Machinery Component Maintenance and Repair

• ISBN13: 9780750677264
• ISBN10: 0750677260
• Edition: 3rd
• Format: Hardcover
• Copyright: 2004-11-03
• Publisher: Elsevier Science

Summary

The names Bloch and Geitner are synonymous with machinery maintenance and reliability for process plants. They save companies like Dow and Equilon millions of dollars a year by extending the life of rotating machinery in their plants. Extending the life of existing machinery is the name of the game in the process industries, not designing new machinery. This series by Bloch and Geitner was the first and is still the best, most comprehensive source for doing just that. This classic text on reliability has been revised to include all new material on risk management, pre-grouted bases, laser alignment, cartridge seals maintenance, and many other topics which have undergone many developments since the last revision.

Table of Contents

Foreword	viii
Acknowledgments ix
Part I: Background to Process Machinery Maintenance Programming	1	(196)
1 Machinery Maintenance: An Overview	3	(8)
2 Maintenance Organization and Control for Multi-Plant Corporations	11	(50)
Type of Operation.
Manager's Role.
Maintenance.
Central Control System.
Incentives for Computer Systems.
Setting Up an Effective System.
Machinery Maintenance on the Plant Level.
Assignment of Qualified Personnel.
Timing and Basic Definition of Critical Pre-Turnaround Tasks.
Specific Preparation and Planning.
Documenting What You've Done.
3 Machinery Foundations and Grouting	61	(87)
What's an Epoxy?
Epoxy Grouts.
Proper Grout Mixing Is Important.
Job Planning.
Conventional Grouting.
Methods of Installing Machinery.
Pressure-Injection Regrouting.
Prefilled Equipment Baseplates: How to Get a Superior Equipment Installation for Less Money.
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.
4 Process Machinery Piping	148	(49)
Fundamentals of Piping Design Criteria.
Piping Design Procedure.
The When, Who, What, and How of Removing Spring Hanger Stops Associated with Machinery.
Flange Jointing Practices.
Primary Causes of Flange Leakage.
The Importance of Proper Gasket Selection.
Flange Types and Flange Bolt-Up.
Controlled Torque Bolt-Up of Flanged Connections.
Recommendations for the Installation, Fabrication, Testing, and Cleaning of Air, Gas, or Steam Piping.
Pickling Procedure for Reciprocating Compressor Suction Piping: Method I.
Cleaning of Large Compressor Piping: Method II.
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.
Part II: Alignment and Balancing	197	(190)
5 Machinery Alignment	199	(59)
Prealignment Requirements.
Choosing an Alignment Measurement Setup.
Checking for Bracket Sag.
Face Sag Effect-Examples.
Interpretation and Data Recording.
The Graphical Procedure for Reverse Alignment.
Thermal Growth Twelve Ways to Correct for It.
Thermal Growth Estimation by Rules of Thumb.
6 Balancing of Machinery Components	258	(129)
Definition of Terms.
Purpose of Balancing.
Types of Unbalance.
Motions of Unbalanced Rotors.
Balancing Machines.
Centrifugal Balancing Machines.
Measurement of Amount and Angle of Unbalance.
Classification of Centrifugal Balancing Machines.
Maintenance and Production Balancing Machines.
Establishing a Purchase Specification.
Supporting the Rotor in the Balancing Machine.
End-Drive Adapters.
Balancing Keyed End-Drive Adapters.
Balancing Arbors.
Testing Balancing Machines.
Inboard Proving Rotors for Horizontal Machines.
Test Procedures.
Balance Tolerances.
Special Conditions to Achieve Quality Grades G1 and G0.4.
Balance Errors Due to Rotor Support Elements.
Recommended Margins Between Balance and Inspection Tolerances.
Computer-Aided Balancing.
Field Balancing Overview.
Field Balancing Examples.
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.
Part III: Maintenance and Repair of Machinery Components	387	(230)
7 Ball Bearing Maintenance and Replacement	369	(78)
Engineering and Interchangeability Data.
Cleanliness and Working Conditions in Assembly Area.
Removal of Shaft and Bearings from Housing.
Cleaning the Bearing.
Shaft and Housing Preparation.
Checking Shaft and Housing Measurements.
Basic Mounting Methods.
Hints on Mounting Duplex Bearings.
Preloading of Duplex Bearings.
Importance of the Correct Amount of Preload.
Assembly of Bearings on Shaft.
Cautions to Observe During Assembly of Bearings into Units.
Mounting with Heat.
Checking Bearings and Shaft After Installation.
Assembly of Shaft and Bearings into Housing.
Testing of Finished Spindle.
Maintain Service Records on All Spindles.
8 Repair and Maintenance of Rotating Equipment Components	447	(54)
Pump Repair and Maintenance.
Installation of Stuffing Box Packing.
Welded Repairs to Pump Shafts and Other Rotating Equipment Components.
How to Decide if Welded Repairs Are Feasible.
Case Histories.
High Speed Shaft Repair.
Shaft Straightening.
Straightening Carbon Steel Shafts.
Casting Salvaging Methods.
OEM vs. Non-OEM Machinery Repairs.
9 Centrifugal Compressor Rotor Repair	501	(35)
Compressor Rotor Repairs.
Impeller Manufacture.
Compressor Impeller Design Problems.
Impeller Balancing Procedure.
Rotor Bows in Compressors and Steam Turbines.
Clean-Up and Inspection of Rotor.
Disassembly of Rotor for Shaft Repair.
Shaft Design.
Rotor Assembly.
Shaft Balancing.
Rotor Thrust in Centrifugal Compressors.
Managing Rotor Repairs at Outside Shops.
Mounting of Hydraulically Fitted Hubs.
Dismounting of Hydraulically Fitted Hubs.
10 Protecting Machinery Parts Against Loss of Surface	536	(81)
Basic Wear Mechanisms.
Hard-Surfacing Techniques.
Special Purpose Materials.
The Detonation Gun Process.
Selection and Application of O-Rings.
Appendix 10-A Part Documentation Record.
Procedures and Materials Used for Hard-Surfacing.
Index	617