandneededtobereplaced. Nowthetoughdecisionshadtobemade.Itwasdecidedthat thecompressorwouldbedisassembledtoinspecttheinterior conditionforthepossiblecausesofsealandbearingfailure.
Uponcompressordisassemblywhichwasdelayedduetothe difficultyofremovingtheinnercompressorbarrel(see Figure1.15.1),nosignificantabnormalitieswerefound,andit wassuccessfullyreassembled.
