introduction to rotating equipment maintenance
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Basic Rotating Equipment Training
Introduction
BASICS OF ROTATINGINDUSTRIAL EQUIPMENTAn Introduction toRotating EquipmentMaintenance
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ObjectivesBasics of Rotating Industrial Equipment
Define safety needs and lockout procedures.Identify rotating equipment.List the major components of rotating equipmentand explain their function.Identify the auxiliary equipment required tomaintain rotating equipment operation.Define inspection and preventative maintenancetechniques.
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Equipment
Compressors- Rotating, screw and centrifugal types
Turbines Gas turbinesPumps
Basic types and Centrifugal
Fans, Blowers, and Louvers
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Basics of Rotating Industrial Equipment
Auxiliary and Support Systems
LubricationBearingSealsAlignmentVibration AnalysisThermal Analysis
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
TOPICS Click to view
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General Safety TopicsCompressorsPumpsTurbinesFans and LouversLubrication RequirementsBearingsSealsAlignmentVibration AnalysisThermal AnalysisPreventative MaintenanceFault Recognition
GENERAL SAFETY TOPICS
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Tenets of Maintenance SafetyBasics of Rotating Industrial Equipment
1.
2.3.
4.5.6.7.
Always operate equipment within design orenvironment limits.Always work in a safe and controlled condition.Always ensure safety devices are in place andfunctioning.Always follow safe work practices and procedures.Always meet or exceed customers requirements.Always maintain integrity of dedicated systems.Always comply with all applicable rules andregulations.
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Basics of Rotating Industrial Equipment
Tenets of Maintenance Safety5.
6.
7.
Always meet or exceed customersrequirements.Always maintain integrity of dedicatedsystems.Always comply with all applicable rules andregulations.
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Basics of Rotating Industrial Equipment
Safety Meetings
The primary purpose of safety meetings is toprevent accidents from happening.Safety Meetings should discuss recent incidents,accident causes, lessons learned, and hazardawareness.
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Basics of Rotating Industrial Equipment
Accident Causes
Whenever an accident occurs, someone alwaysasks, How did it happen?Accidents do not just happenthey are causedIf we are going to eliminate accidents we musthave some idea of what causes of accidents canbe.
Unsafe ConditionsUnsafe Acts
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Basic Rotating Equipment Training
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Basics of Rotating Industrial Equipment
Unsafe Conditions
Unsafe conditions are those things that can beseen by inspecting and looking for hazards in thework environment.Unsafe conditions are usually created by poorhousekeeping, improper storage, defective orbroken equipment, or removing guards frommachinery.This is the principle reason that safetyinspections should be done on a scheduledbasis.
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Basics of Rotating Industrial Equipment
Unsafe Acts
What are unsafe acts or unsafe practices?
Reaching into a running machineOperating a machine without guardsUsing defective tools or equipmentIndulging in horseplay on the job
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Hazard Awareness
The main indicator of an existing hazard is by theposting of signs.Other indicators are listed below:
Safety MeetingsToolbox MeetingsProcedure Warnings and CautionsSystem and Work Site Familiarity
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Basics of Rotating Industrial Equipment
Rotating Equipment Safety
All persons working near or around rotatingequipment should be familiar with the locationand operation of all stopping devices.Be alert when in equipment areas, leaningagainst equipment, and where you put yourhands.Rotating equipment movements are oftensudden and unpredictable.
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Rotating Equipment SafetyBasics of Rotating Industrial Equipment
Maintain good housekeeping practices.
Clear work areas and pathways of debris andobstructions.Properly clean up spilled lubricant and otherslippery materials.
If equipment is down for service, lock outper plant requirements.
Always assume equipment can start at anytime.
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Basics of Rotating Industrial Equipment
Rotating Equipment Safety
Beware of and avoid getting too close tomachinery where guards have been removedand report such conditions.When climbing around or following conveyorpaths, be aware of hazards such as sharpedges, protruding objects, and low clearances.
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Rotating Equipment Safety
Do not operate equipment unless authorized todo so.Stop-start stations should be clearly marked andlocated for easy accessibility, do not hesitate touse them when necessary.Horseplay, scuffling, or other such actionsaround equipment is hazardous.
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Basics of Rotating Industrial Equipment
Rotating Equipment Safety
Promptly report to the proper supervisor alldamage or any irregularities in equipmentoperation.In case of injury, take immediate action to obtainaid by competent personnel.
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Rotating Equipment Safety
If potentially dangerous conditions exist, report itto the proper supervisor immediately.Do not work around equipment while under theinfluence of alcohol, drugs, or narcotics.Avoid entanglement in rotating equipment by:
Removing loose items such as clothing and jewelryTying back long hair
Leave repair functions to the properly trainedmaintenance personnel to perform.
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Basics of Rotating Industrial Equipment
Rotating Equipment Safety
All personnel performing maintenance or repairson the equipment shall be qualified and trained inthe fundamentals governing proper and safemaintenance and repairs and shall follow thestandards for proper lockout energy controlprocedures.
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Rotating Equipment Safety
Bypassing or jumping safety circuits will cause ahazardous condition and must never be done.Do not perform maintenance on a system while itis running unless the nature of the maintenanceabsolutely requires so.Use all recommended safety practices whenusing mechanical aids, hoists, cables, safetyharnesses, and other equipment.
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Basics of Rotating Industrial Equipment
Rotating Equipment Safety
It may be necessary to bleed lines to anypneumatically or hydraulically poweredcomponent of the system to prevent inadvertentoperation to prevent injury inherent in storedenergy. Lockout any associated electricalinterlocked equipment.When power needs to remain on for testingelectrical components or mechanical functions alloperators or personnel involved with theequipment should be made aware of the testingand work being done.
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Rotating Equipment Safety
Be aware of abnormal noises as they oftenprecede mechanical problems and safetyhazards. Investigate as soon as possible toprotect people and machinery.If abnormal noise is due to vibration, check forbuild-up of foreign material, misalignment, orfailed internal rotating components.
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Basics of Rotating Industrial Equipment
Rotating Equipment Safety
Before restarting a piece of equipment that hasbeen shut down for any reason, insure that allpersonnel are clear and that everyone at riskwithin the area is aware that the machine isabout to be started. The equipment should bechecked to see that all obstructions have beenremoved which usually requires a walk of theequipment.Do not restart the equipment unless all safetydevices are working and all guards and fencesare in place.
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Rotating Equipment Safety
Before restarting a piece of equipment that hasbeen shut down for any reason, ensure that allpersonnel are clear and that everyone at riskwithin the area is aware that the machine isabout to be started.
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Basics of Rotating Industrial Equipment
Signs
The following slides are examples of types ofsigns that could be used to warn of hazardousareas, materials or conditions. Always refer toyour plant safety literature for specific applicationof signs.
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Prohibition Signs
No Smoking and No Open Flame signs are for posting atentrances to Open Flame Restricted Areas
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Basics of Rotating Industrial Equipment
Open Flame Restricted Areas
Warehouses with easily ignited and flammablematerialsExplosion hazardous areasLocations with toxic materialsAreas where different activities with flammablematerials are carried out
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Mandatory Signs
Attention, When Entering Facility,Please Advise Operator
Signs are for posting at the entrances to allproduction facilities
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Warning Signs
Warning signs mean
CautionRisk of DangerHazard ahead
Warning signs are designated by whitebackground with a black outline of an equilateraltriangle, yellow inside the triangle, and blacksymbol in the triangle.
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Safety Signs
First Aid signs are forposting at locationshaving a first aid kit.
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Basics of Rotating Industrial Equipment
Fire Safety Signs
Fire Extinguisher signs arefor posting at locations wherefire extinguishers of A, B, Cand D types are available.
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Traffic Signs
Speed LimitIt is prohibited to exceed thespeed specified on the sign
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Traffic Signs
Pedestrian Crossing
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Traffic Signs
Priority signs shall be posted to establish thepassing sequence of road intersection, roadcrossing or narrow road sections.
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Fire Safety
Obey All Warning and Caution Signs
Explosive Hazard AreaNo Open Flames
Report Fires and Call for HelpReport to Muster AreaUse Appropriate Precautions
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Electrical Lock Out
To protect personnel, equipment that is to beworked on must be deenergized to prevent theaccidental release of energy or the inadvertentoperation of equipment.Lockout is the method of placing a lock on anisolating device to ensure that a piece ofequipment cannot be operated.
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LOCKOUT
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DISCONNECT SWITCHLOCKOUT IF WORKINGON CONTROL PANELOR ON ELECTRICALCONTROL CIRCUIT
INCOMINGPOWER
CONTROL PANEL START ANDSTOP SWITCHES, ADJUSTMENTS,CONTROLS, ETC
CIRCUIT BREAKER ANDMOTOR STARTERLOCKOUT BEFOREWORKING ONMOTOR OREQUIPMENTSWITCH IN OFFPOSITION WITHI.D. TAGS ANDTONG ANDLOCK SYSTEMWITH EMPLOYEE PADLOCKS
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LOCKOUT TERMS
LOCKOUTLOCKOUT DEVICEENERGY SOURCEENERGY ISOLATING DEVICESHALLSHOULD
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Basics of Rotating Industrial Equipment
Definitions
Electric Power Source is the main control panel (i.e.,motor control center, circuit breaker, etc.).Electrical equipment must be locked out at the powersource, not at the start/stop switches.Electrical disconnect is the physical removal of electricalleads at the power source (or removal of the fuses), so itis impossible for someone to start the equipment.
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Lock Definitions
Instrumentation/Electrical locks are single-use,disposable locks or locks keyed separately andindividually assigned to electricians,maintenance and instrumentation personnel andare used solely for the purpose of locking outequipment that they will be working on.
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Tagout Definitions
Tagout is the installation of Danger - Do NotOperate tags on equipment controls to warnworkers that the equipment must not be used, orthat the position of a valve or isolating deviceshould not be changed.
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Summary
Potential electrical hazards can be minimizedwhen working with electrical equipment by thefollowing.
Electrical RegulationsElectrical PPESafety CodesLock OutPrecautions
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Basics of Rotating Industrial Equipment
Personal Protective Equipment
Personal Protective Equipment must beworn as protection against hazards thatcannot be eliminated by other means, orwhere no other preventive solution is foundto be practical.
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Definitions
Personal Protective EquipmentImpervious Clothing and GlovesSafety Equipment
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Roles and Responsibilities
Comply with equipment manufacturerrecommendations.Visually inspect the PPE daily or before eachuse.Replace torn or damaged PPE.Properly clean and store equipment.Contact supervisor with questions.
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General PPE Requirements
Make sure that PPE is appropriate to the workcondition.Using PPE that is not required may get in theway.
For example, wearing electrician gloves to calibrate alevel indicator would be a hindrance.
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General PPE Requirements
The minimum PPE in plant areas include:
Hard HatSafety GlassesSafety or Sturdy ShoesMini Filter in some areas
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Head ProtectionHard hats protect the head from impact, andpenetration by falling or flying objects andelectric shock for insulated hard hats
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Basics of Rotating Industrial Equipment
Eye and Face Protection
Eye and face protection is required whenan employee is exposed to eye or facehazards.
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Face ShieldsFace shields must be worn to protect theface and neck. Face shields alone do not provideadequate eye protection.
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Basics of Rotating Industrial Equipment
Eye and Face Protection
Goggles and face shields should be washed withwarm soapy water, rinsed thoroughly, and hungto dry before they are stored.A soft tissue or soft nonabrasive cloth should beused to clean the lenses.
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Hand Protection
Gloves shall be worn when hands are exposedto hazardous substances, sharp objects, ortemperature extremes (hot or cold).Impervious gloves must be used when handlinghydrocarbons and corrosive chemicals such asacids and caustics.Miscellaneous gloves include special-use gloves.The following gloves must be individuallyassigned: Welding gloves, Fire fighters gloves,Electrician gloves
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Basics of Rotating Industrial Equipment
Glove Inspection
Impervious gloves should be checked forpinholes leaks by blowing air into them. Theyshould be replaced when they become crackedor develop holes.
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Body Protection
Appropriate body protection must be worn tokeep acidic, corrosive, oily, dirty, or dustymaterials off the body. The type of protectionrequired depends upon the nature of the hazard.Disposable coveralls and suits are designed tokeep dust and dry material off the worker. Theyprovide minimal protection against liquids andoily substances.
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Basics of Rotating Industrial Equipment
Aprons
Aprons should be worn to keep dirt and materialoff work clothing when pouring liquids, dumpingdry materials, or working with dirty equipment.
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Foot Protection
Employees shall wear safety steel toed footwearwhen they work in an area where there is dangerof foot injury due to falling or rolling objects.Areas and jobs, which require safety footwear,shall be determined by the Facility Owner.Rubber boots should be worn when it isnecessary to protect the feet and shoes fromexcessive water, oil, mud, muck, or corrosivematerial.
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Basics of Rotating Industrial Equipment
Definitions
Air Line RespiratorBreathing Air EquipmentCartridge RespiratorFace Piece-to-Face SealHazard AssessmentHazardous Atmosphere
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Definitions
IDLH AtmosphereQualitative Fit TestSelf Contained Breathing Apparatus (SCBA)Single-Use Disposable Dust RespiratorTolerance Test
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Basics of Rotating Industrial Equipment
Summary
Review
CLICK TO RETURN TO TOPICS
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Basic Rotating Equipment Training
Introduction
COMPRESSORS
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Basics of Rotating Industrial Equipment
Main Topics
Introduction to compressorsCentrifugalReciprocatingScrew
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Basic Rotating Equipment Training
Introduction
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Introduction
Compression is used in all aspects of gasprocessing such as:
Gas LiftGas GatheringHelium RecoveryCondensate RecoveryTransmissionDistribution
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Basics of Rotating Industrial Equipment
Types
Reciprocating
Centrifugal
Sliding Vane
Rotary Screw
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Reciprocating CompressorSuctionValve
Piston
Piston Rod
CylinderHeadCylinder
DischargeValve
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Cylinder Operating ValvesBasics of Rotating Industrial Equipment
SUCTION
SUCTION VALVE
DISCHARGE VALVE
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DISCHARGE
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StagesThe number of stages is governed by the followingfactors:
Allowable discharge temperature.Rod loading.Existence of a fixed side stream pressure level (whereflow is added to or withdrawn from main flow ofcompressor).Allowable working pressure of available cylinders.
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Basics of Rotating Industrial Equipment
Sliding Vane CompressorSliding VaneRotor
Inlet PortDischargePort
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Screw Compressors
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Basics of Rotating Industrial Equipment
Centrifugal CompressorFundamentals
Gas flow pathStageProcess stageVelocity Energy to Pressure
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Basic Rotating Equipment Training
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Centrifugal CompressorBasics of Rotating Industrial Equipment
Gas Suction
Discharge
Torque
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Basics of Rotating Industrial Equipment
Centrifugal Compressor Types
Axial, or horizontallysplit
JOINT
JOINT
JOINT
Radial, orvertically split
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Centrifugal Compressor StageComponents
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Basics of Rotating Industrial Equipment
Surge
Surge is caused by unstable flow withincompressor which results in flow reversal systempressure fluctuations.Frequency of surge
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Causes/Effects of Surge
Restricted suction or discharge such as aplugged strainer.Process changes in pressures or gascomposition.Mis-positioned rotor or internal plugging of flowpassages.Inadvertent speed change such as from agovernor failure.
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Basics of Rotating Industrial Equipment
Dry Gas SealsFace Rotation
RotatingFace
StationaryFace
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Basic Rotating Equipment Training
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Basics of Rotating Industrial Equipment
Summary
Review Question and Answer Session
CLICK TO RETURN TO TOPICS
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PUMPS
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Basic Rotating Equipment Training
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Course Objectives
At the completion of this course students will beable to:
Identify types of pumpsIdentify major components for each type of pumpDefine Characteristics of each type of pumpDescribe applications in which each type of pump isused
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Basics of Rotating Industrial Equipment
Major Topics
Pumps GeneralPositive Displacement PumpsCentrifugal Pumps
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Basic Rotating Equipment Training
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PumpsBasics of Rotating Industrial Equipment
Types
Positive Displacement - Overview
Screw PumpsGear PumpsPiston PumpsPlunger Pumps
Centrifugal - Overview
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Basics of Rotating Industrial Equipment
Positive Displacement Pumps
Screw PumpsGear pumpsPiston pumpsRotating gearsCentrifugal pumps
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Basic Rotating Equipment Training
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Screw Pumps
Screw pumps are the most common type ofrotary pump found in the petroleum industry.The three sub-types of screw pumps:
three-screwtwo- screwsingle-screw
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Basics of Rotating Industrial Equipment
Screw PumpsINLET
INLETOUTLETOUTLET
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Gear PumpsGenerally less expensive than screw pumps,and used when an inexpensive short-lifepump can be tolerated. Also used inintermittent services.Types:
External GearInternal GearLobe
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Basics of Rotating Industrial Equipment
External Gear Pump
Counter-rotating gears
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External Gear Pumps
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Basics of Rotating Industrial Equipment
Internal Gear Pump
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Piston Pumps
Piston Pump DiagramMajor Component ReviewOperation and ApplicationMaintenance and Troubleshooting
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Basics of Rotating Industrial Equipment
Piston Pump
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Basic Rotating Equipment Training
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Major ComponentsInletCheck BallCam Plate
OutletCheck BallOutlet
Inlet
SUCTION
COMPRESSION
DISCHARGE
Drive Shaft
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PumpingChamber
SpringPiston
Basics of Rotating Industrial Equipment
Operation and Application
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Plunger Pumps
Plunger Pump DiagramMajor Component ReviewOperation and Application
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Basics of Rotating Industrial Equipment
Packed Plunger Pump
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Diaphragm Plunger Pump
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Basics of Rotating Industrial Equipment
Example Plunger Pump DiagramOUTLET CHECKVALVE
LUBE INLET
LUBE OUTLET
PRIMER/REGULATINGASSEMBLY
FRONT OFRESERVOIRINLET CHECKVALVEROCKERARMASSEMBLY
CAM
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Centrifugal Pumps
Centrifugal Pump DiagramMajor Component ReviewOperation and ApplicationPump LawsCentrifugal PumpsMaintenance and Troubleshooting
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Basics of Rotating Industrial Equipment
FundamentalsImpeller VanesTongue
Eye
Volute
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Centrifugal Pump Diagram
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Basics of Rotating Industrial Equipment
Sleeve/Coupling/Bearings
Shaft SleeveCoupling
Elastomeric couplings (having properties thatresemble rubber)Non-elastomeric
Bearings
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Impeller Types
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Basics of Rotating Industrial Equipment
Suction and Discharge
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Swing Type Check Valve
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Basics of Rotating Industrial Equipment
Valves
Single disc swing valvesDouble disc or wafer check valvesLift-check valvesSilent or center guide valvesBall-check valvesCone check valves
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Centrifugal Pump Application
High Flow-rate requirementsLow Differential Pressure (Lift) requirementsLow Fluid Viscosity
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Basics of Rotating Industrial Equipment
Centrifugal Pump Operation
Conversion of rotational driver energy into flowenergyWork on the fluid is performed by impeller andVolute (higher flow, lower pressure) or Diffuser(lower flow, higher pressure)
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Centrifugal Flow
Centrifugal pumps generate flow by using one ofthree actions:
Radial flowMixed flowAxial flow
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Basics of Rotating Industrial Equipment
Centrifugal Pump Operation
Flow PathPrecautions
Prevent CavitationAvoid Low Flow Conditions
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Centrifugal Pump Operation
Cavitation
Formation of and subsequent collapse of bubbleswithin a pumped fluid.Formation occurs in regions of low pressure andcollapse occurs in regions of high pressure.
Cavitation can result in:
Loss of capacityLowered Discharge PressureLower EfficiencyNoise, Vibration, and Damage to Pump components.
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Cavitation
Cavitation is Caused by:
VaporizationAir ingestionInternal recirculationFlow turbulenceVane Passing Syndrome
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Vaporization
A fluid vaporizes when its pressure gets too low,or its temperature too high. All centrifugal pumpshave a required head (pressure) at the suctionside of the pump to prevent this vaporization.
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Air Ingestion
Air gets into a system in several ways thatinclude :
Through the stuffing boxLeaking flangesSuction inlet pipe is out of fluid
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Turbulence
We would prefer to have liquid flowing throughthe piping at a constant velocity.Corrosion or obstructions can change thevelocity of the liquid and any time you changethe velocity of a liquid you change its pressure.
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Vane Passing Syndrome
You will notice damage to the tip of the impellercaused by its passing too close to the pumpcutwater.
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Pump Laws
Velocity is directly proportional to Pump Speed
Discharge Head is directly proportional to thesquare of Pump Speed
V flow N
H pump N2
Pump Power consumption is directly proportionalto the cube of Pump Speed
P pump N3
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Pump Laws
Example:
N = 1450 RPMV = 400 m3 / hrH = 100 BargP = 45 kW
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Summary
Review Question and Answer Session
CLICK TO RETURN TO TOPICS
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TURBINES
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Objectives
Define Brayton Cycle.Turbine Theory of OperationDefine major components used in a Gas Turbinesystem.Identify Gas Turbine auxiliary systems.Define Gas Turbine Maintenance requirements.
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Gas Turbine
Function / PurposeProcess Flow
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Gas TurbineBasic Configuration
Air CompressorCombustorTurbine
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Basics of Rotating Industrial Equipment
Gas Turbine
A gas turbine extracts energy from a flowof hot gas produced by combustion of gasor fuel oil in a stream of compressed air. Ithas an upstream air compressor (radial oraxial flow) mechanically coupled to adownstream turbine and a combustionchamber in between. "Gas turbine" mayalso refer to just the turbine element
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Brayton CycleBasics of Rotating Industrial Equipment
Gas turbines are described thermodynamically by theBrayton cycle, in which air is compressed isentropically,combustion occurs at constant pressure, and expansionover the turbine occurs isentropically back to thestarting pressure.
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Steps of the Brayton Cycle
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Performance parameters
Speed of rotationOil TemperatureOil PressureFuel gas pressureRotor axial displacementBearing vibrationsExhaust temperature
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Basics of Rotating Industrial Equipment
Main Components
Turbine CasingCompressor SectionCombustion ChamberBearingsTurbine RotorsAuxiliary Systems
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Turbine Casing
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Basics of Rotating Industrial Equipment
Compressor Section
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Combustion Chamber
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Basics of Rotating Industrial Equipment
Split Shaft DesignExhaustGas
Fuel
CombustionchamberAxialCompressor
H.P.ShaftAssy
L.P.ShaftAssy
Load
Air inlet
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Combustor
Can-annular Type Combustor Example
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Basics of Rotating Industrial Equipment
Bearings
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Turbine Rotors
Rotors/BucketsSplit shaft designVariable Nozzle
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Rotors/Buckets
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Variable Nozzle
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Basics of Rotating Industrial Equipment
Shutdown Sequence
Normal ShutdownEmergency Stop
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Normal Shutdown
Manually initiated, Automatically sequencedTurbine is run at idle to reduce thermal stressesTurbine may operate on starting system to furtherreduce stressesUnit will be jacked at 1 to 2 rpm for several cooldown hours
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Emergency Stop
Can be manually or automatically initiatedAutomatically sequencedDoes NOT include a cool-down delayWhen trip is caused by a fire sensor all lubeoil flow stops
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Filters
Lube oil filterFuel oil filtersHydraulic supply filtersAir filters
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Basics of Rotating Industrial Equipment
Shutdown Maintenance
Major InspectionBorescope InspectionsCombustion InspectionHot Gas Path Inspection
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Major Inspection
Turbine DisassemblyInitial Alignment ChecksComponent InspectionsWear component replacementReassemblyFinal Alignment Checks
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Basics of Rotating Industrial Equipment
Borescope Inspections
Overview and Purpose
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Summary
Review Question and Answer Session
CLICK TO RETURN TO TOPICS
143
FANS AND LOUVERS
144
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Introduction
Basics of Rotating Industrial Equipment
Course Objectives
Define the steps necessary to maintain andreplace fan bearingsDiscuss characteristics of BeltsState the steps necessary to remove, replaceand adjust drive belts
145
Basics of Rotating Industrial Equipment
Course Objectives
Discuss methods of determining cause basedupon effect
146
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Fan Safety
Rotating EquipmentElevationHigh TemperatureH2S
147
Basics of Rotating Industrial Equipment
Rotor and Hub Assembly ExampleTRAILINGEDGE
LEADINGEDGE
148
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Rotors
149
Basics of Rotating Industrial Equipment
Fan Checks
Adjust the pitch of eachblade to the vendorsspecified angleVerify blades rotatefreelyVerify proper motorrotation
150
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Basic Rotating Equipment Training
Introduction
Fin Fan Tip ClearanceBasics of Rotating Industrial Equipment
Blade Tip Clearance
Adjust each bladeassembly to the vendorsspecified tip clearance
151
Basics of Rotating Industrial Equipment
Driver
Variable Speed Drive (VSD) Electric MotorTotally Enclosed Fan Cooled (TEFC)Explosion Proof
152
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Basics of Rotating Industrial Equipment
Basics of Rotating Industrial Equipment
Basic Rotating Equipment Training
RWD
Introduction
Belts
153
HTD Belts
154
Page 77
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
HTD Belts
155
Basics of Rotating Industrial Equipment
Synchronous Belt
156
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
V-belts
157
Basics of Rotating Industrial Equipment
Powerband V-belts
158
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Cog BeltsCog Belt(Side View)
159
Basics of Rotating Industrial Equipment
Belt Alignment
Example mis-alignment of belts
160
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Belt Alignment
Four Point Touch AlignmentCord tied toshaft
Cord touching sheave at pointsindicated by arrows
161
Basics of Rotating Industrial Equipment
Belt Tensioning
Too tight
Slight bowToo loose
162
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Changing Belts
Never lever or pry belts onto sheaves orsprockets
163
Basics of Rotating Industrial Equipment
Bearing
164
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Basics of Rotating Industrial Equipment
Basics of Rotating Industrial Equipment
Basic Rotating Equipment Training
RWD
Introduction
Louvres
165
Louvres
166
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Cylinder Actuator6 7
Supply
Exh.Out 1
5 4 Signal 2
3 10 11 12 9
Exh.Out 2
8
167
Basics of Rotating Industrial Equipment
Vibration Switch
168
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Lubrication System
169
Basics of Rotating Industrial Equipment
Lubrication System
170
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Maintenance Requirements
General InspectionsBlade Angle AdjustmentBlade Tip Clearance AdjustmentBearing Lubrication
171
Basics of Rotating Industrial Equipment
Maintenance Requirements
Vibration MonitoringFan Belt TensioningFan Belt Alignment
172
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
General Inspections
24000 Hours - General Inspection and Cleaning90 Days Vibration Monitoring90 Days Belt Maintenance
173
Basics of Rotating Industrial Equipment
Blade Angle Adjustment
Position the inclinometer on the least curvedpart of the bladeRotate the blade on its own axis until thedesired pitch angle value is obtainedRepeat operations 1 and 2 for each blade
174
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Introduction
Basics of Rotating Industrial Equipment
Blade Angle Adjustment
175
Basics of Rotating Industrial Equipment
Blade Angle Adjustment
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Blade Tip Clearance Adjustment
Unscrew all the positioning boltsPull each blade out so that the head seatsfirmly against the internal rim of the hubassembly
177
Basics of Rotating Industrial Equipment
Vibration Monitoring
178
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Introduction
Basics of Rotating Industrial Equipment
Vibration Switch Adjustment
Caution: Isolate power elsewhere beforeremoval of coversTo set switch, rotate set level screw on top ofswitch fully clockwiseReset switch and check observation window isclear.
179
Basics of Rotating Industrial Equipment
Vibration Switch Adjustment
With machine running normally, rotate set levelscrew anti-clockwise until switch just tripsReset carefully; readjust until switch no longertripsAdjust clockwise rotation of the set level screw
180
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Introduction
Basics of Rotating Industrial Equipment
Vibration Switch Adjustment
Fill Set Level Screw cavity with Silicone greaseandReplace cap
181
Basics of Rotating Industrial Equipment
Fan Belt Tensioning
Review Belt drive data sheetsBelt tensioning is performed by adjusting themotorMotor is adjusted until the proper tension isachievedDeflection should fall between 9 to 15mm
182
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Fan Belt Alignment
Axial alignment is performed by moving themotorMotor is moved by adjusting 2 nut bolts untilproper axial alignment is achievedMotor is adjusted until the motor drive pulley andthe fan pulley are visually parallel
183
Basics of Rotating Industrial Equipment
Troubleshooting
Excessive VibrationImproper Louvre Operation
184
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Fan Vibration
Imbalanced BladeExcessive Blade Pitch VarianceMisalignmentWorn ComponentsResonanceStructural Integrity
185
Basics of Rotating Industrial Equipment
Improper Louvre Operation
Cylinder does not move with rising or falling inputsignal
Cause: Zero adjusting screw is not set properlySolution: Loosen lock-nut and reset the zeroadjustment
186
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Introduction
Basics of Rotating Industrial Equipment
Louvre and Linkage Adjustment
Cylinder stroke is not in relation to inputsignal
Cause: Adjustment of Span Adjuster is notcorrectSolution: Remove the set screw of the outer tubeand give ideal adjustment while maintaininginput signal at 0.6 kg/cm.
187
Basics of Rotating Industrial Equipment
Summary
ReviewQuestion and Answer Session
CLICK TO RETURN TO TOPICS
188
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Introduction
LUBRICATION REQUIREMENTS
189
Basics of Rotating Industrial Equipment
Objectives
Define types of lubricationDistinguish the difference between grease andoilDiscuss the hazards of mixing differentlubricationsDescribe the proper handling of lubricationDescribe replacement of Lube Oil filters
190
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Main Topics
Define types of lubricants
OilGreaseISO and SAE specifications
Distinguish the difference between grease andoilDiscuss the hazards of mixing differentlubrications
191
Basics of Rotating Industrial Equipment
Main Topics
Describe the proper handling of lubricants
ContaminationStorageMethods of applicationDisposal
Describe replacement of Lube Oil filters.
Filter redundancyFlow characteristics,DP = Differential PressureReplace with disposable cartridge
192
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Basics of Rotating Industrial Equipment
Introduction to Lubrication
Why use lubricants?
Reduce FrictionIncrease Cooling
193
Basics of Rotating Industrial Equipment
Lubrication Functions
Form a lubricant film between components.Reduce the effect of frictionProtect against corrosionSeal against contaminantsCool moving parts
194
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Introduction
Basics of Rotating Industrial Equipment
Lubrication
195
Basics of Rotating Industrial Equipment
Friction
Grease and oil lubricate the moving parts of amachineGrease and oil reduce friction, heat, and wear ofmoving machine parts
196
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Introduction
Basics of Rotating Industrial Equipment
Oil = Low Friction and Heat
197
Basics of Rotating Industrial Equipment
No Oil = High Friction and Heat
198
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Introduction
Basics of Rotating Industrial Equipment
Lubrication Prevents Failure of:
BearingsGearsCouplingsPumps
199
Basics of Rotating Industrial Equipment
Lubrication Prevents Failure of:
Engine componentsHydraulic pumpsGas and Steam TurbinesAny moving parts
200
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Introduction
Basics of Rotating Industrial Equipment
Lubricants prevent failure by:
Inhibiting rust and corrosionAbsorbing contaminatesDisplacing moistureFlushing away particles
201
Basics of Rotating Industrial Equipment
Can lubricants cause damage?
YES!!THE WRONG LUBRICANT CAN CAUSEMACHINE FAILURE!
202
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Lubricant SelectionOperating temperatureLoadSpeedEnvironmentGrease LubricationOil Lubrication
203
Basics of Rotating Industrial Equipment
Grease
Grease is a heavy, non-liquid lubricantGrease can have a mineral, lithium or soapbaseGrease is pasty, thick and stickySome greases remain a paste from below 0Cto above 200C.The flashpoint of most greases is above 200CGrease does not become a mist underpressure
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Introduction
Basics of Rotating Industrial Equipment
Oil
Oil can be a heavy or thin liquid lubricantOil can have a natural base (mineral)Oil can have a synthetic base (engineered)Oil remains liquid from below 0C to above200C.The flashpoint of many oils is above 200CThe flashpoint is very low for pressurized oilmist. Why?
205
Basics of Rotating Industrial Equipment
How are grease and oil different?
How oil is used:
Oil used in closed systems with pumps. An oilsump on a diesel engine pumps liquid oil.Oil is used in gas and steam turbinesOil is used in most machines that need liquidlubricant
206
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Introduction
How grease is used?Basics of Rotating Industrial Equipment
In areas where a continuous supply of oil cannot beretained, (open bearings, gears chains, hingedjoints)Factors to be considered when selecting greasesare: Type. Depends on operating temperatures,water resistance, oxidation stability etc Characteristics. Viscosity and consistency
207
Basics of Rotating Industrial Equipment
Grease or Oil?
What determines whether a machine needsgrease or oil?The manufacturer specifies what lubricant isused in their machines, based on the propertiesof the lubricant. One important property isVISCOSITY.
208
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Introduction
Basics of Rotating Industrial Equipment
Viscosity
Viscosity is a liquids resistance to flowViscosity affects the thickness of a liquidHigh viscosity liquids are hard to pourLow viscosity liquids are easy to pour
209
Basics of Rotating Industrial Equipment
Viscosity Rules of Thumb
the lower the temperature, the lighter the oilthe higher the temperature, the heavier the oilthe heavier the load, the heavier the oilthe lighter the load, the lighter the oilthe faster the speed, the lighter the oilthe slower the speed, the heavier the oil
210
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Introduction
ViscosityBasics of Rotating Industrial Equipment
Temperature affects viscosity. Heat decreases viscosity Cold increases viscosity Viscosity is measured in centistokes (cSt)
211
Basics of Rotating Industrial Equipment
Consistency
Fundamental principleThickenerOperating temperatureMechanical conditionsLow temperature effectHigh temperature effect
212
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Grease Lubrication
Thickening agentPropertiesWhere used
213
Basics of Rotating Industrial Equipment
Advantages of Grease Lubrication
Reduction of dripping and splatteringHard to get pointsReduction of frequency of lubricationHelps seal out contaminants and corrosives.Ability to cling to partUsed to suspend other solids
214
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Introduction
Basics of Rotating Industrial Equipment
Grease Selection Factors
Load conditionSpeed rangeOperating conditionsTemperature conditionsSealing efficiencyExternal environment
215
Basics of Rotating Industrial Equipment
Oil Types
Two types of lubrication oil are:Mineral-basedSynthetic
216
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Mineral-Based Oil
Mineral-based oil is refined from crude oilhydrocarbonsMineral-based oil has 2 types of base:
Naphtha Base
A naphtha base is solvent-like
Paraffin Base
A paraffin base is waxy
217
Basics of Rotating Industrial Equipment
Mineral-Based Oil
Naphtha Base
Lower viscosity index (40-80 cs)Lower pour pointLess resistant to oxidation and changes inviscosity indexGood performance at higher temperatures
218
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Basics of Rotating Industrial Equipment
Mineral-Based Oil
Paraffinic Base
Higher viscosity index (>95cs)Higher pour pointVery resistant to changes in viscosity index andoxidationThicken at low temperatures
219
Basics of Rotating Industrial Equipment
Mineral-Based Oil
Mineral-based oils are cheaper to buy thansynthetics.Mineral-based oils can contain traces ofsulfur and nitrogen. These impurities cancause oil to form sludge.
220
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Introduction
Synthetic OilBasics of Rotating Industrial Equipment
Synthetic oil is NOT refined from crude oilhydrocarbonsSynthetic oil is made without a mineral baseSynthetic oil is made by careful control of achemical reaction that yields a puresubstance
221
Basics of Rotating Industrial Equipment
Synthetic Oil
Synthetic oils are chemically engineered to bepure. They do not contain the traces of sulfuror nitrogen present in mineral-based oils.Synthetic oils are expensive
222
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Introduction
Basics of Rotating Industrial Equipment
Synthetic Oil
Synthetic oil is less flammable than mineralbased oil at low pressure. (Pressure causesmost oils to become more flammable)Synthetic oils are generally more expensivethan mineral based oils
223
Basics of Rotating Industrial Equipment
Lubricant Specifications
ISO = International Standards Organization
SAE = Society of Automotive Engineers
224
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
ISO Lubricant Specifications
ISO Grade lubricants are for industrial use.ISO specifications exist for lubricants inextreme industrial environments.
225
Basics of Rotating Industrial Equipment
ISO LubricantsISO GRADE
Viscosity40C100C
32
46
68
100
30.45.2
43.76.6
64.68.5
30.45.2
222(432)
224(435)
245(473)
262(504)
-36(-33)
-36(-33)
-33(-27)
-30(-22)
Flash Point
C(F)
Pour PointC(F)
226
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Using Different Lubricants
Why do we use different lubricants?What happens if oils are mixed?
227
Basics of Rotating Industrial Equipment
Mixing Lubricants
Consequences of mixing different lubricantsare:Change of viscosityStripping of machines internal coatings,damage to sealsReduced flash point, risk of fire
228
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Mixing Lubricants
Loss of corrosion protectionPoor water separationFoamingThermal instability
229
Basics of Rotating Industrial Equipment
Booster Compressor Lubes
230
RWD
Equipment
SpecifiedLubricant
ChevronEquivalent
Consumption Rate
ServiceInterval
Turbine and CompressorLube Oil System
ISO VG 32
GST ISO 32
5 Liters per day
Based on oilanalysis
Electric Motor (Starter)
Grease
SRI Grease NLGI2
negligible
1750 Hours
Electric Motor (Ventilation)
Grease
SRI Grease NLGI2
negligible
11500 Hours
Electric Motor (Aux LubeOil Pump)
Grease
SRI Grease NLGI2
negligible
3000 Hours
Electric Motor (Aux LubeOil Cooler)
Grease
SRI Grease NLGI2
negligible
1000 Hours
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Introduction
Basics of Rotating Industrial Equipment
Water Pump Lubes
231
Equipment
Specified Lubricant
ChevronEquivalent
ConsumptionRate l/year
ServiceInterval
Utility Water Pump
Texaco UrsatexSAE 20/20W
Chevron Delo400 SAE 20
.5L
Yearly
Utility Water PumpMotor
Esso Unirex N3
Chevron SRIGrease 2
50g
2 years
DemineralisedWater Pump Motor
Texaco UrsatexSAE 20/20W
Chevron Delo400 SAE 20
100L
Yearly
Fire Water JockeyPump
Texaco UrsatexSAE 20/20W
Chevron Delo400 SAE 20
.5L
Yearly
Fire Water JockeyPump Motor
Esso Unirex N3
Chevron SRIGrease 2
50g
2 Years
Basics of Rotating Industrial Equipment
Water Pump LubesEquipment
SpecifiedLubricant
ChevronEquivalent
ConsumptionRate g/year
ServiceInterval
BS12A Fire WaterPump
TexacoMulti-purposeAP EP2
Chevron Dura-LithEP #2
200
Yearly
Fire Water PumpMotor (SIEMENS)
Shell Alvania G3
Chevron SRIGrease 2
100
3 Years
Fire Water PumpMotor (Caterpillar)
Texaco Ursa SuperLA 15W-40
ChevronDelo 400 15W-40
100
3 Years
232
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Introduction
Basics of Rotating Industrial Equipment
Nitrogen Generation Lubes
Equipment
Specified Lubricant
Chevron Equivalent
ServiceInterval
Screw Compressor72-F 9269/89
Total Dacnis VS 32
Chevron Hydraulic OilAW ISO 32
4000 hours
73-MGC-9251 A/BBearings
Total MultiElf
Chevron SRI Grease 2
4500 hours
73-MEA-9202A/B01/02 Bearings
Filled for life of bearings
233
Basics of Rotating Industrial Equipment
Propane Compressor Lubes
Equipment
Specified Lubricant
Chevron Equivalent
ServiceInterval
GC 740 compressor anddrive bearings, oil pumps
ISO VG 46
Chevron GST ISO46
Monitor andservice if outof spec
MG 741 A/B oil pump driveand electric motor
ShellAlvania R3
Chevron SRIGrease 2
40000 hoursor 4.5 years
MEA-709 A1/2/3 oil coolerdrive
ShellAlvania R3
Chevron SRIGrease 2
20000 hoursor 2.25 years
234
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Introduction
Basics of Rotating Industrial Equipment
Propane Compressor Lubes
Equipment
Specified Lubricant
Chevron Equivalent
ServiceInterval
GC 701 gas compressorand drive bearings, oilpumps
ISO VG 46
Chevron GST ISO46
Monitor andservice if outof spec
MG 711 A/B oil pumpdrive and electric motor
ShellAlvania R3
Chevron SRIGrease 2
40000 hoursor 4.5 years
MEA-708 A1/2/3 oil coolerdrive
ShellAlvania R3
Chevron SRIGrease 2
20000 hoursor 2.25 years
235
Basics of Rotating Industrial Equipment
Fundamentals of Lubrication
Equipment lubrication
BearingsGearsCouplingsPumpsEngine componentsHydraulic pumps
236
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Lubricant Delivery Methods
Force Feed LubricantOil MistConstant CirculationOil SlingerZerk FittingsSurface Application (brush or spray)
237
Basics of Rotating Industrial Equipment
Force Feed Lubrication
A force feed lubricant system is like anautomated version of the hand held oil can.An automatic plunger applies pressure todeliver a few drops at predetermined timeintervals.
238
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Introduction
Basics of Rotating Industrial Equipment
Oil Mist Lubrication
This method keeps rotating machinery operatingeffectively for extended time periods.
239
Basics of Rotating Industrial Equipment
Oil Mist Lubrication
Centralized lubrication system thatgenerates, conveys and automaticallydelivers lubricant.The generator utilizes the energy ofcompressed air to atomize oil into micronsized particlesThe particles can be conveyed considerabledistances.
240
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Benefits - Oil Mist Lubrication
Bearing failures reducedLubricant consumption reduce by 40%Equipment runs cooler Saves energyContaminants are excludedMore efficient lubrication
241
Basics of Rotating Industrial Equipment
Constant Circulation
A Constant Circulation system re-circulates oil ina closed system like your heart circulates bloodin your body.
242
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Lubrication Check ExampleHandgreasesquare slideshaft andworm shaft(Monthly)1 to 2pumps pershaft of(MobilXHP222)
Basics of Rotating Industrial Equipment
Greasesupportwheelbearings(Quarterly)1 to 2pumps with(MobilXHP222)
Grease Variable Pitch Pulley(Quarterly) 1 to 2 Pumps of(Mobil XHP222)
243
Hand Oil Roller Chain,[behind guard] (Quarterly)(LPS) (24810)
CheckWindupGear Boxes(Quarterly)Oil typeISO360(Mobil Gear636)
Basics of Rotating Industrial Equipment
Oil Slinger
Small disc that loosely rotateson a shaftLubricates moving parts byagitating or splashing oil in thecrankcase.Allows a thin film of oil toremain on the piston rod.The Oil Slinger is installed onthe piston rod between thepacking case and the wipercase
244
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Basics of Rotating Industrial Equipment
Zerk Fittings
Zerk Fittings are grease fill points that havean internal check valve that preventscontaminates from entering the fitting.Always clean the Zerk fitting before applyinggrease.
245
Basics of Rotating Industrial Equipment
Surface Application
Sometimes lubricants are painted on with abrush, sprayed from an aerosol can, or wipedonto the part.
246
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Pump System
A Pump System automates lubrication.Grease or oil is fed from a central pumpthrough lines and block valves to thenecessary lube points.
247
Basics of Rotating Industrial Equipment
Lubricant Storage Factors
TemperatureLightWaterParticulate ContaminationAtmospheric ContaminationOil Separation
248
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Basics of Rotating Industrial Equipment
Storage - Temperature
High heat (greater than 45C) and extreme cold (lessthan 20C) affect lubricant stability.Heat increases oxidation that forms depositsCold can increase sediment and wax formationIdeal storage temperature range is 0C to 25C
249
Basics of Rotating Industrial Equipment
Storage - Light and Water
Light can change the color and appearance oflubricants. Store lubricants in their originalcontainer. Keep out of light.Water reacts with additives in the lubricant andforms insoluble matter. Water can causemicrobial growth. Keep water out.
250
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Basic Rotating Equipment Training
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Storage - ContaminationBasics of Rotating Industrial Equipment
Particles in the air and dust can settle into opencontainers. Oxygen and carbon dioxide can change theconsistency and viscosity of lubricants.Always seal lubricant containers tightly.Always store and use a clean container.
251
Basics of Rotating Industrial Equipment
Storage - Oil Separation
Oil will naturally separate out of most greasesover time.Temperature greater than 45C increase oilseparation in grease.
252
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Basic Rotating Equipment Training
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Basics of Rotating Industrial Equipment
Storage Shelf LifeLubricants have a finiteshelf life.The estimated shelf lifefor UNOPENEDcontainers in idealconditions is:
Product
Shelf Life InYears
Base Oils
5+
Lube Oils(Mineral or Synthetic)
5
Greases(Mineral or Synthetic)
5
Rust Preventatives
2
Open Gear Lubes
2
253
Basics of Rotating Industrial Equipment
Summary
ReviewQuestion and Answer Session
CLICK TO RETURN TO TOPICS
254
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Basic Rotating Equipment Training
Introduction
BEARINGS
255
Basics of Rotating Industrial Equipment
IntroductionPurpose
of a bearingFriction bearingAntifriction bearing
256
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Basic Rotating Equipment Training
Introduction
BearingsBasics of Rotating Industrial Equipment
SEPARATOR/CAGEBALLROLLER
Ball Bearing
Roller Bearing
Sleeve Bearing
257
Basics of Rotating Industrial Equipment
Sleeves and JournalsFriction
bearingsJournal and SleeveLubricationRotational SpeedHighest friction point.
258
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Balls and RollersRolling
contact bearingsStarting frictionCages/SeperatorsLubrication
259
Basics of Rotating Industrial Equipment
Anti-Friction Bearing Types
Tapered RollersSpherical RollersNeedle Rollers
Ball Rollers
Cylindrical Rollers
260
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Thrust Bearings
261
Ball Thrust Bearing
Spherical Roller
Roller Thrust Bearing
Tapered Roller
Basics of Rotating Industrial Equipment
Bearing LoadsThrust LoadRadial Load
262
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Example of LoadsThrust Load
TaperedRollerBearingsRadial Load
263
Basics of Rotating Industrial Equipment
Bearing Contact
Ball
Roller
264
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Tapered Roller Bearings
265
Basics of Rotating Industrial Equipment
How Do Bearings Fail Passage of electric current through the bearing. Misalignment. Improper mounting. Incorrect shaft and housing fits. Defective bearing seating on shafts and inhousings. Ineffective sealing. Vibration while bearing is not rotating. Inadequate lubrication.
266
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Introduction
Basics of Rotating Industrial Equipment
Types of Failure
Spalling.Fretting.
Spalling on inner ring
267
Basics of Rotating Industrial Equipment
Types of Failure
Brinelling
268
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Types of Failure
VibrationElectric Currents.
Pitting from largeelectrical current.False Brinelling
269
Basics of Rotating Industrial Equipment
Types of Failure - Misalignment
270
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Basic Rotating Equipment Training
Introduction
Bearing LubricationBasics of Rotating Industrial Equipment
All bearings need lubrication to preventmetal-to-metal contact between components.Lubrication PracticesToo Much LubricationInadequate LubricationSmearing
271
Basics of Rotating Industrial Equipment
Summary
ReviewQuestion and Answer Session
CLICK TO RETURN TO TOPICS
272
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Introduction
SEALS
273
Basics of Rotating Industrial Equipment
Major Topics
SealsSeal TypesDry Gas SealsLabyrinth SealsFirewater Pump Packing SealsSupport Systems Seal FlushingTroubleshooting
274
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Purpose
Shaft Seal Purpose is to prevent leakageinto or out of a pump or compressor alongits shaft and other moving parts.
Shaft seals includes two common types.
Pack stuffing boxes
Simple mechanical seals
275
Basics of Rotating Industrial Equipment
Packed Stuffing Box
276
RWD
A soft pliable material or packing is placed in abox and compressed into rings encircling thedrive shaft is used to prevent leakage.
Packingchamber or box
Packingrings
Gland followeror stuffinggland
Page 138
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Gland Packing
Used in Firewater pumpsFluid not toxic or flammableLeak rate not critical
277
Basics of Rotating Industrial Equipment
Mechanical Seals
Fluid is Toxic or FlammableLeak rate is critical
278
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Gland Packing
DescriptionApplicationAdvantagesDisadvantagesOperation
279
Basics of Rotating Industrial Equipment
Gland Packing
AdjustmentNutSeal Flush
Pump CasingGlandFollower
Packing
Lantern RingShaft
280
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Gland Packing
281
Basics of Rotating Industrial Equipment
Mechanical Seals
Pusher SealsBellows Seals
MetalElastomer
Cartridge Seals
282
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Advantages
Advantages
Extremely low leakage rates can be attained withproper selection and implementationReduced Preventative Maintenancerequirements with proper selection andimplementation
283
Basics of Rotating Industrial Equipment
Pusher Seal
284
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Pusher Seal
285
Basics of Rotating Industrial Equipment
Bellows Seals
286
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Bellows Seal (Elastomeric)
287
Basics of Rotating Industrial Equipment
Bellows Seal (Elastomeric)
288
RWD
Page 144
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Bellows Seal (Metallic)
289
Basics of Rotating Industrial Equipment
Bellows Seal (Metallic)
290
RWD
Page 145
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Cartridge Seals
291
Basics of Rotating Industrial Equipment
Cartridge Seals
292
RWD
Page 146
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
General Terminology
Rotating SealStationary SealBalanced SealUnbalanced Seal
293
Basics of Rotating Industrial Equipment
Stationary Seal
294
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Unbalanced
295
Basics of Rotating Industrial Equipment
Balanced
296
RWD
Page 148
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Dry Gas Seals
DescriptionLocationMaintenance
297
Basics of Rotating Industrial Equipment
Dry Gas Seal
298
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Description
299
Basics of Rotating Industrial Equipment
Gas Seal Description
300
RWD
Page 150
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Labyrinth Seals
DescriptionLocationMaintenance
301
Basics of Rotating Industrial Equipment
Description
302
RWD
Impeller
Shaft
InternalLabyrinth Seals
Page 151
Basic Rotating Equipment Training
Introduction
Firewater Pump DiagramBasics of Rotating Industrial Equipment
Seal flush
Gland packing
Lantern ring
303
Basics of Rotating Industrial Equipment
Packing Construction
Lattyflon 2790AL
PTFE ImpregnantedPolyacrylic YarnsSilicone Lubricant
304
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Packing Replacement
305
Basics of Rotating Industrial Equipment
Packing Replacement
306
RWD
Page 153
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Packing ReplacementPacking
Dummy shaft
307
Basics of Rotating Industrial Equipment
Packing Replacement
45
308
RWD
Page 154
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Mechanical Seal Service
Flowserve Single Pusher Cartridge Seal Type CSCPX
309
Basics of Rotating Industrial Equipment
Support Systems - Seal Flush
DescriptionMaintenance
310
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Flushing
A small amount of fluid that is introduced into theseal chamber close to the sealing facesImproves the fluid conditions near the facesSuppress vapor formation at or near the faces byheat removal and pressurization
311
Basics of Rotating Industrial Equipment
Seal Flush Piping
LPG, toxic services, or T> 450F:
Orifice should be provided at the discharge orsuction nozzle connection.Flush and quench lines should be Type 316stainless steel tubing
312
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Flush Plansinlet
Plan 11
Seal endview
orifice
313
Flush PlansBasics of Rotating Industrial Equipment
Plan 21
inletCoolantout
Seal endvieworifice
Temperaturesensor
coolerCoolantin
314
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Flush Plansinlet
Plan 31Seal endview
Cycloneseparator
315
Basics of Rotating Industrial Equipment
Cyclone Separator
316
RWD
B. To mechanical seal
A.Dischargein
C. Return to pump suction
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Quenching
317
FlushQuench
Impeller endStationaryfaceGland gasketgroove
Fixed throttlebushing
Drain
Basics of Rotating Industrial Equipment
Water Quenching
When some liquids evaporate, they leave an abrasivecrystal deposit behind (caustic, for example)Crystals forming on the atmospheric side of thesecondary seal stop the secondary and rotating membersfrom moving forwardThis condition is commonly called seal hang-upThe seal faces are also damaged by abrasives andcrystals centrifuged between themThese problems can be avoided by quenching the sealwith water
318
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Other Support Systems
CoolingPressurization
319
Basics of Rotating Industrial Equipment
Pressurization
Cooling is always preferable to pressurizationto suppress vaporization at the seal faces, butcooling is not always feasibleOften the pressure must be raised in the sealchamber to create the necessary marginbetween vapor pressure (at seal chambertemperature) and seal chamber pressure
320
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Basic Rotating Equipment Training
Introduction
Overview of Seal FailuresBasics of Rotating Industrial Equipment
Loss of Face LubricationBellows crackingCorrosion
321
Basics of Rotating Industrial Equipment
Overview of Seal Failures
Corrosion fretting (wear) of the sleeve under thesecondary sealCoke or crystal build up on the atmosphere sideof the seal under the faces
322
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Causes of Seal Failures
Review Operating DataReview Maintenance History
323
Basics of Rotating Industrial Equipment
Causes of Seal Failures
Inspect Mechanical Condition
324
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Causes of Seal Failures
Inspect Mechanical Seal
325
Basics of Rotating Industrial Equipment
Seal Chamber
Causes for a reduction in sealchamber pressureCauses for a temperature increaseat the seal faces
326
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Summary
ReviewQuestion and Answer Session
CLICK TO RETURN TO TOPICS
327
ALIGNMENT
328
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Major Topics
Alignment OverviewMethods of AlignmentUse of the Rotalign Pro SystemAlignment of Simple Driver/Load SystemsSoft FootAlignment of Equipment TrainsSheave AlignmentAlignment TroubleshootingThermal Growth
329
Basics of Rotating Industrial Equipment
Alignment Overview
Reasons for Proper Alignment
TimeCostEffort
330
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Alignment Terminology
Offset
Side View
Motor
Vertical
Pump
Top View
Motor
331
Horizontal
Pump
Basics of Rotating Industrial Equipment
Alignment Terminology
Angularity
Side View
Motor
Vertical
Pump
Top View
Motor
Horizontal
Pump
332
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Methods of Alignment
Straight Edge
Dial Indicator
Laser Alignment
333
Basics of Rotating Industrial Equipment
Dial Indicator
Rim Alignment
Side View
Motor
RWD
Pump
Top View
Motor
334
Vertical
Horizontal
Pump
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Dial Indicator
Face Alignment
Side View
Motor
Vertical
Pump
Top View
Motor
Horizontal
Pump
335
Basics of Rotating Industrial Equipment
Dial Indicator
Bar Sag
336
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Introduction
Basics of Rotating Industrial Equipment
Dial Indicator Caution: If the Coupling faces appearas below, it will be necessary to replace
337
Basics of Rotating Industrial Equipment
Laser Alignment
338
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Soft Foot
Any condition where tightening or loosening thebolts of a single foot distorts the machine frame.Must be corrected before proper final alignmentcan be achieved.
339
Basics of Rotating Industrial Equipment
Internal Misalignment
340
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Soft Foot
Causes
Bent legs/feetDeformed shimsDirt or debrisStrain from attached componentsMachine frame distortion
341
Basics of Rotating Industrial Equipment
Soft Foot
Effects
VibrationStrain and DeformationBearing Wear/DistortionPremature Equipment Failure
342
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Soft Foot - Types
Parallel Air Gap
343
Basics of Rotating Industrial Equipment
Soft Foot - Types
Bent
344
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Soft Foot - Types
Squishy
345
Basics of Rotating Industrial Equipment
Soft Foot - Types
Induced
Strain
InducedSoft Foot
346
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Soft Foot Detection
Dial Indicator
Parallel
Angular
Soft Foot
347
Basics of Rotating Industrial Equipment
Soft Foot Detection
Feeler Gauges
348
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Soft Foot DetectionTypical Soft FootReadings
0
0
0
1525
25
10
8
256
25
5
25
12
0
25
349
Basics of Rotating Industrial Equipment
Soft Foot
Soft Foot Correction
Parallel
Angular
Soft Foot
350
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Step Shimming
351
Basics of Rotating Industrial Equipment
Sheave Alignment
352
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Shaft Deflection
Cause:
Test:
Weight of CouplingShaft Run outUse a dial indicator to measure deflection during 180 degreesof rotation
Caution:
Do Not forget about Bar Sag when performing this testIt is better to use two indicators, reverse alignment
353
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Solution:
Replace the coupling with another type of equalSpeed (RPM) and Power (HP) rating that is of a lighterweightRemove the coupling and hubs and align machinesusing just the shafts
354
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Solution:
Replace the machine shaft if necessaryConsult the equipment manufacturer
355
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Shaft Deflection (Continued)
Affect on Alignment
Alignment readings will be different with and without thecouplingNo indication what the alignment will be while the machine isin operation
356
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Bolt Bound
Affect on Alignment
Motor will not move far enough to bring the motor and pumpback into alignment
357
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Bolt Bound
The pump and motor were not aligned properly beforethe skid was groutedSomething, such as a pipe, has moved from itsoriginal positionThe motor or pump is not the same as the original
358
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Bolt Bound
Bolts in improper position
Pipe Strain
Re-position machine on SkidCorrect Piping mis-alignment
Wrong Motor / Pump
Replace Incorrect Part
359
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Coupling Lateral Clearance
Cause:
Wrong CouplingImproper machine positionExcessive Axial Shaft movement
360
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Alignment Troubleshooting
Solution:
Loosen the Shaft grub screws and move the coupling flange(s) asnecessary to establish the correct clearanceIf excessive shaft axial play was present, repair the cause for thisplay.Consult the equipment manufacturer
361
Basics of Rotating Industrial Equipment
Thermal GrowthSide View
Motor
Top View
Motor
362
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Pump
Pump
Page 181
Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Summary
Review Question and Answer Session
CLICK TO RETURN TO TOPICS
363
VIBRATION ANALYSIS
364
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Course Objectives
Define the need for analysisDefine the cause and effects of equipmentvibrationState how vibration is measured
365
Basics of Rotating Industrial Equipment
Introduction
Method to detect and control the mechanicalcondition of rotating equipment.
366
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
What is vibration?
Motion of a machine from rest.Method to detect and control the mechanicalcondition of rotating equipment.Vibration amplitude.Vibration facts.
367
Basics of Rotating Industrial Equipment
VibrationVibration is the mechanical oscillation or motionabout a reference point of equilibrium- Violin string- Rotating machinery
368
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Vibration
Vibratory system includes:
Spring or ElasticityMass or InertiaExternal Force
50 mm
1.2 m
369
Basics of Rotating Industrial Equipment
Oscillatory MotionExternal force causes thesystem to oscillate as thespring stores andreleases energy50 mm
1.2 m
pAO
A sin wAw
=w
2
370
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
VibrationVibrations may:
Repeat (reciprocating machinery)Occur at specific times (impact)
371
Basics of Rotating Industrial Equipment
Repetitive Vibrations
The period of repetition may be measured asfrequencyMost equipment vibrations occur between 10 and2000Hz
372
RWD
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Normal Vibrations
Machines will have a characteristic vibrationsignature during normal operation20
G PK0
-200
T
0.80000
373
Basics of Rotating Industrial Equipment
Resonance
The resonance combines with the naturalfrequency of the system resulting in an amplifiedvibration. This can lead to destruction.
Example: Bridge resonance
374
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Effects of Machine Vibration
Efficiency lossWear accelerationMachine failurePersonnel injury
375
Basics of Rotating Industrial Equipment
Source of Equipment Vibration
Normal motion of machine operationUnbalanced partsWorn bearingsLoose mountingExternal impact
376
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Basic Rotating Equipment Training
Introduction
Basics of Rotating Industrial Equipment
Causes of Unbalance
Deposit
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