Table Of ContentSECOND EDITION
Practical Machinery Management for Process Plants
Volume 3
.
.
Turb.om achinery Overhau.ls Foundations and
Grouting Alignment and Balancing Pump Shaft
Repairs Mechanical Seals Machinery Components
.
Heinz P. Bloch Fred K. Geitner
Practical Machinery Management tor Process Plants
Volume 3, Second Edition
Machinery Component
Maintenance and Repair
Gulf Publishing Company
Houston. Texas
Practical Machinery Management for Process Plants
Volume 3, Second Edition
Machinery Component
Maintenance and Repair
Heinz P. Bloch and
Fred K. Geitner
This edition was
reviewed by the authors
and reprinted in 1999.
I I
Practical Machinery Management for Process Plants
Volume 3, Second Edition
Machinery Component Maintenance and Rerair
Copyright 0 1985, 1990 by Gulf Publishing Company, Hous-
ton, Texas. All rights reserved. Printed in the United States of
America. This book, or parts thereof, may not be reproduced
without permission of the publisher.
Gulf Publishing Company
Book Division
P.O. Box 2608 0 Houston, Texas 77252-2608
10 9 8 7 6 5 4 3
Library of Congress Cataloging-in-Publication Data
Bloch, Heinz P., 1933-
Machinery component maintenance and repairlHeinz P. Bloch and
Fred K. Geitner.-1st ed.
p. cm.-(Practical machinery management for process plants; v. 3)
Includes index.
ISBN 0-87201-781-8
1. Machinery-Maintenance and repair. 2. Industrial equipment-
Maintenance and repair. 1. Geitner, Fred K. 11. Title.
111. Series: Bloch, Heinz P., 1933-. Practical machinery management
for process plants; v. 3.
TJIS3.BS83 1990
670‘ .28’8-d~20 90-3579
CIP
Series ISBN 0-87201-675-7
Note: The reader is reminded that many of the techniques and procedures de-
scribed herein are of a general nature and may have to be modified or adapted
to be directly applicable to the specific machinery in his plant. In casc of con-
flict, observe the manufacturer’s instructions or ask the manufacturer to assist
in resolving any differences.
Printed on Acid-Free Paper (co)
iv
Contents
...........................................
Foreword viii
......................................
Acknowledgments ix
Part I: Background to Process Machinery Maintenance
......................................
Programming 1
...................
1 Machinery Maintenance: An Ovaview 3
2 Maintenance Organization and Control for Multi-Plant
......................................
Corporations 12
Type of Operation. Manager’s Role. Central Control System. Planning Turbo-
machinery Overhauls. Assignment of Qualified Personnel. Specific Prepara-
tion and Planning. Inspection. Cleaning. Reassembly. Documenting What
You’ve Done.
...................
3 Machinery Foundations and Grouting 65
What’s An Epoxy? Epoxy Grouts. Proper Grout Mixing is Important. Job Plan-
ning. Conventional Grouting. Methods of Installing Machinery. Pressure-In-
jection Regrouting . Foundation Repairs. Pump Baseplate Installation and Ep-
oxy Grouting. Baseplate Leveling Procedures. Baseplate Preparation. New
Concrete Preparation. Old Concrete Preparation. Anchor Bolts. Grout Forms.
Epoxy Grout Placement. Appendix 3-A-Detailed Checklist for Rotating
Equipment: Horizontal Pump Baseplate Checklist. Appendix 3-B-Specifica-
tion for Portland Cement Grouting of Rotating Equipment. Appendix 3-C-De-
tailed Checklist for Rotating Equipment: Baseplate Grouting. Appendix 3-D-
Specifications for Epoxy Grouting of Rotating Equipment.
...........................
4 Process Machinery Piming 142
Fundamentals of Piping Design Criteria. Piping Design Procedure. Flange
Jointing Practices. Primary Causes of Flange Leakage. Proper Gasket Selec-
V
tion. Controlled Torque Bolt-Up of Flanged Connections. Recommendations
for the Installation, Fabrication, Testing, and Cleaning of Air, Gas, or Steam
Piping. Appendix 4-A-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 Equip-
ment: Pump Piping.
.........................
Part II: Aliflnment and Balancing 16s
...............................
5 Machinery Alignment 171
Prealignment Requirements. Choosing an Alignment Measurement Setup.
Checking for Bracket Sag. Face Sag Effect-Examples. Interpretation and Data
Recording. Graphical Techniques. Reverse Indicator Method Using Crossover
Brackets. Horizontal Movement by Vertical Adjustment. Thermal Growth-
Eleven Ways to Correct for it. Thermal Growth Estimation by Rules of Thumb.
...................
6 Balancing of Machinery Components 238
Definition of Terms. Purpose of Balancing. Units of Unbalance. Types of Un-
balance. Motions of Unbalanced Rotors. Balancing Machines. Centrifugal Bal-
ancing Machines. Measurement of Amount and Angle of Unbalance. Classifi-
cation of Centrifugal Balancing Machines. Maintenance and Production
Balancing Machines. Supporting the Rotor. Balancing Keyed End-Drive
Adapters. Balancing Arbors. Testing Balancing Machines. Test Procedures.
Balance Tolerances. Balance Errors Due to Rotor Support Elements. Com-
puter-Aided Balancing. Field Balancing Overview. The Vector Diagram. Ap-
pendix 6-A-Balancing Terminology. Appendix 6-B-Balancing Machine No-
menclature. Appendix 6-C-Balancing and Vibration Standards. Appendix
6-D-Critical Speeds of Solid and Hollow Shafts.
....
Part 111: Maintenance and Repair of Machinery Components 349
.............
7 Ball Bearing Maintenance and Replacement 351
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 Mea-
surements. 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 Bear-
ings into Units. Mounting with Heat. Checking Bearings and Shaft After Instal-
lation. Testing of Finished Spindle. Maintain Service Records on All Spindles.
vi
8 Repair and Maintenance of Mechanical Seals and Rotating
............................
Equipment Components .430
Mechanical Seal Installation, Repair, and Maintenance. Lapping and Seal Face
Flatness. 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.
..................
9 Centrifugal Compressor Rotor Repair 487
Compressor Rotor Repairs. Impeller Manufacture. Compressor Impeller De-
sign Problems. Impeller Balancing Procedure. Rotor Bows in Compressor 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. Mount-
ing of Hydraulically Fitted Hubs. Dismounting of Hydraulically Fitted Hubs.
......
10 Protecting Machinery Parts Against loss of Surface 518
Basic Wear Mechanisms. Hard Surfacing Techniques. Special Purpose Materi-
als. The Detonation Gun Process. Selection and Application of 0-Rings. Cas-
ing Joint Compounds. Sealing Compounds.
..............................................
Index 586
vii
