Rotating Machineries: Aspects of Operation and Maintenance

110 Pages·2019·3.38 MB·English

by  Shaharin Anwar Sulaiman

SPRINGER BRIEFS IN
APPLIED SCIENCES AND TECHNOLOGY
Editor
Shaharin Anwar Sulaiman   
Rotating
Machineries
Aspects of
Operation and
Maintenance
123
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Shaharin Anwar Sulaiman
Editor
Rotating Machineries
Aspects of Operation and Maintenance
123
Editor
ShaharinAnwar Sulaiman
Department ofMechanical Engineering
Universiti TeknologiPetronas
Seri Iskandar, Perak, Malaysia
ISSN 2191-530X ISSN 2191-5318 (electronic)
SpringerBriefs inApplied SciencesandTechnology
ISBN978-981-13-2356-0 ISBN978-981-13-2357-7 (eBook)
https://doi.org/10.1007/978-981-13-2357-7
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Preface
Rotatingmachineries,oftenreferredtoasturbomachines,aremachinesthattransmit
energybetweenarotorandafluid.Theyincludeturbines,compressors,andpumps
andarewidelyusedinindustries,namelypowergeneration,oilandgasproduction,
and petrochemical. This book discusses the maintenance aspect of rotating
machines,throughthecollectionofvariousworksfromdifferentauthors.Thebook
has been written to provide views of experienced engineers in the aspect of
maintenance of rotating machines. The book will be useful as a reference for
practicing engineers in the related industries mentioned earlier. The book will
provide them with a glimpse of some of the problems associated with rotating
machinesorequipmentinthefieldandhelpthemtoachievemaximumperformance
efficiencyandhighavailability.Theeditorwouldliketoexpresshisgratitudetoall
the contributing authors for their time, effort, and dedication in preparing the
manuscripts for the book.
Seri Iskandar, Malaysia Shaharin Anwar Sulaiman
v
Contents
Condition Monitoring and Assessment for Rotating
Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Sundralingam Muthanandan and Khairul Anwar B. M. Nor
Turnaround Activities of Rotating Machinery for Mechanical
Engineers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
M. B. Baharom and M. Azrul Nizam B. M. Zahir
Localization of Gas Turbine Maintenance by Malaysian
Gas Turbine Owners and Operators . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Mohd Amin Abd Majid and Ismady Ismail
Probabilistic Life Cycle Costing: A Case Study of Centrifugal
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Ainul Akmar Mokhtar, Freselam Mulubran and Masdi Muhammad
CFD Analysis of Fouling Effects on Aerodynamics Performance
of Turbine Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
A. T. Baheta, K. P. Leong, Shaharin Anwar Sulaiman and A. D. Fentaye
Electrohydrodynamic Pumps for Dielectric Liquid Application . . . . . . . 85
Mohammad Shakir Nasif
Experimental Study on Electrical Power Generation from a 1-kW
Engine Using Simulated Biogas Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Suhaimi Hassan and Hamdan Ya
vii
Contributors
Mohd Amin Abd Majid Universiti Teknologi PETRONAS, Perak, Malaysia
M. B. Baharom Universiti Teknologi PETRONAS, Seri Iskandar, Perak,
Malaysia
A. T. Baheta Universiti Teknologi PETRONAS, Seri Iskandar, Perak, Malaysia
A. D. Fentaye Universiti Teknologi PETRONAS, Seri Iskandar, Perak, Malaysia
Suhaimi Hassan Universiti Teknologi PETRONAS, Seri Iskandar, Perak,
Malaysia
Ismady Ismail TNB Repair and Maintenance, Selangor, Malaysia
K. P. Leong Universiti Teknologi PETRONAS, Seri Iskandar, Perak, Malaysia
Ainul Akmar Mokhtar Universiti Teknologi PETRONAS, Perak, Malaysia
Masdi Muhammad Universiti Teknologi PETRONAS, Perak, Malaysia
Freselam Mulubran Universiti Teknologi PETRONAS, Perak, Malaysia
Sundralingam Muthanandan PETRONAS, Kuala Lumpur, Malaysia
Mohammad Shakir Nasif Universiti Teknologi PETRONAS, Perak, Malaysia
M.AzrulNizamB.M.Zahir PETRONASChemicalsMTBE,Pahang,Malaysia
Khairul Anwar B. M. Nor PETRONAS, Kuala Lumpur, Malaysia
Shaharin Anwar Sulaiman Universiti Teknologi PETRONAS, Seri Iskandar,
Perak, Malaysia
Hamdan Ya Universiti Teknologi PETRONAS, Seri Iskandar, Perak, Malaysia
ix
Condition Monitoring and Assessment
for Rotating Machinery
SundralingamMuthanandanandKhairulAnwarB.M.Nor
Initially, when rotating machinery was used in industry, the maintenance practice
wasruntofailurebasis.Thismeansthatanequipment wasbeingoperated untilit
was unable to continue its intended function. This was the situation when correc-
tive maintenance was later being introduced and implemented. As the technology
progressandtherotatingequipmentbecomesmorecriticaltooperationandbusiness,
preventivemaintenancewasintroduced.Thepreventivemaintenancetaskisusually
recommendedbytheOriginalEquipmentManufacturer(OEM).Thismaintenance
requiresafixedtimebaseoroperationalhour-basedinterventionsothatsomeofthe
criticalcomponentsatahigherprobabilityoffailurecanbeinspectedandreplaced
ifrequired.
Astimeprogress,rotatingmachinerybecomesmorecriticaltooperationandmore
complex machine is being introduced into the rotating equipment. This made the
reliabilityoftheequipmentbecomesverycrucial,equipmentreliabilitystartedtobe
tracked,andunplanneddowntimetomachinesbecameunacceptable.Assuch,con-
dition monitoring technologies were evolved to assess the equipment health while
in operation in order to understand and detect any incipient and hidden failures.
These technologies enable some failure modes detectable early, and consequently,
timelymaintenancecanbeexecutedtopreventcostlycorrectivemaintenance.This
technology,whichisusedtodetectandpredictfailures,isalsoknownaspredictive
maintenance. Thus, most of the oil and gas industry limits the corrective mainte-
nance to non-critical equipment where the cost of corrective maintenance is more
economicalandjustifiableascomparedtopreventiveandpredictivemaintenance.
B
S.Muthanandan( )·K.A.B.M.Nor
PETRONAS,KualaLumpur,Malaysia
e-mail:[email protected]
©TheAuthor(s),underexclusivelicencetoSpringerNatureSingaporePteLtd.2019 1
S.A.Sulaiman(ed.),RotatingMachineries,SpringerBriefsinAppliedSciences
andTechnology,https://doi.org/10.1007/978-981-13-2357-7_1
2 S.MuthanandanandK.A.B.M.Nor
Fig.1 Conditionmonitoring(CM)technologiesforrotatingmachineries
Introduction
Condition monitoring is the use of special devices to measure specific aspects of
equipment deterioration in order to diagnose the cause and recommend remedial
action. Condition monitoring involves technical tasks in which operating parame-
tersareperiodicallyorcontinuouslymeasuredandrecorded.Thedatawillbelater
analyzedbycomparinganddisplayingthedatasothatitcouldsupportanydecision
makingforoperationandmaintenanceoftherotatingmachinery.
Mostoftheindustrypractitionersandexpertsrealizethatunplanneddowntimeis
very costly and time-consuming. Failure detrimental to equipment integrity could
lead to organizational reputation and opportunity for value leakages. Therefore,
detecting developing insipient failures or issues before they lead to catastrophic
failuresisoneofthemostchallengingandimminenttasks.Thisdetectionnotonly
providesinsightintotheoperatingconditionbutalsoprovidesdirectiontomainte-
nanceactivitiessothatonecanpreventunplanneddowntime.Withthedevelopment
ofvarioustypesofconditionmonitoringtechniquesincludingadvancetechniques,
thedetectionanddiagnosisbecomeseasier,enablingappropriateprescriptiveactions
tobetakeninatimelymanner.
Conditionmonitoringtechnologiesforrotatingmachineriesinplants,asshown
inFig.1,mainlyincludethefollowings:
• Visualinspectionandobservation
• Vibrationanalysis
• Lubeoilanalysis
• Thermography—temperaturedistributionandcontouranalysis
• Ultrasonicinspection
• Motorcurrentsignatureanalysis
• Performancemonitoring
• Equipmentonlineoperatingparametersanalysis