Machinery Component Maintenance and Repair
4th Edition
Published on 28. June 2019
668 pages
978-0-12-818730-2 (ISBN)
Description
Machinery Component Maintenance and Repair, Fourth Edition, Volume three in the Practical Machinery Managment for Process Plants series provides the latest research and industry approaches in easy to understand, bite-sized chunks. Extending the life of existing machinery is the name of the game in the process industries, and this classic text is still the best, most practical and comprehensive source for doing just that. This updated edition is completely revised and updated throughout, especially in sections regarding Maintenance Organization and Control for Multi-Plant Corporations, Repair and Maintenance of Rotating Equipment Components, and Protecting Machinery Parts Against Loss of Surface.
- Describes step-by-step procedures to guide readers through a best practices approach to machinery maintenance
- Helps readers optimize their maintenance plan to reduce downtime in plants and extend the service life of machinery
- Provides a wealth of practical technical data and advice on crucial subjects, such as machinery alignment and maintenance programming
Fred K. Geitner is a registered Professional Engineer in the Province of Ontario, Canada, engaged in process machinery consulting. He retired from Imperial Oil with 20 years of service as an engineer.
More details
Other editions
Additional editions
Fred K. Geitner | Heinz P. Bloch
Machinery Component Maintenance and Repair: Volume 3
Book
06/2019
4th Edition
Gulf Professional Publishing
€174.56
Shipment within 15-20 days
Content
- Front Cover
- Machinery Component Maintenance and Repair
- Copyright
- Dedication
- Contents
- About the authors
- Foreword
- Acknowledgments
- Part I: Background to process machinery maintenance programming
- Chapter 1: Machinery maintenance: An overview
- References
- Bibliography
- Chapter 2: Maintenance organization and control for multiplant corporations
- Type of operation
- Manager's role
- Maintenance
- Central control system
- Principal applications areas for the maintenance computer
- Incentives for computer systems
- Justification of systems
- Setting up an effective system
- Manuals prepared
- Performance reports
- Breakdowns reduced
- Central parts depot
- Plant engineering
- Summary
- Machinery maintenance on the plant level
- Assignment of qualified personnel
- Timing and basic definition of critical preturnaround tasks
- Senior machinery specialist
- Turbotrain turnaround engineers
- Mechanical supervisors/planners
- Specific preparation and planning
- Safety
- Planning
- Spare parts
- The spare rotor
- Diagrams
- Miscellaneous items
- The factory serviceperson
- The overhaul
- Opening the machine
- Inspection
- Cleaning
- Reassembly
- Documenting what youve done
- Nonstandard parts
- References
- Chapter 3: Machinery foundations and grouting
- What's an epoxy?
- Epoxy grouts
- Proper grout mixing is important
- Job planning
- Conventional grouting
- Concrete characteristics
- Methods of installing machinery
- Anchor bolts: Overview
- Original anchor bolt installations
- Anchor bolt replacement
- Outdoor installations
- Expansion joints
- Postponement of regrouting is risky
- Preparation of concrete surfaces prior to grouting
- Repairing failures between block and mat
- Grouting skid-mounted equipment
- Grouting of oil-degraded concrete
- Pressure-injection regrouting
- Shoulder removal method
- Through-the-case method
- Pressure grouting sole plates
- Prefilled equipment baseplates: How to get a superior equipment installation for less money
- Why be concerned
- Conventional grouting methods
- Field installation problems explained
- Voids and bonding issues
- Distortion of mounting surfaces
- Hidden budget busters
- Pregrouted baseplates
- Proper surface preparation
- Void-free grout installation
- Postcuring of the grout
- Mounting surfaces
- Field installation methods for pregrouted baseplates
- Field leveling
- Conventional grouting method
- Hydraulic lift of a pregrouted baseplate
- Baseplate stress versus anchor bolt torque
- New field grouting method for pregrouted baseplates
- Concrete foundation preparation
- New grout-forming technique
- Field installation cost comparison
- Consider prefilled baseplates
- 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
- References
- Bibliography
- Chapter 4: Process machinery piping
- Fundamentals of piping design criteria
- Piping design procedure
- Design considerations
- Design pressure loads
- Weight loads
- Dynamic loads
- Thermal expansion/contraction effects
- Effects of support, anchor, and terminal movements
- The when, who, what, and how of removing spring hanger stops associated with machinery
- Initial tasks prior to machinery commissioning
- Final check, immediately prior to machinery operation
- Flange jointing practices
- Primary causes of flange leakage
- The importance of proper gasket selection
- Gasket width
- Gasket thickness
- Flange types and flange bolt-up
- Factors affecting gasket performance
- Spiral wound gaskets manufactured in accordance with American society of mechanical engineers (ASME) B16.20
- Torque tables
- Gasket installation
- Bolting procedures
- Hydrostatic testing precautions
- Prestressing bolts for thermal expansion
- Calculating load requirements
- General installation and inspection procedure
- Prior to gasket insertion
- Controlled torque bolt-up of flanged connections
- Preparation
- Equipment
- Hot bolting and leakage control
- Hot bolting procedure
- Using bolt tensioners
- Using hammer and wrench or torque wrench
- If hot bolting does not stop leak
- Torqueing in machinery assemblies
- Example
- Background evaluation
- Recommendations for the installation, fabrication, testing, and cleaning of air, gas or steam piping
- Pickling procedure for reciprocating compressor suction piping: method I
- General recommendations
- Preliminary work
- Pretreatment
- Acid treatment
- Neutralization
- Passivation
- Cleaning of large compressor piping: method II
- Temporary line filters
- 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
- Reference
- Part II: Alignment and balancing
- Chapter 5: Machinery alignment
- Prealignment requirements
- Alignment tolerances
- Choosing an alignment measurement setup
- Reverse-indicator method
- Face-and-rim method
- Face-face-distance method
- State-of-the-art alignment
- Checking for bracket sag
- Bracket sag effect on face measurements
- Face sag effect-examples
- Example 1
- Example 2
- Example 3
- Leveling curved surfaces
- Jig posts
- Interpretation and data recording
- Calculating the corrective movements
- The graphical procedure for reverse alignment
- What is reverse alignment?
- Learning how to graph plot
- Sag check
- Making the moves
- Summary of graphical procedure
- The ``optimum move´´ alignment method
- Thermal growth-Twelve ways to correct for it
- Laser measurements
- Thermal growth estimation by rules of thumb
- Alignment choices have consequences
- References
- Chapter 6: Balancing of machinery components
- Definition of terms
- Purpose of balancing
- The balancing machine as a measuring tool
- Causes of unbalance
- Units of unbalance
- Types of unbalance
- Static unbalance
- Couple unbalance
- Quasi-static unbalance
- Dynamic unbalance
- Motions of unbalanced rotors
- Effects of unbalance and rotational speed
- Correlating CG displacement with unbalance
- Balancing machines
- Gravity balancing machines
- Centrifugal balancing machines
- Soft-bearing balancing machines
- Hard-bearing balancing machines
- Measurement of amount and angle of unbalance
- Plane separation
- Classification of centrifugal balancing machines
- Maintenance and production balancing machines
- Universal balancing machines
- Semi-automatic balancing machines
- Fully-automatic balancing machines
- Establishing a purchase specification
- Rotor description
- Supporting the rotor in the balancing machine
- Means of journal support
- Rotors with more than two journals
- Rotors with rolling element bearings
- Driving the rotor
- Drive system limitation
- Weight-speed limitation (Wn2)
- Determining the right balancing speed
- Is the rotor ``rigid´´?
- Flexibility test
- Direction of rotation
- End-drive adapters
- Design considerations
- Balancing keyed end-drive adapters
- Half-key method
- Balancing arbors
- Definition
- Basic design criteria
- Error analysis
- Statistical evaluation of errors
- Balancing the arbor
- Special design features
- Biasing an arbor
- The double compensator
- Unbalance correction methods
- Addition of mass
- Removal of mass
- Mass centering
- Testing balancing machines
- Tests for production machines
- Basic test concepts
- Inboard proving rotors for horizontal machines
- Test masses
- Test procedures
- Umar (or traverse) test
- Unbalance reduction test
- Balance tolerances
- Balance quality grades
- Special conditions to achieve quality grades G1 and G0.4
- Applying tolerances to single-plane rotors
- Applying tolerances to two-plane rotors
- Experimental determination of tolerances
- Applying tolerances to rotor assembly components
- Testing a rotor for tolerance compliance
- Balance errors due to drive elements
- Balance errors due to rotor support elements
- Index-balancing procedure
- Recommended margins between balance and inspection tolerances
- Computer-aided balancing
- Features
- Prompting guides, storage, and retrieval
- Multiple machine control and programs
- Field balancing overview
- Field balancing equipment
- Field balancing examples
- First problem: Unbalance vibration in blowers
- Solution: Field balancing in one plane
- Second problem: Unbalance vibration in centrifuges
- Solution: Field balancing in two planes
- Explanation of schedule and of calculator program
- Third problem: Unbalance vibration in twisting and stranding machine
- Solution: Field balancing in several planes
- 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
- References
- Bibliography
- Further reading
- Part III: Maintenance and repair of machinery components
- Chapter 7: Ball-bearing maintenance and replacement
- Engineering and interchangeability data
- Standardization
- Ball bearing variations
- Cleanliness and working conditions in assembly area
- Removal of shaft and bearings from housing
- Bearing removal from shaft
- Removal from shaft
- Applying pressure with bearing puller
- Identification and handling of removed bearings
- Bearing pullers
- Bearing removal through application of heat
- Cleaning and inspection of spindle parts
- Cleaning the bearing
- Cleaning the shaft
- Cleaning the housing
- Keep spindle parts coated with oil
- Inspect all spindle parts
- Shaft and housing preparation
- Bearing seats on shaft
- Shaft shoulders
- Shaft fillets and undercuts
- Break corners to prevent burrs
- Check spindle housing surfaces
- Shaft and housing shoulder diameters
- Checking shaft and housing measurements
- Check bearing seat for out-of-round
- Check shoulders for off-square (Figure 7-31)
- Check housing bore dimensions
- Recheck dimensions if necessary
- Duplex bearings
- Basic mounting methods
- Packaging
- Spacers separating duplex bearings
- Hints on mounting duplex bearings
- Do not use two single-row bearings as duplex bearings unless properly ground or shimmed
- Fit on shaft
- Faces of outer rings square with housing bore
- Dismounting and remounting of duplex bearings
- Preloading of duplex bearings
- Preload offset
- DTDB and DTDF sets
- Importance of the correct amount of preload
- Factors affecting preload
- Preload classifications
- Preloaded replacement bearings
- Preloaded bearings with different contact angles
- Assembly of bearings on shaft
- Bearing salvage versus replacement considerations
- Cautions to observe during assembly of bearings into units
- High point of eccentricity
- Thrust here
- Mount bearings with push fit
- Mounting with heat
- Other mounting methods
- Exercise caution when starting bearing on shaft
- Checking bearings and shaft after installation
- Check for internal clearance
- Make visual check of bearing
- Check for bearing squareness on the shaft
- Balancing the shaft assembly
- Common causes of unbalance in shaft assemblies
- Correction of unbalanced shaft assemblies
- Protect bearings and shaft assembly from contamination
- Assembly of shaft and bearings into housing
- Testing of finished spindle
- Maintain service records on all spindles
- Shaft and housing shoulder diameters
- Bearing maintenance checklist
- Chapter 8: Repair and maintenance of rotating equipment components
- Pump repair and maintenance
- Seal checkpoints
- Installation of the seal
- Optical flat
- Monochromatic light
- Flatness readings
- Installation of stuffing box packing
- Steady leakage flow is a must
- Consider upgrading to mechanical seals
- Continuous improvement through materials upgrading
- Welded repairs to pump shafts and other rotating components
- How to decide if welded repairs are feasible
- Repair techniques
- Shaft Preparation (Figure 8-14)
- Welding Procedure
- Welding Technique
- Case histories
- Other components
- Impellers
- Water Injection Pump Case
- Seal Flanges
- Impeller Wear Rings
- Unsolved problems
- Outlook and conclusions
- High speed shaft repair
- Chemical plating
- Flame spray coatings
- Shaft repair by diameter reduction
- Strapping
- Stoning
- Shaft straightening
- Straightening carbon steel shafts
- Repair techniques for carbon steel shafts
- The Peening method
- The Heating method
- The heating and cooling method
- Casting salvaging methods
- Repair of castings
- Of sundries, nuts and bolts
- Use of threadlocking compounds
- General
- Application
- Caution
- Use of pipe and hydraulic sealants
- General
- Application
- Curing time
- Caution
- Application of anti-seize compounds
- Properties
- Application
- Caution
- Lockwiring of threaded fasteners
- Purpose
- General rules
- Application method
- Installation
- Spare parts availability and the need for non-OEM options
- Random failures demand ready availability of good options
- Contact with service shops [5]
- OEM versus non-OEM machinery repairs
- When to consider repairing a worn or damaged component or assembly instead of buying new
- How to find out if the component is repairable
- What Components can be repaired
- Knowing how to manufacture a component that is totally destroyed
- Will a repairer manufacture spare parts?
- Proof of repairability
- Ascertaining integrity of the repair process
- Specifications applied to the process
- Resolving different opinions: Scrap versus repair
- Knowledge base of repairers
- Cost and delivery issues
- Repair guarantees and insurance issues
- Initiating the repair sequence
- Considering component upgrade and replacement options
- Installation versus reinstallation
- Shipments to other countries
- Transporting damaged or repaired components
- References
- Further reading
- Chapter 9: Centrifugal compressor rotor repair
- Compressor rotor repairs
- Built-up rotor
- Drum type rotor
- Impeller manufacture
- Overspeed test of impellers
- Impeller materials
- Impeller attachment
- Compressor impeller design problems
- Impeller balancing procedure
- Other compressor balancing
- Marking of impellers
- Critical areas
- Rotor bows in compressors and steam turbines
- Balancing
- Clean up and inspection of rotor
- Disassembly of rotor for shaft repair
- Shaft design
- Rotor assembly
- Shaft balancing
- Rotor thrust in centrifugal compressors
- Rotor thrust calculations
- Design solutions
- Managing rotor repairs at outside shops
- Procedures for inspection, disassembly, stacking, and balance of centrifugal compressor rotors
- Incoming inspection
- If disassembly is required
- Assembly
- Final inspection
- Turbo specification chrome plating and finish grinding
- Repair facility to provide to vendor
- Vendor to provide to repair facility
- Finish grinding
- Mounting of hydraulically fitted hubs
- Dismounting of hydraulically fitted hubs
- Reference
- Chapter 10: Protecting machinery parts against the loss of surface
- Basic wear mechanisms
- Adhesive wear
- Abrasive wear
- Corrosive wear
- Surface fatigue
- Hard-surfacing techniques
- Cushion or buffer layer
- Tool steels
- Iron-chromium alloys
- Iron-manganese alloys
- Cobalt-base alloys
- Nickel-chromium-boron alloys
- Composites
- Copper-base alloys
- Ceramics
- Special purpose materials
- Test results
- Discussion
- Selecting a surfacing method
- Selecting a surfacing material
- The detonation gun process
- Process details
- Coating details
- Limitations
- Applications
- High-velocity thermal spray coatings
- Application-Upgrading reciprocating compressor piston rods and crankshafts
- Coating compositions match the application
- Documenting your repair procedure
- Industrial plating
- Chrome plating of cylinder liners
- Bonding
- Low coefficient of friction
- Hardness
- Corrosion resistance
- Lubrication
- Thermal conductivity
- Abrasion resistance
- Chromium in turbocharged engines
- Operating verification
- Conclusion
- Onsite electroplating techniques
- Hardening of machinery components
- Diffusion alloys
- Tungsten carbide and diffusion alloying
- Application
- Electrospark deposition coatings
- Other coatings for machinery components
- Application of thin films of Teflon to metals
- Fluoropolymer (Teflon) infusion process
- Application of carbon-filled polymers
- Concluding comments on coatings and procedures
- Selection and application of O-rings
- Deterioration in storage
- Temperature
- Mechanical damage
- Chemical attack
- What makes an O-ring
- Nitrite, Buna N, or NBR
- Ethylene-propylene, EP, EPT, or EPDM
- Chloroprene, neoprene, or CR
- Fluorocarbon, Viton, Fluorel, or FKM
- Silicone or PVMQ
- Fluorosilicone or FVMQ
- Styrene-butadiene or SBR
- Polyacrylate or ACM
- Polyurethane, AU, or EU
- Butyl or IIR
- Polysulfide, thiokol, or T
- Chlorosulfonated polyethylene, hypalon, or CSM
- Epichlorohydrin, hydrin, or ECO
- Phosphonitrilic fluoroelastomer, polyphosphazene, PNF, or PZ
- UTEX HTCR fluororubber
- Perfluoroelastomer (Kalrez)
- Backup rings
- O-ring, backup ring, and gland dimensions
- Appendix 10-A. Part documentation record
- References
- Index
- Back Cover
