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INDUSTRIAL EQUIPMENT
An Introduction to
Rotating Equipment
Maintenance
1
Objectives
– Define safety needs and lockout procedures.
Basics of Rotating Industrial Equipment
2
Equipment
Compressors
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3
Auxiliary and Support Systems
Lubrication
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Bearing
Seals
Alignment
Vibration
Analysis
Thermal Analysis
4
TOPICS – Click to view
General Safety Topics
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Compressors
Pumps
Turbines
Fans and Louvers
Lubrication Requirements
Bearings
Seals
Alignment
Vibration Analysis
Thermal Analysis
Preventative Maintenance
Fault Recognition
5
GENERAL SAFETY TOPICS
6
Tenets of Maintenance Safety
1. Always operate equipment within design or
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environment limits.
2. Always work in a safe and controlled condition.
3. Always ensure safety devices are in place and
functioning.
4. Always follow safe work practices and procedures.
5. Always meet or exceed customer’s requirements.
6. Always maintain integrity of dedicated systems.
7. Always comply with all applicable rules and
regulations.
7
Tenets of Maintenance Safety
requirements.
6. Always maintain integrity of dedicated
systems.
7. Always comply with all applicable rules and
regulations.
8
Safety Meetings
The primary purpose of safety meetings is to
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9
Accident Causes
Whenever an accident occurs, someone always
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10
Unsafe Conditions
Unsafe conditions are those things that can be
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11
Unsafe Acts
What are unsafe acts or unsafe practices?
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12
Hazard Awareness
The main indicator of an existing hazard is by the
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posting of signs.
Other indicators are listed below:
– Safety Meetings
– Toolbox Meetings
– Procedure Warnings and Cautions
– System and Work Site Familiarity
13
Rotating Equipment Safety
All persons working near or around rotating
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14
Rotating Equipment Safety
Maintain good housekeeping practices.
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15
Rotating Equipment Safety
Beware of and avoid getting too close to
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16
Rotating Equipment Safety
Do not operate equipment unless authorized to
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do so.
Stop-start stations should be clearly marked and
located for easy accessibility, do not hesitate to
use them when necessary.
Horseplay, scuffling, or other such actions
around equipment is hazardous.
17
Rotating Equipment Safety
Promptly report to the proper supervisor all
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18
Rotating Equipment Safety
Ifpotentially dangerous conditions exist, report it
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19
Rotating Equipment Safety
Allpersonnel performing maintenance or repairs
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20
Rotating Equipment Safety
Bypassing or jumping safety circuits will cause a
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21
Rotating Equipment Safety
Itmay be necessary to bleed lines to any
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23
Rotating Equipment Safety
Before restarting a piece of equipment that has
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24
Rotating Equipment Safety
Before restarting a piece of equipment that has
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25
Signs
The following slides are examples of types of
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26
Prohibition Signs
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27
Open Flame Restricted Areas
Warehouses with easily ignited and flammable
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materials
Explosion hazardous areas
Locations with toxic materials
Areas where different activities with flammable
materials are carried out
28
Mandatory Signs
Attention,
When Entering Facility,
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29
Warning Signs
Warning signs mean
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– Caution
– Risk of Danger
– Hazard ahead
Warning signs are designated by white
background with a black outline of an equilateral
triangle, yellow inside the triangle, and black
symbol in the triangle.
30
Safety Signs
First Aid signs are for
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posting at locations
having a first aid kit.
31
Fire Safety Signs
Fire Extinguisher signs are
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32
Traffic Signs
Speed Limit
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15
33
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34
Pedestrian
Traffic Signs
Crossing
Traffic Signs
Priority
signs shall be posted to establish the
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35
Fire Safety
Obey All Warning and Caution Signs
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36
Electrical Lock Out
To protect personnel, equipment that is to be
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37
LOCKOUT
INCOMING CONTROL PANEL START AND
POWER STOP SWITCHES, ADJUSTMENTS,
DISCONNECT SWITCH
CONTROLS, ETC
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LOCKOUT IF WORKING
ON CONTROL PANEL
OR ON ELECTRICAL
CONTROL CIRCUIT
LOCKOUT DEVICE
ENERGY SOURCE
ENERGY ISOLATING DEVICE
SHALL
SHOULD
39
Definitions
Electric Power Source is the main control panel (i.e.,
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40
Lock Definitions
Instrumentation/Electrical locks are single-use,
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41
Tagout Definitions
Tagout is the installation of “Danger - Do Not
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42
Summary
Potential electrical hazards can be minimized
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43
Personal Protective Equipment
44
Definitions
Personal Protective Equipment
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45
Roles and Responsibilities
Comply with equipment manufacturer
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recommendations.
Visually inspect the PPE daily or before each
use.
Replace torn or damaged PPE.
Properly clean and store equipment.
Contact supervisor with questions.
46
General PPE Requirements
Make sure that PPE is appropriate to the work
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condition.
Using PPE that is not required may get in the
way.
– For example, wearing electrician gloves to calibrate a
level indicator would be a hindrance.
47
General PPE Requirements
The minimum PPE in plant areas include:
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– Hard Hat
– Safety Glasses
– Safety or Sturdy Shoes
– Mini Filter in some areas
48
Head Protection
Hard hats protect the head from impact, and
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49
Eye and Face Protection
Eye and face protection is required when
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50
Face Shields
Face shields must be worn to protect the
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51
Eye and Face Protection
Goggles and face shields should be washed with
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52
Hand Protection
Gloves shall be worn when hands are exposed to
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53
Glove Inspection
Impervious gloves should be checked for
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54
Body Protection
Appropriate body protection must be worn to
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55
Aprons
Aprons should be worn to keep dirt and material
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56
Foot Protection
Employees shall wear safety steel toed footwear
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57
Definitions
AirLine Respirator
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58
Definitions
IDLH Atmosphere
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59
Summary
Review
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60
COMPRESSORS
61
Main Topics
Introduction to compressors
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Centrifugal
Reciprocating
Screw
62
Introduction
Compression is used in all aspects of gas
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63
Types
Reciprocating
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Centrifugal
Sliding Vane
Rotary Screw
64
Reciprocating Compressor
Suction Piston
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Valve
Piston Rod
Cylinder
Head
Discharge
Cylinder Valve
65
Cylinder Operating Valves
SUCTION
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SUCTION VALVE
DISCHARGE VALVE
DISCHARGE
66
Stages
The number of stages is governed by the following
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factors:
– Allowable discharge temperature.
– Rod loading.
– Existence of a fixed side stream pressure level (where
flow is added to or withdrawn from main flow of
compressor).
– Allowable working pressure of available cylinders.
67
Sliding Vane Compressor
Sliding Vane
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Rotor
Inlet Port
Discharge
Port
68
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69
Screw Compressors
Centrifugal Compressor
Fundamentals
Gas flow path
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Stage
Process stage
Velocity Energy to Pressure
70
Centrifugal Compressor
Gas Suction Discharge
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Torque
71
Centrifugal Compressor Types
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Axial, or horizontally
split JOINT
JOINT JOINT
Radial, or
vertically split
72
Centrifugal Compressor Stage
Components
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73
Surge
Surge is caused by unstable flow within
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74
Causes/Effects of Surge
Restricted suction or discharge such as a
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plugged strainer.
Process changes in pressures or gas
composition.
Mis-positioned rotor or internal plugging of flow
passages.
Inadvertent speed change such as from a
governor failure.
75
Dry Gas Seals
Face Rotation
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Stationary
Face
Rotating
Face
76
Summary
Review Question and Answer Session
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77
PUMPS
78
Course Objectives
Atthe completion of this course students will be
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able to:
– Identify types of pumps
– Identify major components for each type of pump
– Define Characteristics of each type of pump
– Describe applications in which each type of pump is
used
79
Major Topics
Pumps – General
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80
Pumps
Types
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– Centrifugal - Overview
81
Positive Displacement Pumps
Screw Pumps
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Gear pumps
Piston pumps
Rotating gears
Centrifugal pumps
82
Screw Pumps
Screw pumps are the most common type of
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83
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84
INLET
OUTLET
Screw Pumps
INLET
OUTLET
Gear Pumps
85
External Gear Pump
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Counter-rotating gears
86
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87
External Gear Pumps
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88
Internal Gear Pump
Piston Pumps
PistonPump Diagram
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89
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90
Piston Pump
Major Components
Inlet
Check Ball Outlet
Check Ball
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Cam Plate
Outlet
Inlet
SUCTION
COMPRESSION
DISCHARGE
Drive Shaft
Pumping
Chamber
Spring
Piston
91
Operation and Application
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SUCTION
COMPRESSION
DISCHARGE
92
Plunger Pumps
Plunger Pump Diagram
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93
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94
Packed Plunger Pump
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95
Diaphragm Plunger Pump
Example Plunger Pump Diagram
OUTLET CHECK
LUBE INLET
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VALVE
LUBE OUTLET PRIMER/REGULATING
ASSEMBLY
FRONT OF
RESERVOIR
INLET CHECK
VALVE
ROCKER
ARM
ASSEMBLY
CAM
96
Centrifugal Pumps
Centrifugal Pump Diagram
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97
Fundamentals
Impeller Vanes
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Tongue
Eye Volute
98
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99
Centrifugal Pump Diagram
Sleeve/Coupling/Bearings
ShaftSleeve
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Coupling
– Elastomeric couplings (having properties that
resemble rubber)
– Non-elastomeric
Bearings
100
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101
Impeller Types
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102
Suction and Discharge
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103
Swing Type Check Valve
Valves
Single disc swing valves
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104
Centrifugal Pump Application
HighFlow-rate requirements
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105
Centrifugal Pump Operation
Conversion of rotational driver energy into flow
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energy
Work on the fluid is performed by impeller and
Volute (higher flow, lower pressure) or Diffuser
(lower flow, higher pressure)
106
Centrifugal Flow
Centrifugal pumps generate flow by using one of
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three actions:
Radial flow
Mixed flow
Axial flow
107
Centrifugal Pump Operation
Flow Path
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Precautions
– Prevent Cavitation
– Avoid Low Flow Conditions
108
Centrifugal Pump Operation
Cavitation
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109
Cavitation
Cavitation is Caused by:
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– Vaporization
– Air ingestion
– Internal recirculation
– Flow turbulence
– Vane Passing Syndrome
110
Vaporization
A fluid vaporizes when its pressure gets too low,
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111
Air Ingestion
Air gets into a system in several ways that
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include :
– Through the stuffing box
– Leaking flanges
– Suction inlet pipe is out of fluid
112
Turbulence
We would prefer to have liquid flowing through
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113
Vane Passing Syndrome
Youwill notice damage to the tip of the impeller
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114
Pump Laws
Velocity is directly proportional to Pump Speed
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– V flow α N
Discharge Head is directly proportional to the
square of Pump Speed
– H pump α N2
Pump Power consumption is directly proportional
to the cube of Pump Speed
– P pump α N3
115
Pump Laws
Example:
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– N = 1450 RPM
– V = 400 m3 / hr
– H = 100 Barg
– P = 45 kW
116
Summary
Review Question and Answer Session
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117
TURBINES
118
Objectives
Define Brayton Cycle.
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119
Gas Turbine
Function/ Purpose
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Process Flow
120
Gas Turbine
Basic Configuration
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AirCompressor
Combustor
Turbine
121
Gas Turbine
A gas turbine extracts energy from a flow
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122
Brayton Cycle
Gas turbines are described thermodynamically by the
Brayton cycle, in which air is compressed isentropically,
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123
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124
Steps of the Brayton Cycle
Performance parameters
Speed of rotation
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Oil Temperature
Oil Pressure
Fuel gas pressure
Rotor axial displacement
Bearing vibrations
Exhaust temperature
125
Main Components
Turbine Casing
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Compressor Section
Combustion Chamber
Bearings
Turbine Rotors
Auxiliary Systems
126
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127
Turbine Casing
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128
Compressor Section
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129
Combustion Chamber
Split Shaft Design
Exhaust
Fuel
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Gas
Combustion
chamber
L.P.
H.P.
Axial Shaft Load
Shaft
Compressor Assy
Assy
Air inlet
130
Combustor
Can-annular Type Combustor Example
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131
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132
Bearings
Turbine Rotors
Rotors/Buckets
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Splitshaft design
Variable Nozzle
133
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134
Rotors/Buckets
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135
Variable Nozzle
Shutdown Sequence
NormalShutdown
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Emergency Stop
136
Normal Shutdown
Manually initiated, Automatically sequenced
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137
Emergency Stop
Can be manually or automatically initiated
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Automatically sequenced
Does NOT include a cool-down delay
When trip is caused by a fire sensor all lube
oil flow stops
138
Filters
Lube oil filter
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139
Shutdown Maintenance
MajorInspection
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Borescope Inspections
Combustion Inspection
Hot Gas Path Inspection
140
Major Inspection
Turbine Disassembly
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141
Borescope Inspections
Overview and Purpose
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142
Summary
Review Question and Answer Session
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143
FANS AND LOUVERS
144
Course Objectives
Define the steps necessary to maintain and
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145
Course Objectives
Discussmethods of determining cause based
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upon effect
146
Fan Safety
Rotating Equipment
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Elevation
High Temperature
H2S
147
Rotor and Hub Assembly Example
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TRAILING
EDGE
LEADING
EDGE
148
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149
Rotors
Fan Checks
Adjust the pitch of each
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150
Fin Fan Tip Clearance
Blade Tip Clearance
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151
Driver
Variable Speed Drive (VSD) Electric Motor
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152
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153
Belts
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154
HTD Belts
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155
HTD Belts
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156
Synchronous Belt
10.7 mm 14 mm Pitch
V-belts
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V-Belt
Matrix
157
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158
Powerband V
-Belt
Powerband V-belts
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159
Cog Belts
Cog Belt
(Side View)
Belt Alignment
Example mis-alignment of belts
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160
Belt Alignment
Four Point Touch Alignment
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Cord tied to
shaft
161
Belt Tensioning
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Too tight
Slight bow
Too loose
162
Changing Belts
Neverlever or pry belts onto sheaves or
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sprockets
163
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164
Bearing
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165
Louvres
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166
Louvres
Cylinder Actuator
6 7 Supply 5 4 Signal 2 3 10 11 12 9
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Exh. Exh.
Out 1 Out 2 8
167
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168
Vibration Switch
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169
Lubrication System
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170
Lubrication System
Maintenance Requirements
General Inspections
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171
Maintenance Requirements
VibrationMonitoring
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172
General Inspections
24000 Hours - General Inspection and Cleaning
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173
Blade Angle Adjustment
Position the inclinometer on the least curved
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174
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175
Blade Angle Adjustment
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176
Blade Angle Adjustment
Blade Tip Clearance Adjustment
Unscrew all the positioning bolts
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177
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178
Vibration Monitoring
Vibration Switch Adjustment
Caution: Isolate power elsewhere before
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removal of covers
To set switch, rotate set level screw on top of
switch fully clockwise
Reset switch and check observation window is
clear.
179
Vibration Switch Adjustment
With machine running normally, rotate set level
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180
Vibration Switch Adjustment
Fill
Set Level Screw cavity with Silicone grease
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and
Replace cap
181
Fan Belt Tensioning
Review Belt drive data sheets
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182
Fan Belt Alignment
Axial alignment is performed by moving the
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motor
Motor is moved by adjusting 2 nut bolts until
proper axial alignment is achieved
Motor is adjusted until the motor drive pulley and
the fan pulley are visually parallel
183
Troubleshooting
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Excessive Vibration
Improper Louvre Operation
184
Fan Vibration
Imbalanced Blade
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185
Improper Louvre Operation
Cylinder does not move with rising or falling input
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signal
– Cause: Zero adjusting screw is not set properly
– Solution: Loosen lock-nut and reset the zero
adjustment
186
Louvre and Linkage Adjustment
signal
– Cause: Adjustment of Span Adjuster is not
correct
– Solution: Remove the set screw of the outer tube
and give ideal adjustment while maintaining input
signal at 0.6 kg/cm.
187
Summary
Review
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189
Objectives
Define types of lubrication
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190
Main Topics
Define types of lubricants
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– Oil
– Grease
– ISO and SAE specifications
Distinguish the difference between grease and oil
Discuss the hazards of mixing different
lubrications
191
Main Topics
Describe the proper handling of lubricants
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– Contamination
– Storage
– Methods of application
– Disposal
Describe replacement of Lube Oil filters.
– Filter redundancy
– Flow characteristics,
DP = Differential Pressure
– Replace with disposable cartridge
192
Introduction to Lubrication
Why use lubricants?
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– Reduce Friction
– Increase Cooling
193
Lubrication Functions
Form a lubricant film between components.
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194
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195
Lubrication
Friction
Grease and oil lubricate the moving parts of a
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machine
Grease and oil reduce friction, heat, and wear of
moving machine parts
196
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197
Oil = Low Friction and Heat
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198
No Oil = High Friction and Heat
Lubrication Prevents Failure of:
Bearings
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Gears
Couplings
Pumps
199
Lubrication Prevents Failure of:
Engine components
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Hydraulic pumps
Gas and Steam Turbines
Any moving parts
200
Lubricants prevent failure by:
Inhibiting
rust and corrosion
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Absorbing contaminates
Displacing moisture
Flushing away particles
201
Can lubricants cause damage?
YES!!
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THE
WRONG LUBRICANT CAN CAUSE
MACHINE FAILURE!
202
Lubricant Selection
Operating temperature
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Load
Speed
Environment
Grease Lubrication
Oil Lubrication
203
Grease
Grease is a heavy, non-liquid lubricant
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204
Oil
Oil can be a heavy or thin liquid lubricant
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205
How are grease and oil different?
How oil is used:
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206
How grease is used?
– In areas where a continuous supply of oil cannot be
retained, (open bearings, gears chains, hinged
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joints)
– Factors to be considered when selecting greases
are:
Type. Depends on operating temperatures,
water resistance, oxidation stability etc
Characteristics. Viscosity and consistency
207
Grease or Oil?
What determines whether a machine needs
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grease or oil?
The manufacturer specifies what lubricant is
used in their machines, based on the properties
of the lubricant. One important property is
VISCOSITY.
208
Viscosity
Viscosity is a liquid’s resistance to flow
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209
Viscosity Rules of Thumb
the lower the temperature, the lighter the oil
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210
Viscosity
211
Consistency
Fundamental principle
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Thickener
Operatingtemperature
Mechanical conditions
Low temperature effect
High temperature effect
212
Grease Lubrication
Thickening agent
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Properties
Where used
213
Advantages of Grease Lubrication
Reduction of dripping and splattering
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214
Grease Selection Factors
– Load condition
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– Speed range
– Operating conditions
– Temperature conditions
– Sealing efficiency
– External environment
215
Oil Types
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216
Mineral-Based Oil
Mineral-based oil is refined from crude oil
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hydrocarbons
Mineral-based oil has 2 types of base:
– Naphtha Base
A naphtha base is solvent-like
– Paraffin Base
A paraffin base is waxy
217
Mineral-Based Oil
Naphtha Base
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218
Mineral-Based Oil
Paraffinic Base
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219
Mineral-Based Oil
synthetics.
Mineral-based oils can contain traces of
sulfur and nitrogen. These impurities can
cause oil to form sludge.
220
Synthetic Oil
Synthetic oil is NOT refined from crude oil
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hydrocarbons
Synthetic oil is made without a mineral base
Synthetic oil is made by careful control of a
chemical reaction that yields a “pure”
substance
221
Synthetic Oil
Synthetic oils are chemically engineered to be
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222
Synthetic Oil
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223
Lubricant Specifications
224
ISO Lubricant Specifications
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225
ISO Lubricants
ISO GRADE 32 46 68 100
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226
Using Different Lubricants
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227
Mixing Lubricants
are:
Change of viscosity
Stripping of machine’s internal coatings,
damage to seals
Reduced flash point, risk of fire
228
Mixing Lubricants
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229
Booster Compressor Lubes
Equipment Specified Lubricant Chevron Consumption Rate Service
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Equivalent Interval
Turbine and Compressor ISO VG 32 GST ISO 32 5 Liters per day Based on oil
Lube Oil System
analysis
Electric Motor (Starter) Grease SRI Grease NLGI 2 negligible 1750 Hours
Electric Motor (Ventilation) Grease SRI Grease NLGI 2 negligible 11500 Hours
Electric Motor (Aux Lube Oil Grease SRI Grease NLGI 2 negligible 3000 Hours
Pump)
Electric Motor (Aux Lube Oil Grease SRI Grease NLGI 2 negligible 1000 Hours
Cooler)
230
Water Pump Lubes
Equipment Specified Lubricant Chevron Consumption Rate Service Interval
Equivalent l/year
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Utility Water Pump Texaco Ursatex Chevron Delo 400 .5L Yearly
SAE 20/20W SAE 20
Fire Water Jockey Texaco Ursatex Chevron Delo 400 .5L Yearly
Pump SAE 20
SAE 20/20W
Fire Water Pump Shell Alvania G3 Chevron SRI Grease 100 3 Years
Motor (SIEMENS) 2
232
Nitrogen Generation Lubes
Basics of Rotating Industrial Equipment
Screw Compressor 72- Total Dacnis VS 32 Chevron Hydraulic Oil 4000 hours
F 9269/89 AW ISO 32
233
Propane Compressor Lubes
Basics of Rotating Industrial Equipment
MG 741 A/B oil pump drive Shell Chevron SRI Grease 2 40000 hours or
and electric motor Alvania R3 4.5 years
MEA-709 A1/2/3 oil cooler Shell Chevron SRI Grease 2 20000 hours or
drive Alvania R3 2.25 years
234
Propane Compressor Lubes
Basics of Rotating Industrial Equipment
MG 711 A/B oil pump drive Shell Chevron SRI Grease 40000 hours or
and electric motor Alvania R3 2 4.5 years
MEA-708 A1/2/3 oil cooler Shell Chevron SRI Grease 20000 hours or
drive Alvania R3 2 2.25 years
235
Fundamentals of Lubrication
Equipment lubrication
Basics of Rotating Industrial Equipment
– Bearings
– Gears
– Couplings
– Pumps
– Engine components
– Hydraulic pumps
236
Lubricant Delivery Methods
Force Feed Lubricant
Basics of Rotating Industrial Equipment
Oil Mist
Constant Circulation
Oil Slinger
Zerk Fittings
Surface Application (brush or spray)
237
Force Feed Lubrication
A force feed lubricant system is like an
Basics of Rotating Industrial Equipment
238
Oil Mist Lubrication
Basics of Rotating Industrial Equipment
239
Oil Mist Lubrication
Centralized lubrication system that
Basics of Rotating Industrial Equipment
240
Benefits - Oil Mist Lubrication
– Bearing failures reduced
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241
Constant Circulation
A Constant Circulation system re-circulates oil in
Basics of Rotating Industrial Equipment
242
Lubrication Check Example
Hand
Grease
grease
Basics of Rotating Industrial Equipment
support
square slide
wheel
shaft and
bearings
worm shaft
(Quarterly)
(Monthly)
1 to 2
1 to 2
pumps with
pumps per
(Mobil
shaft of
XHP222)
(Mobil
XHP222)
Check
Windup
Gear Boxes
(Quarterly)
Oil type
Grease Variable Pitch Pulley Hand Oil Roller Chain, ISO360
(Quarterly) 1 to 2 Pumps of [behind guard] (Quarterly) (Mobil Gear
243 (Mobil XHP222) (LPS) (24810) 636)
Oil Slinger
Small disc that loosely rotates
Basics of Rotating Industrial Equipment
on a shaft
Lubricates moving parts by
agitating or splashing oil in the
crankcase.
Allows a thin film of oil to
remain on the piston rod.
The Oil Slinger is installed on
the piston rod between the
packing case and the wiper
case
244
Zerk Fittings
ZerkFittings are grease fill points that have
Basics of Rotating Industrial Equipment
245
Surface Application
Sometimes lubricants are painted on with a
Basics of Rotating Industrial Equipment
246
Pump System
A Pump System automates lubrication.
Basics of Rotating Industrial Equipment
247
Lubricant Storage Factors
Temperature
Basics of Rotating Industrial Equipment
Light
Water
ParticulateContamination
Atmospheric Contamination
Oil Separation
248
Storage - Temperature
High heat (greater than 45°C) and extreme cold (less
Basics of Rotating Industrial Equipment
249
Storage - Light and Water
Light can change the color and appearance of
Basics of Rotating Industrial Equipment
250
Storage - Contamination
Particles in the air and dust can settle into open
containers. Oxygen and carbon dioxide can change the
Basics of Rotating Industrial Equipment
251
Storage - Oil Separation
Oilwill naturally separate out of most greases
Basics of Rotating Industrial Equipment
over time.
Temperature greater than 45°C increase oil
separation in grease.
252
Storage – Shelf Life
Product Shelf Life In
Lubricants have a finite Years
Basics of Rotating Industrial Equipment
shelf life.
The estimated shelf life Base Oils 5+
for UNOPENED
Lube Oils 5
containers in ideal (Mineral or Synthetic)
conditions is:
Greases 5
(Mineral or Synthetic)
Rust Preventatives 2
253
Summary
Review
Basics of Rotating Industrial Equipment
255
Introduction
Purpose of a bearing
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Friction bearing
Antifriction bearing
256
Bearings
SEPARATOR/CAGE
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BALL
ROLLER
Sleeve Bearing
257
Sleeves and Journals
Frictionbearings
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258
Balls and Rollers
Starting friction
Cages/Seperators
Lubrication
259
Anti-Friction Bearing Types
Basics of Rotating Industrial Equipment
Tapered Rollers
Spherical Rollers
Needle Rollers
Cylindrical Rollers
Ball Rollers
260
Thrust Bearings
Basics of Rotating Industrial Equipment
262
Radial Load
Bearing Loads
Thrust Load
Example of Loads
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Thrust Load
Tapered
Roller
Bearings
Radial Load
263
Basics of Rotating Industrial Equipment
264
Ball
Bearing Contact
Roller
Basics of Rotating Industrial Equipment
265
Tapered Roller Bearings
How Do Bearings Fail
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266
Types of Failure
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Spalling.
Fretting.
267
Basics of Rotating Industrial Equipment
268
Brinelling
Types of Failure
Types of Failure
Vibration
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Electric Currents.
269
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270
Types of Failure - Misalignment
Bearing Lubrication
Allbearings need lubrication to prevent metal-
Basics of Rotating Industrial Equipment
271
Summary
Review
Basics of Rotating Industrial Equipment
273
Major Topics
Seals
Basics of Rotating Industrial Equipment
Seal Types
Dry Gas Seals
Labyrinth Seals
Firewater Pump Packing Seals
Support Systems – Seal Flushing
Troubleshooting
274
Purpose
Shaft Seal Purpose is to prevent leakage
Basics of Rotating Industrial Equipment
275
Packed Stuffing Box
A soft pliable material or packing is placed in a
Basics of Rotating Industrial Equipment
Packing
chamber or
box
Packing
rings
Gland follower
276 or stuffing
gland
Gland Packing
277
Mechanical Seals
Fluid is Toxic or Flammable
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278
Gland Packing
Description
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Application
Advantages
Disadvantages
Operation
279
Gland Packing
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Adjustment
Nut
Seal Flush
Pump Casing
Gland
Follower
280
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281
Gland Packing
Mechanical Seals
Pusher Seals
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Bellows Seals
– Metal
– Elastomer
Cartridge Seals
282
Advantages
Advantages
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283
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284
Pusher Seal
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285
Pusher Seal
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286
Bellows Seals
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287
Bellows Seal (Elastomeric)
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288
Bellows Seal (Elastomeric)
Basics of Rotating Industrial Equipment
289
Bellows Seal (Metallic)
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290
Bellows Seal (Metallic)
Basics of Rotating Industrial Equipment
291
End
Impeller
F
A
Cartridge Seals
E
B
D
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292
Cartridge Seals
General Terminology
Rotating Seal
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Stationary Seal
Balanced Seal
Unbalanced Seal
293
Stationary Seal
End Plate
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Rotating
Impeller
End
C D
Stationary Seal Design
294
Unbalanced
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U nbalanced
P ressure
A tm osphere
295
Balanced
Basics of Rotating Industrial Equipment
B alanced
P ressure
B alanced A tm osphere
S houlder
296
Dry Gas Seals
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Description
Location
Maintenance
297
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298
Dry Gas Seal
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299
Description
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300
Gas Seal Description
Labyrinth Seals
Description
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Location
Maintenance
301
Description
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Impeller
Shaft
Internal
Labyrinth Seals
302
Firewater Pump Diagram
Seal flush Gland packing
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Lantern ring
303
Packing Construction
Lattyflon 2790AL
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– PTFE Impregnanted
– Polyacrylic Yarns
– Silicone Lubricant
304
Basics of Rotating Industrial Equipment
305
Packing Replacement
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306
Packing Replacement
Packing Replacement
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Packing
Dummy shaft
307
Basics of Rotating Industrial Equipment
308
Packing Replacement
45°
Mechanical Seal Service
Flowserve Single Pusher Cartridge Seal – Type CSCPX
Basics of Rotating Industrial Equipment
309
Support Systems - Seal Flush
Description
Basics of Rotating Industrial Equipment
Maintenance
310
Flushing
A small amount of fluid that is introduced into the
Basics of Rotating Industrial Equipment
311
Seal Flush Piping
LPG, toxic services, or T> 450°F:
Basics of Rotating Industrial Equipment
312
Flush Plans
Plan 11 inlet
Basics of Rotating Industrial Equipment
Seal end
view
orifice
313
Flush Plans
Plan 21
inlet
Basics of Rotating Industrial Equipment
orifice cooler
Temperature Coolant
sensor in
314
Flush Plans
Plan 31 inlet
Basics of Rotating Industrial Equipment
Seal end
view
Cyclone
separator
315
Cyclone Separator
B. To mechanical seal
Basics of Rotating Industrial Equipment
A.
Discharge
in
Quench
Fixed throttle
Impeller end bushing
Stationary
face
Gland gasket
groove
317 Drain
Water Quenching
318
Other Support Systems
Cooling
Basics of Rotating Industrial Equipment
Pressurization
319
Pressurization
320
Overview of Seal Failures
Loss of Face Lubrication
Basics of Rotating Industrial Equipment
Bellows cracking
Corrosion
321
Overview of Seal Failures
Corrosion fretting (wear) of the sleeve under the
Basics of Rotating Industrial Equipment
secondary seal
Coke or crystal build up on the atmosphere side
of the seal under the faces
322
Causes of Seal Failures
Basics of Rotating Industrial Equipment
323
Causes of Seal Failures
Inspect Mechanical Condition
Basics of Rotating Industrial Equipment
324
Causes of Seal Failures
325
Seal Chamber
chamber pressure
Causes for a temperature increase
at the seal faces
326
Summary
Review
Basics of Rotating Industrial Equipment
328
Major Topics
Alignment Overview
Basics of Rotating Industrial Equipment
Methods of Alignment
Use of the Rotalign® Pro System
Alignment of Simple Driver/Load Systems
Soft Foot
Alignment of Equipment Trains
Sheave Alignment
Alignment Troubleshooting
Thermal Growth
329
Alignment Overview
Reasons for Proper Alignment
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– Time
– Cost
– Effort
330
Alignment Terminology
Offset Side View
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Motor Pump
Vertical
Top View
Motor Pump
Horizontal
332
Methods of Alignment
Straight Edge
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Dial Indicator
Laser Alignment
333
Dial Indicator
Rim Alignment Side View
Basics of Rotating Industrial Equipment
Top View
Motor Vertical
Pump
Top View
Motor Horizontal
Pump
335
Basics of Rotating Industrial Equipment
336
Bar Sag
Dial Indicator
Dial Indicator
Caution: If the Coupling faces appear
as below, it will be necessary to replace
Basics of Rotating Industrial Equipment
337
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338
Laser Alignment
Soft Foot
Any condition where tightening or loosening the
Basics of Rotating Industrial Equipment
339
Basics of Rotating Industrial Equipment
340
Internal Misalignment
Soft Foot
Causes
Basics of Rotating Industrial Equipment
– Bent legs/feet
– Deformed shims
– Dirt or debris
– Strain from attached components
– Machine frame distortion
341
Soft Foot
Effects
Basics of Rotating Industrial Equipment
– Vibration
– Strain and Deformation
– Bearing Wear/Distortion
– Premature Equipment Failure
342
Basics of Rotating Industrial Equipment
343
Parallel Air Gap
Soft Foot - Types
Basics of Rotating Industrial Equipment
344
Bent
Soft Foot - Types
Basics of Rotating Industrial Equipment
345
Squishy
Soft Foot - Types
Soft Foot - Types
Induced
Basics of Rotating Industrial Equipment
Strain
Induced
Soft Foot
346
Soft Foot Detection
Dial Indicator
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Parallel Angular
Soft Foot
347
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348
Feeler Gauges
Soft Foot Detection
Soft Foot Detection
Typical Soft Foot
0 15
Basics of Rotating Industrial Equipment
Readings 25 25
10 8
0 25
6 25
25
5 12 0
0 25
349
Soft Foot
Soft Foot Correction
Basics of Rotating Industrial Equipment
Parallel Angular
Soft Foot
350
Basics of Rotating Industrial Equipment
351
Step Shimming
Basics of Rotating Industrial Equipment
352
Sheave Alignment
Alignment Troubleshooting
Shaft Deflection
Basics of Rotating Industrial Equipment
– Cause:
Weight of Coupling
Shaft Run out
– Test:
Use a dial indicator to measure deflection during 180 degrees
of rotation
Caution:
– Do Not forget about Bar Sag when performing this test
– It is better to use two indicators, reverse alignment
353
Alignment Troubleshooting
Solution:
Basics of Rotating Industrial Equipment
354
Alignment Troubleshooting
Solution:
Basics of Rotating Industrial Equipment
355
Alignment Troubleshooting
Shaft Deflection (Continued)
Basics of Rotating Industrial Equipment
– Affect on Alignment
Alignment readings will be different with and without the
coupling
No indication what the alignment will be while the machine is
in operation
356
Alignment Troubleshooting
Bolt Bound
Basics of Rotating Industrial Equipment
– Affect on Alignment
Motor will not move far enough to bring the motor and pump
back into alignment
357
Alignment Troubleshooting
Bolt Bound
Basics of Rotating Industrial Equipment
358
Alignment Troubleshooting
Bolt Bound
Basics of Rotating Industrial Equipment
359
Alignment Troubleshooting
Coupling Lateral Clearance
Basics of Rotating Industrial Equipment
– Cause:
Wrong Coupling
Improper machine position
Excessive Axial Shaft movement
360
Alignment Troubleshooting
Solution:
Basics of Rotating Industrial Equipment
– Loosen the Shaft grub screws and move the coupling flange(s)
as necessary to establish the correct clearance
– If excessive shaft axial play was present, repair the cause for this
play.
– Consult the equipment manufacturer
361
Thermal Growth
Side View
Basics of Rotating Industrial Equipment
Motor Pump
Top View
Motor
Pump
362
Summary
Review Question and Answer Session
Basics of Rotating Industrial Equipment
363
VIBRATION ANALYSIS
364
Course Objectives
Define the need for analysis
Basics of Rotating Industrial Equipment
365
Introduction
Method to detect and control the mechanical
Basics of Rotating Industrial Equipment
366
What is vibration?
Motion of a machine from rest.
Basics of Rotating Industrial Equipment
367
Vibration
Vibration is the mechanical oscillation or motion
Basics of Rotating Industrial Equipment
368
Vibration
Vibratory system includes:
Basics of Rotating Industrial Equipment
– Spring or Elasticity
– Mass or Inertia
– External Force
50 mm
1.2 m
369
Oscillatory Motion
External force causes the
Basics of Rotating Industrial Equipment
1.2 m
A sin w↑
p A
A
O w↑
θ=w↑
2π
370
Vibration
Vibrations may:
Basics of Rotating Industrial Equipment
371
Repetitive Vibrations
The period of repetition may be measured as
Basics of Rotating Industrial Equipment
frequency
Most equipment vibrations occur between 10 and
2000Hz
372
Normal Vibrations
Machines will have a characteristic vibration
Basics of Rotating Industrial Equipment
G PK
-20
0 ΔT 0.80000
373
Resonance
The resonance combines with the natural
Basics of Rotating Industrial Equipment
374
Effects of Machine Vibration
Efficiency
loss
Basics of Rotating Industrial Equipment
Wear acceleration
Machine failure
Personnel injury
375
Source of Equipment Vibration
Normal motion of machine operation
Basics of Rotating Industrial Equipment
Unbalanced parts
Worn bearings
Loose mounting
External impact
376
Causes of Unbalance
Deposit and Build-Up
Basics of Rotating Industrial Equipment
377
Misalignment
ParallelOffset Misalignment
Basics of Rotating Industrial Equipment
Angular Misalignment
Combination
Tolerances
378
Basics of Rotating Industrial Equipment
379
Eccentricity
Vibration From:
Bent Shafts
Basics of Rotating Industrial Equipment
380
Vibration Sensors
Sensors convert vibrations into electrical signals
Basics of Rotating Industrial Equipment
381
Basics of Rotating Industrial Equipment
382
Velocity Transducer
Basics of Rotating Industrial Equipment
383
Radial Probe Mounting
Basics of Rotating Industrial Equipment
384
Axial Position
Basics of Rotating Industrial Equipment
385
Key Phasor
Basics of Rotating Industrial Equipment
386
Proximity Probes
Basics of Rotating Industrial Equipment
387
Basics of Rotating Industrial Equipment
388
Summary
Review
Basics of Rotating Industrial Equipment
390
Introduction
391
Temperature Measurement
Temperature measurement, just as flow and
Basics of Rotating Industrial Equipment
392
This condition will continue until
Basics of Rotating Industrial Equipment
393
Bimetallic Thermometers
Basics of Rotating Industrial Equipment
Back Bottom
Bi-metallic Spring
394
Thermocouples:
Basics of Rotating Industrial Equipment
DIGITAL THERMOMETER
74.0°F
-20° TO 70° 0° TO 160°F
395
Basics of Rotating Industrial Equipment
396
249°
Thermographic Instruments:
Evaluating thermal signatures of
Basics of Rotating Industrial Equipment
397
To determine an adverse operating
Basics of Rotating Industrial Equipment
temperature of a component, it is
necessary to first determine a baseline.
For electrical systems the baseline is
established when the system is
operating under normal load and
operating conditions. Once a component
or system baseline signature is
determined, the thermography technician
can identify an anomaly through
398 comparison with the baseline.
Most anomalies in electrical systems are
Basics of Rotating Industrial Equipment
399
Other advantages of an infrared inspection
Basics of Rotating Industrial Equipment
are:
1.Safety - Electrical component failure
can be catastrophic, injuring personnel
or damaging equipment.
2.Greater System Security - locate the
problems prior to failure greatly reduces
unscheduled outages, associated
equipment damage and downtime.
400
Thermal energy generated from an
Basics of Rotating Industrial Equipment
401
When performing an infrared inspection of
Basics of Rotating Industrial Equipment
403
The other three (convection, thermal
Basics of Rotating Industrial Equipment
405
Of the real thermal pattern variations,
Basics of Rotating Industrial Equipment
1. I²R Loss
2. Harmonics
3. Induced heating
406
Remember, the actual component
Basics of Rotating Industrial Equipment
407
Basics of Rotating Industrial Equipment
408
The most common loss of power in an
Basics of Rotating Industrial Equipment
409
P = I²R
Basics of Rotating Industrial Equipment
410
This I²R heating, as it is often called, takes
Basics of Rotating Industrial Equipment
415
Poor contact B phase breaker
Basics of Rotating Industrial Equipment
This hot bus stab to the back of the breaker represents an extremely
serious problem. Why?
First because of its location in the system. A failure here will typically
have significant consequences! Second, the heat appears to be
generated inside the breaker. This means the thermal pattern we see is
greatly diminished by comparison to the actual point of contact that is
inside the breaker. Lastly, the material we are looking at has a very low
emissivity, so if it looks at all warm or hot, it is extremely hot! This
type of problem should generally be checked and repaired immediately.
417
Basics of Rotating Industrial Equipment
418
The right phase of this
Basics of Rotating Industrial Equipment
419
Problem Phase to Phase Comments
Classification Temperature Rise
Basics of Rotating Industrial Equipment
* with wind speed less than 15mph * with load conditions greater than 50%
420 Hint: Have an electrical contractor use a clamp on ammeter to verify loading.
Wind will affect your temperature readings due to convection
Basics of Rotating Industrial Equipment
2 1.00
4 1.30
6 1.60
8 1.68
10 1.96
12 2.10
14 2.25
16 2.42
18 2.60
421
Basics of Rotating Industrial Equipment
422
Basics of Rotating Industrial Equipment
423
Basics of Rotating Industrial Equipment
424
Basics of Rotating Industrial Equipment
Harmonics problems
on circuit
427
Summary
Review
Basics of Rotating Industrial Equipment
429
Main Topics
PreventiveMaintenance Programs
Basics of Rotating Industrial Equipment
Maintenance problems
430
Maintenance Problems
Wear and tear
Basics of Rotating Industrial Equipment
431
Prevention Troubleshooting
Troubleshooting is the search for the root cause
Basics of Rotating Industrial Equipment
of a problem
The need to troubleshoot can be minimized by
an effective maintenance programs
432
Types of Maintenance
Preventative maintenance
Basics of Rotating Industrial Equipment
433
Preventive Maintenance
This type of maintenance is performed at set
Basics of Rotating Industrial Equipment
intervals.
Examples of time-based maintenance include:
– Monthly calibration checks
– Weekly lubrication
– Daily housekeeping
434
Condition Monitoring
Temperature
Basics of Rotating Industrial Equipment
Vibration
Changes in noise or sound
Visually observed changes and problems
435
Sound/Noise
Listening
Basics of Rotating Industrial Equipment
Sound Measurements
436
Preventative Maintenance
Preparations
Preparation
Basics of Rotating Industrial Equipment
Precautions
437
Pump Preventative Maintenance
– Observe and record condition of pump
Basics of Rotating Industrial Equipment
438
Fan Preventative Maintenance
– Check all fan bolts for tightness
Basics of Rotating Industrial Equipment
439
Summary
Review
Basics of Rotating Industrial Equipment
441
Course Objectives
Identify
types of maintenance problems
Basics of Rotating Industrial Equipment
442
Main Topics
PredictiveMaintenance
Basics of Rotating Industrial Equipment
Condition Monitoring
443
Predictive Maintenance
Systematic method of monitoring equipment.
Basics of Rotating Industrial Equipment
444
Predictive Maintenance
List the benefits of predictive maintenance
Basics of Rotating Industrial Equipment
445
Condition Monitoring
Temperature
Basics of Rotating Industrial Equipment
Vibration
Changes in noise or sound
Visually observed changes and problems
446
Basics of Rotating Industrial Equipment
447
Surface
Temperature
Temperature
Vibration
Basics of Rotating Industrial Equipment
Screwdriver
Listen
Vibration
Probe
448
Sound/Noise
Listening
Basics of Rotating Industrial Equipment
Sound Measurements
449
Sight
Basics of Rotating Industrial Equipment
Loose
Bearing
Housing
Loose
Bolts
Cracked
Leaking
Housing
Seal Lubrication
450 Problem
Pump – Steps in Troubleshooting
Talk to operators
Basics of Rotating Industrial Equipment
451
Pumps -Symptoms You Can Here
Loud rattling or clanging noise
Basics of Rotating Industrial Equipment
452
Pumps - Symptoms You Can See
Abnormal pressure Readings
Basics of Rotating Industrial Equipment
453
Some Pump Problems/Symptoms
Bearing Lubrication Leak
Basics of Rotating Industrial Equipment
Bearings Damaged
Bearings Worn
Casing Flange Bolts Loose
Casing Flange Gasket Worn
Casing Wearing Ring Damaged
Casing Wearing Rings Worn
Cavitation
Discharge Strainer Clogged
454
Pumps – Symptoms You Can Feel
Excessive Vibration
Basics of Rotating Industrial Equipment
Overheating
455
Summary
Review
Basics of Rotating Industrial Equipment