Practical Machinery Management for Process Plants: Volume 1: Improving Machinery Reliability
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Table of contents
- Cover
- Improving Machinery Reliabilityi
- Copyright Pageiv
- Contentsv
- Prefaceviii
- Introductionx
- Chapter 1. Requirements Specification1
- Industry Standards Available for Major Machinery in Process Plants1
- How to Deal with the Typical API Data Sheet2
- Narrative Specifications Lead to Better Machinery15
- Considering Uprateability and Low Failure Risk21
- Auxiliary Systems for Turbomachinery: The Systematic Approach24
- Dealing with Deviations from the Specification34
- Specifying Machinery Documentation Requirements37
- Conclusion51
- Chapter 2. Vendor Selection and Bid Conditioning53
- Selecting Major Machinery Vendors53
- Applying and Reviewing Machinery Reliability Improvements Derived from Modern Electronics54
- Selecting a Pump Vendor64
- Bid Tabulation and Bid Conditioning: An Overview76
- Reference81
- Chapter 3. Machinery Reliability Audits and Reviews82
- Audits Versus Reviews82
- Where to Concentrate Audit and Review Efforts82
- Rotordynamic Design Audits83
- Auditing and Reviewing Centrifugal Compressors125
- Auditing and Reviewing Steam Turbines135
- Evaluating Major Reciprocating Compressors139
- Reliability Review for Centrifugal Pumps146
- Significant Differences in Bearings and Bearing Housings156
- Marginal Lubrication: A Factor in Pump Failures160
- Applying Roller Bearings in Centrifugal Pumps168
- How Much Oil Is Enough?171
- Bearing Selection Can Make a Difference172
- Air Cooling Provisions for Bearing Housing„How Good?173
- Stuffing Box Cooling Is Not Usually Effective174
- Pumps for Handling Entrained Gases176
- Selection Criteria for Zero Emission Pumps178
- Design Appraisals for Special-Purpose Gearing181
- Evaluating Cooling Tower Fans and Their Drive Systems200
- Reliability Reviews in Uprate Situations203
- Reliable Shaft-Hub Connections for Turbomachinery Couplings213
- How to Keep Track of Reliability Review Tasks224
- Machinery Reliability Audits for Existing Plants238
- References238
- Chapter 4. Maintenance and Benchmarking Reliability242
- Maintenance Measurement242
- Organize to Manage Reliability249
- Maintenance Cost vs. Replacement Asset Value: Another Maintenance Spending Benchmark257
- Chapter 5. Life Cycle Cost Studies259
- Simplified Life Cycle Cost Estimating259
- Life Cycle Cost Assessment: The Rigorous Method272
- Summary310
- References310
- Chapter 6. Extending Motor Life in the Process Plant Environment313
- Squirrel-cage Motors Are Most Prevalent314
- Motor Insulation Systems314
- Insulation Classification315
- Ambient Plus315
- A Bank of Motor Life317
- Running Cooler„A Relative Term318
- Thermal Cushion319
- Enclosures319
- Standard, but Different319
- Learning from Failures320
- More about Thermal Loading320
- Economics of Oversizing321
- Keep Bearings in Mind323
- Motor Mounting Basics325
- Motor System Tuneup326
- Pumping and Piping326
- Power Points326
- Over-Current Insurance327
- Motor Life Insurance Terms328
- Notes328
- Chapter 7. Equipment Reliability Improvement through Reduced Pipe Stress329
- Allowable Load331
- Excessive Flexibility333
- Theoretical Restraints334
- Expansion Joints335
- Other Practical Considerations337
- Chapter 8. Startup Responsibilities339
- Summary of Startup Preparations for Process Plant Machinery339
- Machinery Startup Review Tasks342
- Machinery Startup Reporting Structure344
- Documentation for Effective Tracking of Progress348
- Vendor Assistance and Outside Facilities360
- Consultants and Contract Assistance360
- Chapter 9. Spare Parts and Their Effect on Service Factors361
- Spare Parts Philosophies361
- Spare Parts Storage and Retrieval361
- Spare Parts Documentation363
- Chapter 10. Maintenance for Continued Reliability365
- Modern Maintenance Approaches and when to Apply Them365
- Maintenance Management Options374
- Detailed Task Descriptions Improve Maintenance Effectiveness380
- Machinery Turnaround Planning394
- Turnaround Scope Development through Reliability, Availability, and Maintainability Analysis401
- Effective Maintenance: Preventive or Predictive?416
- Preventive Versus Predictive Maintenance for Typical Centrifugal Pumps421
- How to Be a Better Maintenance Engineer429
- The Role of the Maintenance Engineer in the Knowledge Age431
- References432
- Chapter 11. Maintenance Cost Reduction434
- Eliminating Cooling Water from General-Purpose Pumps and Drivers434
- Economics of Dry-Sump Oil-Mist Lubrication for Anti-friction Bearings440
- Gear Couplings Versus Non-lubricated Couplings451
- Elastomeric Couplings457
- Quantifying the Reliability Impact of Laser Alignment Techniques461
- Quantifying Impact470
- Why and How to Monitor Centrifugal Pump Condition477
- References484
- Chapter 12. Lubrication and Reliability485
- Methods and Criteria for Lube-Oil Purification485
- Cost Justification and Latest Technology for the On-Stream Purification of Turbomachinery Lube Oil491
- Synthetic Lubricants and Reliability Improvement503
- Vibration Performance Improved with Synthetics515
- Automatic Grease Lubrication as a Reliability Improvement Strategy517
- References525
- Chapter 13. Providing Safety and Reliability through Modern Sealing Technology527
- API Standard528
- Low-Emission Single Seal Design531
- Dual Seal Arrangements543
- Compact Gas Seal Technology for Pumps550
- The Reliability Impact of Special Seals for Non-Pump Applications558
- Specialty Seals for Non-Pump Applications565
- Dry Gas Compressor Seals581
- Warding off Equipment Reliability Setbacks: A Postscript593
- References598
- Appendix A600
- Appendix B609
- Index668
This totally revised, updated and expanded edition provides proven techniques and procedures that extend machinery life, reduce maintenance costs, and achieve optimum machinery reliability. This essential text clearly describes the reliability improvement and failure avoidance steps practiced by best-of-class process plants in the U.S. and Europe.