Is My Machine Ok?

by Perez, Robert X.; Conkey, Andrew P.

• ISBN13: 9780831134402
• ISBN10: 0831134402
• Format: Paperback
• Copyright: 2011-09-15
• Publisher: Industrial Pr

Summary

A handy and concise guide for assessing the potential risk of failure and providing a solid basis for reliable and safe machinery operation.

Author Biography

Robert X. Perez has more than 30 years of rotating equipment experience in the petrochemical industry and holds a BSME from Texas AM University (College Station), a MSME degree from the University of Texas (Austin), and is a licensed P. E. in the state of Texas. He is a co-founder of PumpCalcs.com, a web-based site for pump-related calculations, and is the author of Operator's Guide to Centrifugal Pumps. Andrew P. Conkey is an assistant professor of Mechanical Engineering at Texas AM University at Qatar. He has been a member of the Vibration Institute for over 15 years and has conducted research on the application of fiber optic interferometers for machinery response measurements. He earned a BSME degree from Texas AI University, and MSME and Ph.D. degrees from Texas AM.

Table of Contents

Dedication	p. iii
Contributors	p. iv
Acknowledgments	p. xi
Introduction	p. 1
A Brief Introduction to Machinery Monitoring	p. 3
Why Do We Monitor Machines?	p. 3
Assessing Process Machinery	p. 5
Monitoring Systems	p. 6
Medical Monitoring Analogy	p. 9
Some Basic Advice	p. 11
General Machinery Monitoring Guidance	p. 13
Where to Start?	p. 13
When Should a Machine Be Considered Critical Enough to Justify Continuous Monitoring?	p. 29
Machinery Monitoring Recommendations Based on Criticality	p. 30
Simplified Method of Economic Justification	p. 32
Machinery Assessment Steps	p. 37
The Machinery Assessment Maze	p. 38
What machine information do I need before getting started?	p. 39
What analysis equipment do I need?	p. 39
The Potential to Failure Time Interval	p. 40
Machinery Data Analysis	p. 43
Pattern Recognition	p. 43
Trends	p. 44
Correlations	p. 52
Combination Trends	p. 57
Some Rules of Thumb	p. 60
How to Audit Operating Machinery	p. 61
Field Audit Form	p. 62
Risk Ranking Machinery Issues	p. 69
Recommendations and Risk Ratings	p. 70
How to Assess Centrifugal - Pump Performance	p. 75
Why Use Centrifugal Pumps?	p. 75
Head Versus Pressure	p. 77
Centrifugal Pump Performance	p. 80
Summary	p. 88
How to Conduct a Steam Turbine Field Inspection	p. 91
Steam Turbine Types	p. 92
What is the Steam Turbine Speed Telling You?	p. 93
Assessing Steam Turbine Vibrations	p. 94
Steam Turbine Temperature Assessment	p. 95
Common Governor Control Problems	p. 95
Other Inspections	p. 98
Good Rules of Thumb for Steam Turbines	p. 100
AC Electric Motors	p. 103
Introduction	p. 103
Controls	p. 105
Instrumentation	p. 105
The Effects of Voltage Unbalance	p. 106
Insulation Classes and Their Thermal Ratings	p. 108
Re-greasing Electric Motors	p. 109
Unique Vibration Characteristics of Electric Motors	p. 111
Notes About Motors	p. 111
Useful Electric Motor Formulas and Tables	p. 112
Allowable Piping Vibration and Dynamic Strain	p. 115
Dynamic Strain and Stress Guidelines	p. 120
Data Collection Tips	p. 121
Common Types of Field Sensors	p. 121
What Vibration Sensor Should I Use?	p. 122
What Are the Components of Vibration?	p. 123
Guidelines for Accelerometer Usage	p. 124
Accelerometer Measurement Locations	p. 124
Vibration Analysis Tips	p. 127
Machine Vibration Severity Guides	p. 129
Velocity Guidelines	p. 129
Acceleration Guidelines	p. 139
Vibration Guidelines for Displacement, Velocity, and Acceleration	p. 140
Vibration Guidelines for Displacement Measurements in Fluid Film Bearings	p. 142
Vibration Guidelines for Reciprocating Compressors and Engines	p. 147
Basic Vibration Analysis Part I	p. 153
Common Machinery Problems Associated with Vibration	p. 154
Basic Vibration Analysis Part II	p. 159
Vibration Analysis Terms and Tables	p. 159
Examples of Real Vibration Spectra	p. 166
Detection of Machinery Faults Using Utrasonics	p. 171
Monitoring Bearing and Lubrication Condition	p. 171
Monitoring Reciprocating Machinery	p. 173
Other Applications	p. 174
Dynamic Pressure Measurements	p. 175
Pressure Transducer Installation	p. 175
Piezoelectric Transducers	p. 177
Allowable Pulsation Levels for Reciprocating Compressors	p. 177
Allowable Pulsation Levels for Reciprocating Pumps	p. 179
How to Identify Machinery, Piping, and Acoustic Resonances	p. 181
Rotor Critical Speeds	p. 181
Identifying Piping Resonances	p. 182
Identifying Critical Speeds and Resonances	p. 185
The Quality Factor or Q	p. 187
Temperature Limits	p. 191
How Do Infrared Thermometers Work?	p. 191
Bearing Temperature Trending	p. 192
Bearing Temperature Guidelines	p. 195
Compressor Temperature Monitoring	p. 198
K Values for Common Gases	p. 202
Lubrication	p. 203
Introduction	p. 203
Lubrication Overview	p. 204
Key Steps to a Cost-Effective and Reliable Lubrication Program	p. 211
Oil Analysis Limits and Targets	p. 215
Cleanliness Codes	p. 218
Machinery Rules of Thumb	p. 225
Alignment	p. 225
Balancing	p. 227
Static Shaft Bow	p. 229
Mechanical Seal Misalignment Guidelines	p. 230
Journal Bearing Clearance	p. 230
Piping Guidelines	p. 231
Centrifugal Pump Wear Rings	p. 233
Lean Equipment Compliance	p. 235
Applying TPM to Industrial Equipment	p. 237
Applying Poka-Yoke	p. 238
Management Audit and Follow-Up	p. 239
Glossary of Lean Equipment Compliance (LEC) Terms	p. 240
Final Thoughts	p. 243
Importance of Adding Value	p. 243
Keys to a Successful Machinery Assessment Program	p. 244
Ethics and Intellectual Dishonesty	p. 248
Go Forth and Analyze	p. 248
Glossary of Machinery Assessment Terms	p. 249
Useful Conversions and Equations	p. 267
Index	p. 273
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