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SECOND EDITION Practical Machinery Management for Process Plants Volume 3 .. . Turbomachinery Overhauls Foundations and Grouting Alignment and Balancing Pump Shaft Repairs Mechanical Seals Machinery Components . . Heinz P. Bloch Fred K. Geitner Practical Machinery Management tor Process Plants Volume 3, Second Edition Machinery Component Maintenance and Repair Gulf Publishing Company Houston. Texas 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, Houston, 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., 1933Machinery 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 equipmentMaintenance 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 described herein are of a general nature and may have to be modified or adapted to be directly applicable to the specific machinery in his plant. In casc of conflict, observe the manufacturer’s instructions or ask the manufacturer to assist in resolving any differences. Printed on Acid-Free Paper (co) iv Contents ........................................... ...................................... Foreword Acknowledgments viii ix Part I: Background to Process Machinery Maintenance Programming ...................................... 1 1 Machinery Maintenance: An Ovaview ...................3 2 Maintenance Organization and Control for Multi-Plant Corporations ...................................... 12 Type of Operation. Manager’s Role. Central Control System. Planning Turbomachinery Overhauls. Assignment of Qualified Personnel. Specific Preparation and Planning. Inspection. Cleaning. Reassembly. Documenting What You’ve Done. 3 Machinery Foundations and Grouting ...................65 What’s An Epoxy? Epoxy Grouts. Proper Grout Mixing is Important. Job Planning. Conventional Grouting. Methods of Installing Machinery. Pressure-Injection Regrouting . Foundation Repairs. Pump Baseplate Installation and Epoxy Grouting. Baseplate Leveling Procedures. Baseplate Preparation. New Concrete Preparation. Old Concrete Preparation. Anchor Bolts. Grout Forms. Epoxy Grout Placement. Appendix 3-A-Detailed Checklist for Rotating Equipment: Horizontal Pump Baseplate Checklist. Appendix 3-B-Specification for Portland Cement Grouting of Rotating Equipment. Appendix 3-C-Detailed Checklist for Rotating Equipment: Baseplate Grouting. Appendix 3-DSpecifications for Epoxy Grouting of Rotating Equipment. 4 Process Machinery Piming ........................... Fundamentals of Piping Design Criteria. Piping Design Procedure. Flange Jointing Practices. Primary Causes of Flange Leakage. Proper Gasket SelecV 142 tion. Controlled Torque Bolt-Up of Flanged Connections. Recommendations for the Installation, Fabrication, Testing, and Cleaning of Air, Gas, or Steam Piping. Appendix 4-A-Checklist for Rotating Equipment: Machinery Piping. Appendix 4-B-Specifications for Cleaning Mechanical Seal Pots and Piping for Centrifugal Pumps. Appendix 4-C-Detailed Checklist for Rotating Equipment: Pump Piping. ......................... 5 Machinery Alignment ............................... Part II: Aliflnment and Balancing 16s 171 Prealignment Requirements. Choosing an Alignment Measurement Setup. Checking for Bracket Sag. Face Sag Effect-Examples. Interpretation and Data Recording. Graphical Techniques. Reverse Indicator Method Using Crossover Brackets. Horizontal Movement by Vertical Adjustment. Thermal GrowthEleven Ways to Correct for it. Thermal Growth Estimation by Rules of Thumb. 6 Balancing of Machinery Components ................... 238 Definition of Terms. Purpose of Balancing. Units of Unbalance. Types of Unbalance. Motions of Unbalanced Rotors. Balancing Machines. Centrifugal Balancing Machines. Measurement of Amount and Angle of Unbalance. Classification of Centrifugal Balancing Machines. Maintenance and Production Balancing Machines. Supporting the Rotor. Balancing Keyed End-Drive Adapters. Balancing Arbors. Testing Balancing Machines. Test Procedures. Balance Tolerances. Balance Errors Due to Rotor Support Elements. Computer-Aided Balancing. Field Balancing Overview. The Vector Diagram. Appendix 6-A-Balancing Terminology. Appendix 6-B-Balancing Machine Nomenclature. Appendix 6-C-Balancing and Vibration Standards. Appendix 6-D-Critical Speeds of Solid and Hollow Shafts. Part 111: Maintenance and Repair of Machinery Components 7 Ball Bearing Maintenance and Replacement ....349 ............. 351 Engineering and Interchangeability Data. Cleanliness and Working Conditions in Assembly Area. Removal of Shaft and Bearings from Housing. Cleaning the Bearing. Shaft and Housing Preparation. Checking Shaft and Housing Measurements. Basic Mounting Methods. Hints on Mounting Duplex Bearings. Preloading of Duplex Bearings. Importance of the Correct Amount of Preload. Assembly of Bearings on Shaft. Cautions to Observe During Assembly of Bearings into Units. Mounting with Heat. Checking Bearings and Shaft After Installation. Testing of Finished Spindle. Maintain Service Records on All Spindles. vi 8 Repair and Maintenance of Mechanical Seals and Rotating .430 Equipment Components ............................ Mechanical Seal Installation, Repair, and Maintenance. Lapping and Seal Face Flatness. Installation of Stuffing Box Packing. Welded Repairs to Pump Shafts and Other Rotating Equipment Components. How to Decide if Welded Repairs are Feasible. Case Histories. High Speed Shaft Repair. Shaft Straightening. Straightening Carbon Steel Shafts. Casting Salvaging Methods. 9 Centrifugal Compressor Rotor Repair ..................487 Compressor Rotor Repairs. Impeller Manufacture. Compressor Impeller Design Problems. Impeller Balancing Procedure. Rotor Bows in Compressor and Steam Turbines. Clean Up and Inspection of Rotor. Disassembly of Rotor for Shaft Repair. Shaft Design. Rotor Assembly. Shaft Balancing. Rotor Thrust in Centrifugal Compressors. Managing Rotor Repairs at Outside Shops. Mounting of Hydraulically Fitted Hubs. Dismounting of Hydraulically Fitted Hubs. 10 Protecting Machinery Parts Against loss of Surface ...... 518 Basic Wear Mechanisms. Hard Surfacing Techniques. Special Purpose Materials. The Detonation Gun Process. Selection and Application of 0-Rings. Casing Joint Compounds. Sealing Compounds. Index .............................................. vii 586