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Practical Machinery Management for Process Plants Volume 3, Third Edition Machinery Component Maintenance and Repair This page intentionally left blank Practical Machinery Management for Process Plants Volume 3, Third Edition Machinery Component Maintenance and Repair Heinz P. Bloch and Fred K. Geitner AMSTERDAM • BOSTON • HEIDELBERG • LONDON • NEW YORK OXFORD • PARIS • SAN DIEGO • SAN FRANCISCO • SINGAPORE SYDNEY • TOKYO Gulf Professional Publishing is an imprint of Elsevier Gulf Professional Publishing is an imprint of Elsevier 30 Corporate Drive, Suite 400, Burlington, MA 01803, USA Linacre House, Jordan Hill, Oxford OX2 8DP, UK Copyright © 2005, Elsevier Inc. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, 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: permissions@elsevier.com.uk. You may also complete your request on-line via the Elsevier homepage (http://elsevier.com), by selecting “Customer Support” and then “Obtaining Permissions.” Recognizing the importance of preserving what has been written, Elsevier prints its books on acidfree paper whenever possible. Library of Congress Cataloging-in-Publication Data Application submitted British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. ISBN: 0-7506-7726-0 For information on all Gulf Professional Publishing publications visit our Web site at www.books.elsevier.com 04 05 06 07 08 09 10 9 8 7 6 5 4 3 2 1 Printed in the United States of America Contents Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Part I: Background to Process Machinery Maintenance Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Machinery Maintenance: An Overview . . . . . . . . . . . . . . . . . 3 2 Maintenance Organization and Control for Multi-Plant Corporations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Type of Operation. Manager’s Role. Maintenance. Central Control System. Incentives for Computer Systems. Setting Up an Effective System. Machinery Maintenance on the Plant Level. Assignment of Qualified Personnel. Timing and Basic Definition of Critical Pre-Turnaround Tasks. Specific Preparation and Planning. Documenting What You’ve Done. 3 Machinery Foundations and Grouting . . . . . . . . . . . . . . . . . . 61 What’s an Epoxy? Epoxy Grouts. Proper Grout Mixing Is Important. Job Planning. Conventional Grouting. Methods of Installing Machinery. PressureInjection Regrouting. Prefilled Equipment Baseplates: How to Get a Superior Equipment Installation for Less Money. 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-D—Specifications for Epoxy Grouting of Rotating Equipment. Appendix 3-E—Specification and Installation of Pregrouted Pump Baseplates. v 4 Process Machinery Piping . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Fundamentals of Piping Design Criteria. Piping Design Procedure. The When, Who, What, and How of Removing Spring Hanger Stops Associated with Machinery. Flange Jointing Practices. Primary Causes of Flange Leakage. The Importance of Proper Gasket Selection. Flange Types and Flange Bolt-Up. Controlled Torque Bolt-Up of Flanged Connections. Recommendations for the Installation, Fabrication, Testing, and Cleaning of Air, Gas, or Steam Piping. Pickling Procedure for Reciprocating Compressor Suction Piping: Method I. Cleaning of Large Compressor Piping: Method II. Appendix 4-A—Detailed 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. Part II: Alignment and Balancing . . . . . . . . . . . . . . . . . . . . . . . . . 197 5 Machinery Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 Prealignment Requirements. Choosing an Alignment Measurement Setup. Checking for Bracket Sag. Face Sag Effect—Examples. Interpretation and Data Recording. The Graphical Procedure for Reverse Alignment. Thermal Growth— Twelve Ways to Correct for It. Thermal Growth Estimation by Rules of Thumb. 6 Balancing of Machinery Components . . . . . . . . . . . . . . . . . . . 258 Definition of Terms. Purpose of Balancing. 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. Establishing a Purchase Specification. Supporting the Rotor in the Balancing Machine. End-Drive Adapters. Balancing Keyed End-Drive Adapters. Balancing Arbors. Testing Balancing Machines. Inboard Proving Rotors for Horizontal Machines. Test Procedures. Balance Tolerances. Special Conditions to Achieve Quality Grades G1 and G0.4. Balance Errors Due to Rotor Support Elements. Recommended Margins Between Balance and Inspection Tolerances. ComputerAided Balancing. Field Balancing Overview. Field Balancing Examples. Appendix 6-A—Balancing Terminology. Appendix 6-B—Balancing Machine Nomenclature. Appendix 6-C—Balancing and Vibration Standards. Appendix 6D—Critical Speeds of Solid and Hollow Shafts. Part III: Maintenance and Repair of Machinery Components . . . . . 367 7 Ball Bearing Maintenance and Replacement . . . . . . . . . . . . . . 369 Engineering and Interchangeability Data. Cleanliness and Working Conditions in Assembly Area. Removal of Shaft and Bearings from Housing. Cleaning the vi 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. Assembly of Shaft and Bearings into Housing. Testing of Finished Spindle. Maintain Service Records on All Spindles. 8 Repair and Maintenance of Rotating Equipment Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447 Pump Repair and Maintenance. 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. OEM vs. Non-OEM Machinery Repairs. 9 Centrifugal Compressor Rotor Repair . . . . . . . . . . . . . . . . . . 501 Compressor Rotor Repairs. Impeller Manufacture. Compressor Impeller Design Problems. Impeller Balancing Procedure. Rotor Bows in Compressors 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 . . . . . . . 536 Basic Wear Mechanisms. Hard-Surfacing Techniques. Special Purpose Materials. The Detonation Gun Process. Selection and Application of O-Rings. Appendix 10-A—Part Documentation Record. Procedures and Materials Used for Hard-Surfacing. Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617 vii Foreword A machinery engineer’s job was accurately described by this ad, which appeared 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 requires wide knowledge and experience in physical sciences, materials, construction techniques, mathematics and drafting. Competence in the use of spoken and written English is required. Must be willing to suffer personal indignities from clients, professional derision from peers in more conventional jobs, and slanderous insults from colleagues. Job involves frequent physical danger, trips to inaccessible locations 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 future on decisions based on inadequate information and complete lack of control over acceptance of recommendations . . . The situation has not changed. As this third edition goes to press, there is an even greater need to 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 assemble 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 petrochemical process industries. This is what my colleagues, Heinz P. Bloch and Fred K. Geitner, have succeeded 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. Engineers and supervisors concerned with machinery and component selection, installation, and maintenance will find this an indispensable guide. Here, then, is an updated 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 cooperation of many individuals and companies. These contributors have earned our respect and gratitude for allowing us to use, adapt, paraphrase, or otherwise incorporate their work in Volume 3: W. J. Scharle (Multi-Plant Maintenance), J. D. Houghton (Planning Turbomachinery Overhauls), E. M. Renfro/Adhesive Services Company (Major Machinery Grouting and Foundation Repair), M. G. Murray (Grouting Checklists, Machinery Alignment), Prueftechnik A. G. (Laser Alignment), P. C. and Todd Monroe (Machinery Installation Checklists and PreGrouted Baseplates), J. W. Dufour (Machinery Installation Guidelines), W. Schmidt (Piping Connection Guidelines), Garlock Sealing Technologies and Flexitallic, Inc. (Gasket Selection and Flange Torque Requirements), D. C. Stadelbauer, Schenk Trebel Corporation (Balancing of Machinery Components), MRC Division of SKF Industries (Bearing Installation and Maintenance), Flowserve Corporation (Metallic Seal Installation, Repair, Maintenance), H. A. Scheller (Pump Packing), T. Doody (Welded Repairs to Pump Shafts, etc.), H. A. Erb (Repair Techniques for Machinery Rotor and Case Damage), Byron Jackson, Division of Flowserve Corporation (Field Machining Procedures), Terry Washington, In-Place Machining Company (Metal Stitching Techniques), Tony Casillo (OEM vs. NON-OEM Machinery Repairs), Barney McLaughlin, Hickham Industries, Inc., and W. E. Nelson (Compressor Rotor and Component Repairs, Sealing Compounds, etc.), M. Calistrat/Koppers Company (Mounting Hydraulically Fitted Hubs), Larry Ross, C. R. McKinsey and K. G. Budinski (Hard Surfacing), C. R. Cooper, Van Der Horst Corporation (Chrome Plating), Turbine Metal Technology (Diffusion Alloys) and National O-Ring Company (O-Ring Selection and Application). We also appreciate 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. More than ever before, 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 belief 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 person will thus be updated on the availability of “state-of-the-art” tools and individual creativity encouraged. We hope this revised text will allow readers to find new and better ways to do their jobs, broaden their perspective as engineers, and contribute to a fund of knowledge which—if properly tapped—will bring benefits to everyone. Heinz P. Bloch Fred K. Geitner ix