Practical Machinery Management for Process Plants. Machinery Component Maintenance and Repair

595 Pages·1990·45.164 MB·English

by  Heinz P. Bloch and Fred K. Geitner (Auth.)

Practical Machinery Management for Process Plants
Volume 3, Second Edition
Machinery Component
Maintenance and Repair
Heinz P. Bloch and
Fred K. Geitner
This edition was
reviewed by the authors
and reprinted in 1999.
I I
Practical Machinery Management for Process Plants
Volume 3, Second Edition
Machinery Component Maintenance and Rerair
Copyright 0 1985, 1990 by Gulf Publishing Company, Hous-
ton, Texas. All rights reserved. Printed in the United States of
America. This book, or parts thereof, may not be reproduced
without permission of the publisher.
Gulf Publishing Company
Book Division
P.O. Box 2608 0 Houston, Texas 77252-2608
10 9 8 7 6 5 4 3
Library of Congress Cataloging-in-Publication Data
Bloch, Heinz P., 1933-
Machinery component maintenance and repairlHeinz P. Bloch and
Fred K. Geitner.-1st ed.
p. cm.-(Practical machinery management for process plants; v. 3)
Includes index.
ISBN 0-87201-781-8
1. Machinery-Maintenance and repair. 2. Industrial equipment-
Maintenance and repair. 1. Geitner, Fred K. 11. Title.
111. Series: Bloch, Heinz P., 1933-. Practical machinery management
for process plants; v. 3.
TJIS3.BS83 1990
670‘ .28’8-d~20 90-3579
CIP
Series ISBN 0-87201-675-7
Note: The reader is reminded that many of the techniques and procedures de-
scribed herein are of a general nature and may have to be modified or adapted
to be directly applicable to the specific machinery in his plant. In casc of con-
flict, observe the manufacturer’s instructions or ask the manufacturer to assist
in resolving any differences.
Printed on Acid-Free Paper (co)
iv
Foreword
A machinery engineer’s job was accurately described by this ad, which ap-
peared in the classified section of the New York Times on January 2, 1972:
Personable, well-educated, literate individual with college
degree in any form of engineering or physics to work . . . Job re-
quires wide knowledge and experience in physical sciences, mate-
rials, construction techniques, mathematics and drafting. Compe-
tence in the use of spoken and written English is required. Must be.
willing to suffer personal indignities from clients, professional de-
rision from peers in more conventional jobs, and slanderous in-
sults from colleagues.
Job involves frequent physical danger, trips to inaccessible loca-
tions throughout the world, manual labor and extreme frustration
from lack of data on which to base decisions.
Applicant must be willing to risk personal and professional fu-
ture on decisions based on inadequate information and complete
lack of control over acceptance of recommendations . . .
Well, that was in 1972. Since then, however, the job has not become any sim-
pler. The cost of machinery outages and repairs has escalated. The prerequisites
required to be able to perform as a machinery engineer could even be expanded
thus:
A knowledge of stress analysis, measurement techniques, in-
strumentation, vibration analysis, materials, machine shop proce-
dures, fluid flow, rotor dynamics, machinery field erection and
startup procedures, and an understanding of effective maintenance
management.
This list is by no means complete. And since very few of us feel absolute mas-
ter of all of these areas, we seek guidelines, procedures, and techniques that
have worked for our colleagues elsewhere. Collecting these guidelines for every
machinery category, size, type, or model would be almost impossible, and the
resulting encyclopedia would be voluminous and outrageously expensive.
Therefore, the only reasonable course of action has been to be selective and as-
semble the most important, most frequently misapplied or perhaps even some of
the most cost-effective maintenance, repair, installation, and field verification
procedures needed by machinery engineers serving the refining and petrochemi-
cal process industries.
This is what my colleagues, Heinz P. Bloch and Fred K. Geitner, have suc-
ceeded in doing. Volume 3 of this series on machinery management brings us the
know-how of some of the most knowledgeable individuals in the field. Engi-
neers and supervisors concerned with machinery and component selection, in-
stallation, and maintenance will find this an indispensable guide.
Here, finally, is a long-needed source of practical reference information which
the reader can readily adapt to similar machinery or installations in his particular
plant environment.
Uri Sela
Walnut Creek, California
viii
Acknowledgments
It would have been quite impossible to write this text without the help and cooper-
ation of many colleagues and friends. When we explained our intention to follow up
on Wumes 1 and 2 of this series by assembling pertinent material for hlumes 3 and
4, we struck a responsive chord with professionals who shared our goal of providing
a practical reference text on the subject of machinery maintenance and repair. These
companies or individuals have earned our respect and gratitude for allowing us to
use, adapt, paraphrase or otherwise incorporate their work in Wume 3: W. J. Scha-
rle (Multi-Plant Maintenance), J. A. Trotter (Computer-Based Maintenance), J. D.
Houghton (Planning lhtmnachinery Overhauls), E. M. RenfdAdhesive Services
Company (Major Machinery Grouting and Foundation Repair), M. G. Murray
(Grouting Checklists, Machinery Alignment), C. C. Fletcher (Machinery Align-
ment, Installation, Checkout), Pruekhnik Dieter Busch (Laser Alignment). €? C.
M o m ( Machinery Installation Checklists), J. W. Dufour (Machinery Installation
Guidelines), W. Schmidt (Piping Connection Guidelines), D. C. Stadelbauer,
Schenk Trebel Corporation. (Balancing of Machinery Components), MRC Division
of SKF Industries (Bearing Installation and Maintenance), Bill Carpenter, Durame-
talk Corporation (Metallic Seal Installation, Repair, Maintenance), H. A. Scheller
(Pump Packages). T. Doody (Welded Repairs to Pump Shafts. etc.). H. A. Erb (Re-
pair Techniques for Machinery Rotor and Case Damage), Byron Jackson Pumps
(Field Machining Procwiures). %rry Washington, In-Place Machining Company
(Metal Stitching Techniques), Barney McLaughlii, Hickham Industries, Inc.. and
W. E. Nelson (Compressor Rotor and Component Repairs, Sealing Compounds.
etc.), M. CalistratfKoppers Company (Mounting Hydraulically Fitted Hubs), C. R.
McKinsey and K. G. Budinski (Hard Surfacing), C. R. Cooper, hD er Horst Cor-
poration (Chrome Plating), Tbrbine Metal Bchnology (Diffusion Alloys) and Na-
tional 0-Ring Company (0-Ring Selection and Application).
Three highly qualified machinery engineers. D. L. E. Jacobs, W. A. Clark
and Dino Troisi, took care of the appropriate Exxon Chemicals manuscript re-
views; their efforts were sincerely appreciated as, of course. were those of our
close personal friend Uri Sela who devoted so much of his personal time to a
detailed review of the entire draft, galleys, and page proofs. Uri counseled us on
technical relevance. spelling, syntax and other concerns. Last. but not least. we
are indebted to our editor, Brad Sagstetter.
As we put the finishing touches on the simultaneously released companion
Volumes 3 and 4 in our series on “Practical Machinery Management for Process
Plants,” we are reminded of some important remarks made by Exxon Chemical
Technology Vice President W.J . Porter, Jr. in early 1984. Mr. Porter expressed
the helief that through judicious use of outside contacts, participation in relevant
activities of technical societies, and publication of pertinent material. we can be
sure that our technical productivity will continue to improve. The technical per-
son will thus be updated on the availability of “state-of-the-art” tools and indi-
vidual creativity encouraged.
With these sentiments, which so fittingly express our thoughts. we conclude
by thanking Exxon Chemical Company for permitting us to tackle this challeng-
ix
ing task on our own. It certainly accomplished for us what it is to accomplish for
the reader: Find new and better ways to do our jobs, broaden our perspective as
engineers, and contribute to a fund of knowledge which-if properly tapped-
will bring benefits to everyone.
Heinz I? Bloch
Fred K. Geitner
X
Chapter 1
Machinery Maintenance: An
Overview
Maintenance and repair of machinery in a petrochemical process plant
was defined in a preceding volume as simply “defending machinery
equipment against deterioration.” Four strategies within the failure-
fighting role of maintenance were defined:
Preventive
Predictive
Breakdown or demand based
“Bad actor” or weak spot management
0
Machinery maintenance can often be quite costly in a petrochemical
plant operation. Prior to the the publication of the first two volumes of
this series. very few studies were available describing quantitative or ob-
jective methods for arriving at the optimization of the four strategies’.
Though our readers should not expect detailed contributions to those sub-
jects in this volume, we did opt to include an overview section describing
the maintenance philosophy practiced in a large multi-plant corporation
which makes effective use of centralized staff and computerized planning
and tracking methods.
What, then, can our readers expect? After a short definition of the ma-
chinery maintenance problem we will highlight centralized maintenance
planning. We will then guide our readers through the world of machinery
maintenance procedures by identifying the What, When, Where, Why.
How-and sometimes Who-of most maintenance and repair activities
around petrochemical process machinery. We ask. however, that our
readers never lose sight of the total picture. What. then is the total pic-
ture?
3
4 Machinery Component Maintenance and Repair
It is the awareness that true cost savings and profitability can only be
achieved by combining machinery reliability, safety, availability, and
maintainability into a cost-effective total-consistent with the intent of
our series of volumes on process machinery management. Figure 1-1 il-
lustrates this concept. Consequently, machinery maintenance cannot be
looked at in isolation. It will have to be governed by equipment failure
experience, by our effectiveness in failure analysis and troubleshooting',
and by built-in reliability3.
Maintenance in a broad definition is concerned with controlling the
condition of equipment. Figure 1-2 is a classification of most machinery
maintenance problems.
Deterministic or predictive component life problems are those where
no uncertainty is associated with the timing or consequence of the main-
tenance action. For example, we may have equipment whose components
are not subject to actual failure but whose operating cost increases with
time. A good illustration would be labyrinths in a centrifugal process
compressor. To reduce operating cost caused by increasing leakage rate,
some form of maintenance work can be done-usually in the form of re
I I
OPERRTINB
STFINDQRDS
AVAILABILITY (S.F.) OPERATING COSTS TECH. OBSOLESCENCE
Eux. (MTBF) MlN. (KITR) RX. EFFICIENCY
Figure 1-1. The total picture: Possible goals of process machinery management.
e) s P 3 n d s 9' ii 3 rr ? % 0 5 5. F
Lif
nt
Probabilistic minate Compone Organizational Concerns
er
et
d
n
(I
Bad Actor Management - 8 inspection Failure Analysis - Spot Weak identification - Modification in Operating 8 Procedures, Maintenance Design nce problems.
a
n
s e
si nt
kdownlDemand Based 8 pection Failure Analypair placement of on machinery mai
Brea - ins- Re- Re sificati
PredictivelCondition Based - Monitoring Surveillance 8 - Inspection (On10ftLine) - Overhaul Repair 8 - Replacement Figure Clas1-2.
g
Deterministic dictable Component Life) PreventivelPeriodic - Inspection - Adjustment - Alignment - Replenishing - Charging - Cleaning - Loosening - DrainingNentinglDryin- Lubricating - Balancing - 8 Overhaul Repair - Replacement
e
Pr
(
6 Machinery Component Maintenance and Repair
placement or overhaul. After maintenance the future trend in operating
cost is known or at least anticipated. Such a deterministic situation is il-
lustrated in Figure 1-3.
In probabilistic or indeterminate component life problems, the timing
and result of maintenance may depend on chance. In the simplest situa-
tion a piece of machinery can be described as being “good” or “failed.”
From a frequency distribution of the time elapsed between maintenance
activity and failure it is possible to determine the variations in the proba-
bility of failure with elapsed time. These relationships are thoroughly
dealt with in Reference 1.
Wi: saw from Figure 1-2 that inspection, overhaul, repair and finally
replacement are common to all maintenance strategies. The basic pur-
pose of inspection is to determine the condition of our equipment. All
machinery inspection should be based on these considerations:
1. Expected failure experience:
Deterministic
Probabilistic
2. Inspection cost.
3. Probability and risk of failure.
4. Probable consequences of failure, Le., safety-health, and business
loss.
5. The risk that inspection will cuuse a problem4.
6. The quality of on-stream condition monitoring results.
I : time
Figure 1-3. Deterministic trend in costs.
Machinery Maintenance: An Overview 7
The terms overhaul and repair are often reserved for maintenance ac-
tions that improve the conditions of an item, but may or may not establish
“good as new” condition. In fact, overhaul is often interpreted as a pre-
ventive maintenance action while repair is strictly reserved for mainte-
nance of an item that has reached a defined failed state or defect limit?.
Replucemenr should be understood in our context as a broad term that
includes the replacement of components, operating fluids and charges, as
well as of complex machinery and systems. Finally, we understand or-
ganizational srrucrure problems in machinery maintenance as those con-
cerns that deal with maintainability parameters such as facilities, man-
power, training, and tools. Figure 1 4 i llustrates this point.
Most petrochemical process plants have a preventive maintenance
(PM) system. The authors know of a plant where 95 96 of the maintenance
work orders are turned in by the PM crews and not the operators. While
this is an extreme-and probably not a very cost effective-way of fail-
ure fighting, we can support a moderate approach to machinery PM.
This moderate approach begins with an attempt to plan all PM actions by
following this pattern:
1. Determine what defect, failure, or deterioration mode’ it is you
want to prevent from occurring.
2. Determine whether the defect, failure, or deterioration mode can be
prevented by periodic actions. If not, determine how it can be pre-
WINTAINABILITY
MAXIMIZE OWOFF-LINE HAXIMIZE f44XIMIZE
MTC. ACCESSIBILITY MINIMIZE -ON-LIHE CONDITION/ ECONOllICALLV
ON-LINE INSPEC PERFOMNEE INSURAHCE
CLEANING MONITORING AND SPARE PARTS
pn
(SERYICIBILITY)
LIGHTING
SPECIAL TWLS
SHELTER
ACCESSIBILITY
OTHER
Figure 1-4. Process machinery maintainability components.