Maintenance, Reliability and Troubleshooting in Rotating Machinery - Methods in Rotating and Process Machiner

Maintenance, Reliability and Troubleshooting in ROTATING MACHINERY
 
This broad collection of current rotating machinery topics, written by industry experts, is a must-have for rotating equipment engineers, maintenance personnel, students, and anyone else wanting to stay abreast with current rotating machinery concepts and technology.
 
Rotating machinery represents a broad category of equipment, which includes pumps, compressors, fans, gas turbines, electric motors, internal combustion engines, and other equipment, that are critical to the efficient operation of process facilities around the world. These machines must be designed to move gases and liquids safely, reliably, and in an environmentally friendly manner. To fully understand rotating machinery, owners must be familiar with their associated technologies, such as machine design, lubrication, fluid dynamics, thermodynamics, rotordynamics, vibration analysis, condition monitoring, maintenance practices, reliability theory, and other topics.
 
The goal of the "Advances in Rotating Machinery" book series is to provide industry practitioners a time-savings means of learning about the most up-to-date rotating machinery ideas and best practices. This three-book series will cover industry-relevant topics, such as design assessments, modeling, reliability improvements, maintenance methods and best practices, reliability audits, data collection, data analysis, condition monitoring, and more.
 
Volume one began the series by focusing on design and analysis. Volume two continues the series by covering important machinery reliability concepts and offering practical reliability improvement ideas. Best-in-class production facilities require exceptional machinery reliability performance. In this volume, exceptional machinery reliability is defined as the ability of critical rotating machines to consistently perform as designed, without degradation or failure, until their next scheduled overhaul. Readers will find this volume chock-full of practical ideas they can use to improve the reliability and efficiency of their machinery.
 
Maintenance, Reliability and Troubleshooting in Rotating Machinery covers, among many other topics:
* General machinery reliablity advice
* Understanding failure data
* Design audits and improvement ideas
* Maintenace best practices
* Analyzing failures

List of contents

Preface xvii
 
Acknowledgements xix
 
Part I: General Reliability Advice 1
 
1 Machinery Reliability Management in a Nutshell 3
By Robert X. Perez
 
Criticality 4
 
Environmental Consequences 6
 
Safety Consequences 6
 
Equipment History 7
 
Safeguards 12
 
Compressor Operating Limits 12
 
Compressor Flow Limits 12
 
Critical Speeds 14
 
Horsepower Limits 15
 
Temperatures 16
 
Layers of Machinery Protection 19
 
Machinery Reliability Assessment Example 20
 
Background 20
 
History 22
 
Safeguards 22
 
Conclusion 22
 
Closing Remarks 23
 
2 Useful Analysis Tools for Tracking Machinery Reliability 25
By Robert X. Perez
 
Commonly Used Metrics for Spared Machinery 28
 
Mean Time to Repair (MTTR) 28
 
Mean Time Between Failure (MTBF) 28
 
Additional Reliability Assessment Tools for Spared Machines 29
 
Pareto Charts & 80-20 Rule 33
 
Cumulative Failure Trends 33
 
Metrics for Critical Machines 36
 
Availability 37
 
Critical Machine Events 38
 
Process Outage Trends 38
 
Process Outage Related to Machinery Outages 40
 
Planned Maintenance Percentage (PMP) 41
 
Reliability Analysis Capabilities of your CMMS Software 43
 
3 Improving the Effectiveness of Plant Operators 45
By Julien LeBleu
 
Look, Listen and Feel 47
 
Applying Look, Listen, and Feel Techniques to Troubleshooting 47
 
Why the Operator's Input is Important to the Troubleshooting Process 47
 
Operator Tools 48
 
Understanding the Equipment - Pumps, Seals and Sealing Support Systems 50
 
Centrifugal Pump Relationships to Remember 51
 
Positive Displacement Pump Relationships to Remember 52
 
Mechanical Seals 54
 
Capital Projects 55
 
Writing Quality Work Request 55
 
Procedures (Procedures and Decision Trees) 56
 
Must Give Operators Feedback 56
 
Must be Required to Use their Training 58
 
Discipline 58
 
Conclusion 59
 
Appendix A References 59
 
4 Spare Parts Strategies for Optimizing Rotating Machinery Availability 61
By Robert X. Perez
 
Some Stocking Examples 67
 
Capital Spares 70
 
Insurance Spares 71
 
Analyzing Spare Part Inventories Using Monte Carlo Simulations 72
 
Closing 72
 
Some Definitions Related to Spare Parts 73
 
5 Switch-Over Methodology and Frequency Optimization for Plant Machinery 75
By Abdulrahman Alkhowaiter
 
Machinery Switchover Frequency Optimization Benefits 76
 
Time-Dependent Issues Involved in Setting Switchover Frequency for Standby Machines 76
 
Frequent Switchover Introduces the Following Negative Impact to Rotating Equipment 79
 
Calculation of Start-Stop Damaging Cycles for A, B
 
Configured Equipment: See Definitions Below for More Information 81
 
Definitions 82
 
Examples of Short Start-Stop Intervals in Process Machinery 83
 
Philosophy of Reliability-Centered Switchover Strategy 84
 
Part II: Design Audits and Improvement Ideas 87
 
6 Evaluating Centrifugal Pumps in Petrochemical Applications 89
By Robert X. Perez
 
Crude Oil Processing 92
 
Desalting 94
 
Crude Oil Distillation 94
 
Properties of Distillation and Fractionator Fractions 98
 
Defining NPSHr, NPSH3, and NPSH Margin 101
 
Natural Gas Processing: NGL Processing 101
 
Centrifugal Pump Design Audits 104
 
Design St

About the author

Robert X. Perez is a mechanical engineer with more than 40 years of rotating equipment experience in the petrochemical industry. He has worked in petroleum refineries, chemical facilities, and gas processing plants. He earned a BSME degree from Texas A&M University at College Station, an MSME degree from the University of Texas at Austin and holds a Texas PE license. Mr. Perez has written numerous technical articles for magazines and conferences proceedings and has authored five books and coauthored four books covering machinery reliability, including several books also available from Wiley-Scrivener.

Summary

Maintenance, Reliability and Troubleshooting in ROTATING MACHINERY

This broad collection of current rotating machinery topics, written by industry experts, is a must-have for rotating equipment engineers, maintenance personnel, students, and anyone else wanting to stay abreast with current rotating machinery concepts and technology.

Rotating machinery represents a broad category of equipment, which includes pumps, compressors, fans, gas turbines, electric motors, internal combustion engines, and other equipment, that are critical to the efficient operation of process facilities around the world. These machines must be designed to move gases and liquids safely, reliably, and in an environmentally friendly manner. To fully understand rotating machinery, owners must be familiar with their associated technologies, such as machine design, lubrication, fluid dynamics, thermodynamics, rotordynamics, vibration analysis, condition monitoring, maintenance practices, reliability theory, and other topics.

The goal of the "Advances in Rotating Machinery" book series is to provide industry practitioners a time-savings means of learning about the most up-to-date rotating machinery ideas and best practices. This three-book series will cover industry-relevant topics, such as design assessments, modeling, reliability improvements, maintenance methods and best practices, reliability audits, data collection, data analysis, condition monitoring, and more.

Volume one began the series by focusing on design and analysis. Volume two continues the series by covering important machinery reliability concepts and offering practical reliability improvement ideas. Best-in-class production facilities require exceptional machinery reliability performance. In this volume, exceptional machinery reliability is defined as the ability of critical rotating machines to consistently perform as designed, without degradation or failure, until their next scheduled overhaul. Readers will find this volume chock-full of practical ideas they can use to improve the reliability and efficiency of their machinery.

Maintenance, Reliability and Troubleshooting in Rotating Machinery covers, among many other topics:
* General machinery reliablity advice
* Understanding failure data
* Design audits and improvement ideas
* Maintenace best practices
* Analyzing failures

Product details

• Authors: Perez, Robert X Perez, Robert X. Perez, Rx Perez
• Assisted by: Robert X. Perez (Editor), Perez Robert X. (Editor), Robert X Perez (Editor)
• Publisher: Wiley, John and Sons Ltd
• Languages: English
• Product format: Hardback
• Released: 31.01.2022
• EAN: 9781119631644
• ISBN: 978-1-119-63164-4
• No. of pages: 384
• Subjects: Natural sciences, medicine, IT, technology > Technology > General, dictionaries; Maschinenbau, Technologiemanagement, Prozesssteuerung, Industrial Engineering, Chemical Engineering, Mechanical Engineering, chemische Verfahrenstechnik, Maschinenbau - Entwurf, Mechanical Engineering - Design, Industrielle Verfahrenstechnik, Process Engineering, Engineering Technology Management