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Pracrical Machinery Management for Process Plan@
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VOLUME 4
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SECOND EDITION
Practical Machinery Management for Process Plants
Volume 4
Major Process Equipment
Maintenance and
Repair
Gulf Publishing Company
Houston, Texas
SECOND EDITION
Practical Machinery Management for Process Plants
Volume 4
Major Process Equipment
Maintenance and
Repair
Pumps w Fans and Blowers w Mixers w Compressors
Turboexpanders Motors w Turbines
Heinz P. Bloch
Fred K. Geitner
Dedicated with gratitude’ to those who taught us, who inspired us, and
who gave us their support and encouragement.
Practical Machinery Management for Process Plants
Volume 4, Second Edition
Major Process Equipment
Maintenance and Repair
Copyright 0 1985, 1997 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 in any form 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 2
Library of Congress Cataloging-in-PublicationD ata
Bloch, Heinz P., 1933-
Major process equipment maintenance and repair / Heinz P. Bloch, Fred
K. Geitner. -2nd ed.
p. cm.-(Practical machinery management for process plants; v. 4)
Includes index.
ISBN 0-88415-663-X
1. Chemical plants-Equipment and supplies-Maintenance and repair.
I. Geitner, Fred K. 11. Title. 111. Series: Bloch, Heinz P., 1933- Prac-
tical machinery management for process plants. 2nd ed. ; v. 4
TP157.B56 1996
660’.283’02884c20 96- 18768
CIP
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
case of conflict, observe the manufacturer’s instructions or ask the manufac-
turer to assist in resolving any differences.
iv
Acknowledgmen. ..................................... ix
..... ......................................
Foreword xi
. . .
Part I: Installation and Repair of Major Process Equipment 1
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. . . . .
1 Installation, Maintenance, and Repair of Horizontal Pumps 3
Principles of Installation of Pumps and Drivers. Baseplate and
Soleplate Preparation. Grouting Overview. Cement-Based
Grouts. Machinery Alignment. Pre-Operational Checks.
Pump Preparation for Startup. Shutting Down the Pump.
Pump Preventive Maintenance. Calculating the Cost of Your
Excess Clearances. Pump Assembly Procedures. Bearing
Housing-Sleeve Bearing Construction. Stuffing Box with
Mechanical Seal. Reassembling Bearing Housing. How and Why
Centrifugal Pumps Continue to Fail.
. . . . . . .
2 Installation, Maintenance, and Repair of Vertical Pumps , 72
Types of Wrtical Pumps for Process Plants. Types of Drivers.
Deepwell Pump Shaft Adjustment. Maintenance and Repair of
Packed Stuffing Boxes. Maintenance and Repair of Pump
Bearings.
V
...............
3 Reciprocating and Liquid Ring Vacuum Pumps .118
Pump Classification. Liquid-End Components. Packing Main-
tenance. Stuffing Boxes. Plunger Material. Drive-End Com-
ponents. Maintenance of Liquid Ring Vgcuum Pumps.
................
4 Positive Displacement and Dynamic Blowers ,142
Maintenance Instructions for Positive Displacement Rotary
Blowers. Care and Maintenance of Fans. VBriable Inlet Vanes
(VIV’s). Installing Fixed and Floating Pillow Blocks. Stuffing
Box Installation. Temperature Detectors.
................
5 Reciprocating Gas Engines and Compressors .176
Introduction. Compression Cylinder Maintenance. Packing
Maintenance. Vglve Breakage. Analyzing Crankshaft Def lec-
tion Readings. Determining Bearing Clearances. Reciprocat-
ing Compressor Component Overhaul and Repair. Reciprocat-
ing Unit Preventive and Predictive Maintenance. Upper
PortiodCylinders. Valves. Compressor. Oil System. Routine
Checks and Adjustments.
.
Part II: Maintenance for Power Generation and Transmission , .223
...............................
6 Power Transmission Gears ,225
Introduction. Gear Types. Gear Terminology. How Gears
Work. Bearings. Basic Installation Procedures. Shaft Operat-
ing Positions. Thermal and Mechanical Movement. Tooth
Contact Check. Checklist Before Startup. Checklist After
Startup. Lubricant Function. Lubricant Selection. Methods of
Supplying Lubricant. Lubrication of High Speed Units. Inop-
erative Periods. Journal Bearing Maintenance. Rolling Ele-
ment Bearing Maintenance. Gear Unit Disassembly and As-
sembly. Overheating. Appendix 7A-Helical Gear Formulas,
Standard Gearing. Appendix 7B-Typical Gear Unit Arrange-
ments.
...............
7 Installation and Maintenance of V-Belt Drives .310
Inspection While Running. Belt and Sheave Gauges. Maintain
Proper Belt Tension. Typical Sheave and Bushing Installation
Instruction. Typical Sheave and Bushing Removal Instruction.
Installation of Belts. Force Deflection Engineering Formulas.
vi
.......................
8 Steam Turbines and Turboexpanders .329
Special Purpose Steam Turbines. Review of lhrbine Hard-
ware. Special Purpose lhrbine Inspection and Repair. Special
Purpose Steam nrbine Operation and Maintenance. Proper
Break-in of Carbon Rings. Operation of Large Steam Tur-
bines. How to Avoid Steam lbrbine Distress. General Purpose
Steam lbrbine Maintenance and Repair. Maintenance Over-
view. Water-cooled Bearings. Rotor Locating Bearing. Gov-
ernor Valve. Steam Turbine Lubrication. Governor Lubrica-
tion. Operation and Maintenance of Cryogenic Plant
Turboexpanders. Troubleshooting. Disassembling Tbrboex-
panders. Inspection and Allowable Wear Data.
..........................................
9 Gas Turbines .442
Gas Turbine Maintenance Philosophy and Objectives. Spare
PartdSpecial Tools. Inspection/Overhaul/Repair.A ir Inlet and
Compression. Fuel System and Combustion. Turbine and Ex-
haust. Controls. Lube Oil System. Maintenance Concepts for
Aircraft Derivative Gas Turbines. Inspections.
...........
10 Maintenance of Hydraulic Governors Disassembly .480
.
11 Maintenance of Electric Motors and Associated Apparatus , , , ,495
Electric Motor Maintenance. Motor Nameplate Data. Motor
Receiving, Handling and Storage. Motor Installation. Preven-
tive Maintenance of Nonrotating Apparatus. Appendix 11A-
Electrical Machines Maintenance Report. Appendix 11B-
EASA Standards for the Electrical Apparatus Sales and
Service Industry.
......
Part 111: General Preventive and Predictive Maintenance .543
............
12 Storage Protection and Lubrication Management .545
Centrifugal and Rotary Pumps. Lubrication Management.
Master Lubrication Schedules. Bearing Labyrinth Purge. Gear
Coupling Lubrication. Principles of Oil Mist Lubrication. Oil
Mist Properties. Principles of Grease Lubrication. Character-
istics of Thickeners. Application Limits for Greases. Relubri-
cation Frequency Recommended by Manufacturers. Synthetic
Lubricants. A Two-Level Monitoring Strategy.
VU
