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Petrochemical Machinery Insights
1st Edition - September 8, 2016
Author: Heinz P Bloch
Paperback ISBN:9780128092729
9 7 8 - 0 - 1 2 - 8 0 9 2 7 2 - 9
eBook ISBN:9780128112465
9 7 8 - 0 - 1 2 - 8 1 1 2 4 6 - 5
Petrochemical Machinery Insights is a priceless collection of solutions and advice from Heinz Bloch on a broad range of equipment management themes, from wear to warranty issues,… Read more
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Petrochemical Machinery Insights is a priceless collection of solutions and advice from Heinz Bloch on a broad range of equipment management themes, from wear to warranty issues, organizational problems and oil mist lubrication, and professional growth and pre-purchase of machinery.
The author draws on his industry experience to hone in on important problems that do not get addressed in other books, providing actionable details that engineers can use. Mechanical, reliability, and process engineers will find this book the next best thing to having Heinz Bloch on speed dial.
Focuses on pieces of hard-won experience from the industry that are rarely included in other books
Presents not just a guide to technical problems, but also to crucial themes in management and organization
Includes an informal and honest style, making author Heinz Bloch's 40 years of experience accessible to a broad audience of readers
Contains a uniting theme that successful asset management requires the separation of application and implementation details
Mechanical engineers, reliability engineers, process engineers
Dedication
List of Figures
List of Figure Credits
Foreword
Preface
Acknowledgments
Introduction
Subject Category 1: Agitators
Abstract
Chapter 1.1: Your Agitator Just Failed: What Now?
Introduction
Consistency Is One of the Keys to Performance
Subject Category 2: Alignment
Abstract
Chapter 2.1: Alignment Choices have Consequences
Introduction
Alignment Rule of Thumb Explained
Chapter 2.2: Pump Alignment Reduces Power Demand
Introduction
Lambley's Work Summarized
Subject Category 3: Asset Management
Abstract
Chapter 3.1: Alignment Specifics Contribute to Effective Asset Management
Introduction
An Equipment Alignment Problem Points to the Need to Upgrade
Chapter 3.2: Dealing With Asset Management and Life Extension
Introduction
Charter and Plant Data Explained
Piping and Foundations Affect Remaining Life
Compressors: All of the Above Are Important
Subject Category 4: Bearings
Abstract
Chapter 4.1: Picking the Right Oil Viscosity for Your Machines
Introduction
Learning From a Recent Case History
Chapter 4.2: Bearing Styles and Configurations
Introduction
Bearing Types
Bearing Cage Material
Chapter 4.3: Optimized Lubricant Application for Rolling Element Bearings
Introduction
Rankings Examined
Chapter 4.4: Pump Bearings and Allowable Temperatures
Introduction
Rolling Element Versus Plain Bearings
Chapter 4.5: Ranking Bearings and Lube Application Methods for Process Pumps and Drivers
Introduction
Making Choices
Oil Versus Grease
Oil Lubrication Experience
Constant-Level Lubricators
Vulnerability of Oil Rings
Brief Overview of Grease Lubrication
Shields Versus No Shields in Electric Motor Bearings
Chapter 4.6: Bearing Housing Protector Seals and the Value of Reducing Lube Oil Contamination Risk
Introduction
Rotating Labyrinth Seals
Justifying the Cost of Modern Bearing Housing Protector Seals
Subject Category 5: Blowers
Abstract
Chapter 5.1: Modern Blowers Can Be Reliable
Introduction
How Best-of-Class Performers Groom Project Expertise
Practicing Reliability Thinking and Checking Things Out
Chapter 5.2: Positive Displacement Blowers With Bearings Using Both Pure and Purge Oil Mist Lubrication
Introduction
Cooperation Is Essential to Success
The Quest for Case Histories
Subject Category 6: Compressors, General
Abstract
Chapter 6.1: Upgrade Your Compressor Antisurge Control Valves
Improvements Are Possible
On-Line Monitoring and Diagnostics
Improved Valve Packing Systems
Chapter 6.2: Consider Single-Point Responsibility for Compressors
Introduction
Agreement Needed on “Train Responsibility”
Exceptions to the Rule
Focusing on the Bright Side
Chapter 6.3: Toroidal Chamber Rotary Compressors
Introduction
Operating Principle
Application Summary
Chapter 6.4: Vent Gas Compressor Selection
Introduction
Emphasis Often Differs
Experience Checks are Important
Follow-Up is Needed
Subject Category 7: Cooling Tower Fans and Drives
Abstract
Chapter 7.1: Consider Innovative Cooling Tower Fan Motor and Drive Technology
Introduction
The Search for a Better Solution
A Mature Product
Subject Category 8: Couplings
Abstract
Chapter 8.1: Coupling Types and Styles
Introduction
Flexing Elements Made From Elastomer Materials
Obtain User Feedback
Installation and Hub Removal
Subject Category 9: Dry Gas Seals
Abstract
Chapter 9.1: Advances in Dry Gas Seal Technology for Compressors
How Dry Gas Seals Function
Minimizing the Risk of Sealing Problems
Seal Safety and Reliability
Combining OEM and Repair Expertise
Making Technically Sound Choices
Making Economically Sound Choices
Testing Capabilities are Important
DGS Technology Advances Through Global Repair Services
The DGS Repair Process
Replacement and Rebuilding Steps
Duration and Documentation
Subject Category 10: Dynamic Compressors
Abstract
Chapter 10.1: Three- to Eight-Stage Integral Gear-Driven Centrifugal Process Gas Compressor Overview
Subject Category 11: Electric Motor Life
Abstract
Chapter 11.1: Monitoring Electric Motor Vibration and Optimizing Motor Bearing Lubricant Application
Introduction
Commendations for a Case History Admirably Tabulated
Treat Root Causes, Not Symptoms
Evidence of Outdated Lubrication Technology
Chapter 11.2: Electric Motors and Mechanical Efficiency
Introduction
Synthetics for Motors
Quantifying the Energy Savings Potential
Chapter 11.3: Smart Motor Lubrication Saves Energy
Introduction
Long and Successful History
Quantifying the Energy Savings Potential
Chapter 11.4: Oil Mist and Electric Motor Windings
Introduction
History
Subject Category 12: Foundation and Grouting Systems
Abstract
Chapter 12.1: Consider Pregrouted Pump Baseplates and New Grout Systems
Introduction
Concrete Foundation Preparation
New Grout Forming Technique
Field Installation Cost Comparison
Chapter 12.2: Field Erection and Installation Specifications for Special Purpose Machinery
Introduction
Commonalities Observed
Chapter 12.3: How Pump Installation Differs From the Way Pumps Were Shipped to Your Plant
Introduction
Mounted for Shipping
As Shipped Condition Is Not Yet Ready for Installation
Subject Category 13: Gasket Designs
Abstract
Chapter 13.1: Assessing Advances in Gasket Designs
Introduction
Kammprofile Gaskets
Subject Category 14: Gear and General Bearing Housing Protection
Abstract
Chapter 14.1: Sealing Gearboxes Against Water Intrusion
Introduction
Lip Seals and Other Solutions
Dual-Face Magnetic Bearing Protector Seals Still Important
Early History of Magnetic Bearing Housing Protector Seals
Operating and Application Limits Explained
Technical Reports on Magnetic Seal Experience
Testing Proves Compliance
Lift and Wear of Advanced Bearing Protectors
Chapter 14.2: Why Bearing Housing Protector Seals are Needed
Introduction
Bearing Housing Issues
Subject Category 15: Grounding Technology
Abstract
Chapter 15.1: Grounding Ring Technology for Variable Frequency Drives (VFDs)
Introduction
Fundamentals of Shaft Grounding Rings (SGRs)
Circumferential Rows of Fibers
Selection Strategy
Subject Category 16: Innovation Versus Unnecessary Developments
Abstract
Chapter 16.1: Innovations that are Duplications of Effort
Introduction
Good Innovations
Chapter 16.2: Process Innovations that Pose Dangers
Introduction
Chapter 16.3: Involve Innovators in Fluid Machinery Upgrading
Chapter 30.11: Upgrading the Mechanical Design of Vertical Multistage Centrifugal Pumps in Low-Temperature Service
Introduction
Chapter 30.12: Recognizing the Pitfalls of Pumping at Part Load or in Parallel
Introduction
Defect Elimination More Valuable Than Defect Detection
No Two Pumps Are Fully Identical
Know All About Operating Pumps in Parallel
Efficiency Is Worth Real Money
Neglecting Risk Is Negligent in a Return-On-Investment Calculation
What To Do to Avoid Undue Risk
Experience at a Major Utility Buttresses Our Point
Conclusion and Advice
Chapter 30.13: Buying Better Pumps
Introduction
Predictive Maintenance Tools
Subject Category 31: Reciprocating Compressors
Abstract
Chapter 31.1: Reciprocating Compressors with Floating Pistons
Introduction to Nonlubricated Compressors
Operating Principle Explained
Experience and Key Advantages
Chapter 31.2: Upgrading Compressor Piston Rods
Introduction
Documenting Your Repair Procedure
Chapter 31.3: Gaining Flexibility With Special Liners for Reciprocating Compressor Cylinders
Introduction
Design Overview
Chapter 31.4: Interpreting API Standard 618 for Reciprocating Compressors
Introduction
Are There Discrepancies?
Common Practice Explained
The Automobile Analogy
Always Examine Experience
Chapter 31.5: Upgrade Kits and Service Bulletins
Introduction
Abstracts Provide an Overview
Details Disclose Particulars
Special Service Organizations
Subject Category 32: Reliable Plants and Machines Benefit From MQA
Abstract
Chapter 32.1: Reliable Because of Up-Front Investment in “MQA”
Introduction
Up-Front Investment in Reliability Is the Better Way
Good Plants and the Audit and Review Process
Don't Take Risks With Reliability
Successful Interfacing Assures Uptime Goals are Met
Flow Sheets and Specifications
Chapter 32.2: Buy From Knowledgeable and Cooperative Pump Vendors
Introduction
Equipment Selection Demands Forethought
Cheap Pumps are Rarely a Wise Choice
Use Supplemental Specifications
Chapter 32.3: Selection of Better Equipment Starts With Understanding Available Upgrade Options
Introduction
How Best-of-Class Performers Do It
Chapter 32.4: Unreliability, Engineers, and Lawyers
Introduction
Background
Surviving a Deposition
The Human Factor
Chapter 32.5: How to Trim-Cut Closed Pump Impellers
Introduction
Trimming Using “Field Wisdom”
Chapter 32.6: Equipment Life Extension Involves Upgrades
Introduction
Examples of What to Upgrade
Chapter 32.7: Top Ways to Improve Pump Life
Introduction
Know About Better Bearings and Bearing Protectors
Superior Bearing Housing Protector Seals Will Surprise You in Some Pumps
Insist on Safest Possible Mechanical Seal Test Protocols
Ascertain Safety and Reliability
Subject Category 33: Repair Quality and Statistics
Abstract
Chapter 33.1: Reasonable Pump Life Assessed from Published Statistics and Proprietary Consulting Access
Examining Pump Repair Records and MTBF
Other Studies of Pump Statistics
Target Pump and Component Lifetimes
Chapter 33.2: How to Improve Equipment Repair Quality
Introduction
Spelling Out the Goals
How Working With a CPRS Makes Sense
Subject Category 34: Resource Utilization
Abstract
Chapter 34.1: Notes from a Consulting Assignment
Introduction
Chapter 34.2: Consider the Most Effective Approach to Data Collection
Introduction
Why Operators Collect Data
Chapter 34.3: Why Users Must Update Design Contractors' Understanding
Introduction
Protecting the Client's Interest
Does the EPC Need Technology Updates?
Mechanical Seal Optimization
Lessons Learned
Chapter 34.4: What to Consider When It's No Longer Safe to Work at Your Workplace
Acknowledgment
Introduction
A Frustrated Maintenance Manager
Subject Category 35: Root Caus
No. of pages: 784
Language: English
Published: September 8, 2016
Imprint: Butterworth-Heinemann
Paperback ISBN: 9780128092729
eBook ISBN: 9780128112465
HB
Heinz P Bloch
Heinz P Bloch is the owner and principal of Process Machinery Consulting Co, and has been the reliability editor of Hydrocarbon Processing Magazine since 1990. He is the author or co-author of over 650 technical papers or articles, and 19 full text books. He was a founding member of Texas A&M University’s International Pump Users Symposium.
Affiliations and expertise
Process Machinery Consulting, Westminster, Colorado, USA