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Submit a ProposalProcess Machinery Handbook
 | For Field Personnel, Decision Makers, and Students Edited by Robert X. Perez Copyright: 2025 | Expected Pub Date:2025// ISBN: 9781394214457 | Hardcover | 744 pages Price: $225 USD  |
One Line Description
Process Machinery Handbook: For Field Personnel, Decision Makers, and Students equips newcomers and seasoned professionals with essential insights into the diverse world of process machinery, empowering them to understand unique performance characteristics, common failure modes, and effective strategies for enhancing reliability in their operations.
Audience
Students, educators, industry professionals, and manufacturers working to improve the longevity of machinery
Students, educators, industry professionals, and manufacturers working to improve the longevity of machinery
Description
Any professional working at a production site for any length of time knows that process machinery comes in a wide range of designs and sizes, but not all process machines are considered equal. Some machines are more critical to the process than others, some are small, some are very large, some spin fast, and some turn relatively slowly. The great diversity in their construction and application can be daunting to those new to the industry and sometimes even challenge machinery veterans. There are many common concepts that apply to all equipment types, but each equipment category has its own unique application and performance characteristics, including cavitation in liquid handling pumps, surging in centrifugal gas compressors, rotor instability in high-speed centrifugal compressors, and the effect of the compression ratio on a reciprocating compressor’s the discharge temperature. It is also essential for users to understand how and why different types of machinery fail, keeping in mind that the common failure modes differ greatly between rotating machinery types. We know that by addressing the common types of failure modes associated with each machine type, we can achieve significant improvements in their reliability.
The first step in organizing an effective machinery reliability program is committing to performing failure analyses and gathering failure statistics. These activities will help users learn how and why their machines are failing. The next step is to continuously modify machines, processes, and methods to avoid common failures. Process Machinery Handbook: For Field Personnel, Decision Makers, and Students gives students and professionals alike the tools they need to understand the fundamentals of working with rotating machinery.
Back to Top
Any professional working at a production site for any length of time knows that process machinery comes in a wide range of designs and sizes, but not all process machines are considered equal. Some machines are more critical to the process than others, some are small, some are very large, some spin fast, and some turn relatively slowly. The great diversity in their construction and application can be daunting to those new to the industry and sometimes even challenge machinery veterans. There are many common concepts that apply to all equipment types, but each equipment category has its own unique application and performance characteristics, including cavitation in liquid handling pumps, surging in centrifugal gas compressors, rotor instability in high-speed centrifugal compressors, and the effect of the compression ratio on a reciprocating compressor’s the discharge temperature. It is also essential for users to understand how and why different types of machinery fail, keeping in mind that the common failure modes differ greatly between rotating machinery types. We know that by addressing the common types of failure modes associated with each machine type, we can achieve significant improvements in their reliability.
The first step in organizing an effective machinery reliability program is committing to performing failure analyses and gathering failure statistics. These activities will help users learn how and why their machines are failing. The next step is to continuously modify machines, processes, and methods to avoid common failures. Process Machinery Handbook: For Field Personnel, Decision Makers, and Students gives students and professionals alike the tools they need to understand the fundamentals of working with rotating machinery.
Back to Top
Author / Editor Details
Robert 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 and coauthored 11 books covering machinery reliability, including several books also available from Wiley-Scrivener.
Robert 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 and coauthored 11 books covering machinery reliability, including several books also available from Wiley-Scrivener.
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Table of Contents
Preface
Acknowledgements
1. Overview of Rotating Machinery
By Robert X. Perez
Unspared versus Spared Machine Trains
Driven-Process Machines
Critical Machine Components
Bearing Life
Process Machinery
Pumps
Classification of Pumps
Dynamic (Centrifugal) Pumps
Vertical, Multistage Centrifugal Pumps
Positive Displacement (PD) Pumps
Rotary Positive Displacement Pumps
Screw Pumps
Comparison of Centrifugal and PD Pumps
Compressor Types
Multi-Staging
Drivers
Electric Motors
Steam Turbines
Speed Control
Gas Turbines
Natural Gas Engines
Closing
Part I: Fluid Movers
2. Positive Displacement Pumps
By Robert X. Perez
What is a Positive Displacement Pump?
Rotary Positive Displacement Pumps
Screw Pumps
Rotary Pump Design Limits
Safety Concerns
Reciprocating Positive Displacement Pumps
Classification of Reciprocating Pumps
Calculating the Required by a Reciprocating Pump Horsepower
Some Reciprocating Pumps Advice
Some Words of Caution
Pulsation and Surge Control
Comparison of Centrifugal and PD Pumps
Troubleshooting PD Pumps
References
3. Centrifugal Pumps: Part 1
By Robert X. Perez
Head Versus Pressure
Centrifugal Pump Performance
Determining the Minimum Safe Operating Point When You Know the Suction Specific Speed and the Best Efficiency Flow
Basic Centrifugal Pump Construction
Types of Centrifugal Pumps
Fixed Speed Versus Variable Speed Operation
Pumping Systems
The Importance of System Head Curve
Summary
References
4. Centrifugal Pumps: Part 2
By Robert X. Perez
Can I Use a Centrifugal Pump?
Net Positive Suction Head - NPSH
Summary
References
5. Sealless Centrifugal Pumps
By Robert X. Perez
Magnetic Drive Centrifugal Pumps
Bearings for Magnetic Drive Pumps
Internal Flush Flow
Advantages and Disadvantages of Mag Drive Pumps
Canned Motor Pumps
Comparing Canned Motor Pumps and Mag Drive Pumps
Monitoring Advice for Sealless Pumps
Monitoring Can Motor Pumps
References
6. Compressors
By Robert X. Perez
Commonly Used Compressor Flow Terms
Ideal Gas Law
Example of How to Convert from SCFM to ACFM
Visualizing Gas Flow
Compressibility Factor (Z)
Sizing Compressors
Compression Processes
Polytropic Compression
An Overview of Process Compressors
Compression Basics
Defining Gas Flow
Compressor Types
Multi-Staging
Key Reliability Indicators
Centrifugal Compressors
Centrifugal Compressor Piping Arrangements
Start-Up Configuration
Centrifugal Compressor Horsepower
How Process Changes Affect Centrifugal Compressor Performance
Baseball Pitcher Analogy
How Gas Density Affects Horsepower
Theory Versus Practice
How to Read a Centrifugal Compressor Performance Map
The Anatomy of a Compressor Map
Design Conditions
Keeping Your Centrifugal Compressor Out of Harm’s Way
Compressor Operating Limits
Compressor Flow Limits
Critical Speeds
Horsepower Limits
Temperatures
Reciprocating Compressors
Reciprocating Compressor Installations
Screw Compressors
Oil Injected Screw Compressors
Screw Compressor Modulation
Pressure Pulsation Issues
Troubleshooting Screw Compressors
References
Part II: Drivetrains, Foundations, and Piping
7. Introduction to Process Drivers and Drivetrains
By Robert X. Perez
Drivers, Speed Modifiers, and Driven Machines
Drivers
Selection Factors
Sizing
Signs of a Driver Problem
Closing Thoughts
References
8. Machinery Foundation and Baseplate Design Recommendations
By Robert X. Perez
Foundations
Foundation Rules of Thumb
Grouted Baseplates
Foundation Design Details
Grouting
Epoxy Pre-Filled Base Plates
Understanding the Importance of Machine Bases
Anchor Bolt Spacing
Bolt Preload
Foundation Design and Installation Standards
References
9. Process Piping Design and Installation Best Practices
By Robert X. Perez
Thermal Expansion
Effects of Piping Strain
Piping Flexibility
Elbows and Expansion Loops
Expansion Loop and Expansion Joint
Piping Installation Checks
Pump Piping Best Practices
Monitoring Pipe Stress While Bolting Up
Steam Turbine Piping
Dial Indicator Checks
Hot Alignment Checks
Final Advice
References
10. AC Induction Motors
By Robert X. Perez
Theory of Operation
Electric Motor Selection
Electric Motor Driver Enclosures
Open Drip Proof (ODP)
Totally Enclosed Fan Cooled (TEFC)
Totally Enclosed Air Over (TEAO)
Totally Enclosed Non-Ventilated (TENV)
Totally Enclosed Force Ventilated (TEFV)/ Totally Enclosed Blower Cooled (TEBC)
Weather Protective 1 (WP1)
Weather Protective 2 (WP2)
Totally Enclosed Air to Air Cooled (TEAAC)
Totally Enclosed Water to Air Cooled (TEWAC)
Explosion Proof (XP)
Motor Reliability Concerns
Controls
Instrumentation
Electrical Safety
The Effects of Voltage Unbalance
Insulation Classes & Their Thermal Ratings
Chapter 10, Addendum A: Reasons Why Motors Fail
Chapter 10, Addendum B: Using VFDs to Minimize Centrifugal Pump Power Usage
Flow Control Techniques
Energy Savings by Variable Frequency Drives
When VFDs Don’t Make Sense
VFD Advances
Chapter 10, Addendum C
References
11. General Purpose Back Pressure Steam Turbines
By Robert X. Perez and David W. Lawhon
Single-Stage Back Pressure Steam Turbine
Steam Flow Path
Mechanical Components in General Purpose Back-Pressure Steam Turbines
Bearing Lubrication
Force Lubrication Systems
Lubrication
Bearing Housing Seals
Lip Seals
Labyrinth Seals
Steam Packing Rings and Seals
Steam Turbine Speed Controls and Safety Systems
Introduction
Speed Controls
Governor Classes
Overspeed Trip System
Overpressure Protection
Parting Advice
References
12. Gas Turbine Drivers
By Robert X. Perez
Overview
Theory of Operation
Two Shaft Gas Turbine Design Details
Typical Conditions Inside an Industrial Gas Turbine
Effect of Atmospheric Conditions
Protection
Fuel and Fuel Treatment
Gas Fuels
Degradation and Water Washing
Advanced Materials for Land Based Gas Turbines
Condition Monitoring Approaches
Gas Turbine Maintenance Inspections
Final Words of Advice
References
13. Natural Gas Engine Drivers
By Robert X. Perez
Natural Gas Engines
2 Stoke Engines versus 4 Stoke Engines
The 4-Stroke Engine Cycle
The Differences Between 2-Stroke and 4-Stroke Engines
Turbochargers
Emissions Control
Rich versus Lean Burn Engines
Mechanical Condition Monitoring Techniques
Natural Gas Engine Lubrication and Oil Analysis
Engine Manufacturers’ Lubricant Recommendations
Maintenance and Reliability Recommendations
Oil Filtration
Engine Cooling Systems
Ensuring Engine Reliability
References
14. Turboexpanders for Gas Processing
By Robert X. Perez
Introduction
Turboexpanders in Gas Processing
The Benefits of a Turboexpander Over a J-T Valve
Preliminary Sizing of a Turboexpander
Basic Design and Special Features
Rotor
Bearings
Seals
Inlet Guide Vanes (IGVs)
Casings
Spare Parts
Potential Operating Issues
Control
Compressor Surge Control
Automatic Thrust Balancing System
Maintenance Requirements
Common Troubleshooting
Industry Specifications
Capacity Rerates
Inlet Guide Vane Open Area
Expander Wheel Outlet Area
Compressor Wheel Inlet Area
Bearings
Frame Size Increase
Repairs
Turboexpander Best Practices
Importance of Logging Field Data
Sample Data Log Sheet
Addition Information
Takeaway
References
Part III: Gearboxes, Couplings, and Seals
15. Gears and Gearboxes
By Robert X. Perez
Gears
Industrial Gearing Advice
Ways to Increase the Reliability of a Gearbox
Temperature of the Gear Teeth
Micro-Geometry of the Gear Teeth
Alignment
Surface Finish
Dynamic Loads
Vibration Analysis in Gearboxes
Other Predictive Technologies
Final Words
References
16. Industrial Drive Couplings
By Heinz P. Bloch and Robert X. Perez
Misalignment Concerns
Misalignment Results in Power Losses Across a Coupling
How Vibration Affects Bearing Life
Types of Flexible Couplings
Elastomeric Couplings
Tire Coupling
Gear Couplings
Gear Coupling Periodic Maintenance
Grid Couplings
Grid Couplings Periodic Maintenance
Disc Coupling
Operational Disc Coupling Inspection
Diaphragm Coupling
Couplings Design Considerations
Some Advantages of Diaphragm and Disc Coupling Designs
Advantages and Disadvantages of Gear Couplings
Advice for Users of Medium Horsepower Couplings
References
17. Seals
By Robert X. Perez
Mechanical Seal Configurations and Flush Plans
Practical Ways to Improve Mechanical Seal Reliability
Process Compressor Seals
References
Part IV: Bearings and Lubrication
18. Rolling Element Bearings
By Robert X. Perez
Bearing Element Bearings
Ball Bearings
Gear Drives
Notes
References
19. Hydrodynamic Bearings
By John K. Whalen, PE
API Mechanical Equipment Standards for Refinery Service
Bearings
Hydrodynamic Lubrication
Tower’s Experiments
Reynolds Equation
Journal Bearings
Thrust Bearings
Fixed Geometry Thrust Bearings
Babbitt
Current and Future Work
References
20. Introduction to Machinery Lubrication
By Robert X. Perez
Lubrication Regimes
Types of Lubricating Oils
Lubrication Methods
Splash Lubrication
Bearing Housing Protection
Contacting Bearing Protector Seals
Venting and Housing Pressurization Effects on Bearing Protector Seals
Oil Mist Lubrication
Fluid Film Bearing Lubrication
Plain Bearings
Oil Ring Lubrication
High-Speed Fluid Film Bearings
Fluid Film Bearing Lubrication
Closed-Loop Lubrication Systems
Assessing Lube Oil Cleanliness
Another ISO Cleanliness Code Example
Lubricant Storage and Handling
Lubrication Responsibilities of Operations, Maintenance, and Reliability
References
Part V: Condition Monitoring
21. Machinery Vibration Monitoring
By Robert X. Perez
Vibration Measurements and Monitoring Systems
Data Presentation
Data Collection Tips
Common Types of Field Sensors
What Vibration Sensor Should I Use?
What are the Components of Vibration?
Useable Frequency Spans for Accelerometer Mounting Methods
Measurement Locations
Machine Vibration Spectrums
Common Machinery Issues
Velocity Guidelines
Overall Vibration Levels
When Spectral Content is Known
Using the Commercial Standards (DLI Machinery Vibration Severity Chart)
Monitoring Critical Machinery with Fluid Film Bearings
Proximity Probe Benefits
Theory of Operation
Runout Concerns
Grounding and Noise
Shaft Orbits
General Machinery Monitoring Recommendations
Should You Use One or Two Probes?
Vibration Guidelines for Displacement Measurements in Fluid Film Bearings
For Other Centrifugal Compressors
For Other Centrifugal Machines, Such As Motors, Pumps, etc.
Rule of Thumb for Field Evaluations
Alternate Guidelines for Fluid Film Bearings
ISO 7919 Part 3 Shaft Vibration Guidelines
Managing Site Vibration Data
References
22. Centrifugal Pump Monitoring, Troubleshooting, and Diagnosis Using Vibration Technologies
William D. Marscher
Nomenclature
Introduction
Conclusions
Acknowledgments
References & Bibliography
23. Optimizing Lubrication and Lubricant Analysis
By Jim Fitch and Bennett Fitch Introduction
What You Might Not Know About Lubrication
Ensuring Reliable Testing
Determining the Optimum Course of Action
Noria Corporation
Bibliography
24. Troubleshooting Temperature Problems
By Robert X. Perez
Temperature Assessments
How Do Infrared Thermometers Work?
Bearing Temperature Trending
Rolling Element and Sleeve Bearing Temperature Guidelines
Bearing Temperature Guidelines for Instrumented Hydrodynamic Bearings
Recommended Guidelines for Babbitt Bearings*
Bearing Temperature Sensor Placement
Sleeve Bearings
Tilting Pad Journal (TPJ) Bearings—Load on Pad
Tilting Pad Journal Bearings—Load Between Pads
Thrust Bearings-Tilting Pad
General Temperature Probe Installation Guidelines
Compressor Discharge Temperature Assessments
Heat of Compression
Types of Compression Processes
Adiabatic Compression
Polytropic Compression
Why Compression Ratio Matters
What Role It Plays in Compressor Design and Selection
Compression Ratio versus Discharge Temperature
Design Temperature Margin
Design Trade-Offs
Reciprocating Compressor Temperature Monitoring
Valve temperature Monitoring
Temperature Monitoring Example
Summary
References
Part VI: Machinery Reliability
25. Machinery Reliability Management in a Nutshell
By Robert X. Perez
Criticality
Environmental Consequences
Safety Consequences
Equipment History
Safeguards
Compressor Operating Limits
Compressor Flow Limits
Critical Speeds
Horsepower Limits
Temperatures
Layers of Machinery Protection
Machinery Reliability Assessment Example
Background
History
Safeguards
Conclusion
Closing Remarks
References
26. Useful Analysis Tools for Tracking Machinery Reliability
By Robert X. Perez
Commonly Used Metrics for Spared Machinery
Mean Time to Repair (MTTR)
Mean Time Between Failure (MTBF)
Additional Reliability Assessment Tools for Spared Machines
Cumulative Failure Trends
Metrics for Critical Machines
Availability
An Alternative Means of Determining Availability is as Follows
Critical Machine Events
Process Outage Trends
Process Outage Related to Machinery Outages
Planned Maintenance Percentage (PMP)
Reliability Analysis Capabilities of Your CMMS Software
References
27. Improving the Effectiveness of Plant Operators
By Julien LeBleu
Items that will be covered in this chapter are the following
Look, Listen, and Feel
Applying Look, Listen, and Feel Techniques to Troubleshooting
Why the Operator’s Input is Important to the Troubleshooting
Process
Operator Tools
Understanding the Equipment – Pumps, Seals, and Sealing Support
Systems
Centrifugal Pump Relationships to Remember
Positive Displacement Pumps Relationships to Remember
Mechanical Seals
Capital Projects
Writing Quality Work Request
Procedures (Procedures and Decision Trees)
Must Give Operators Feedback
Must Be Required to Use Their Training
Discipline
Conclusion
References
28. Improving Machinery Reliability by Using Root Cause Failure Analysis Methods
By Robert X. Perez
Introduction
What is a Root Cause Failure Analysis?
Root Cause Failure Analysis Example #1: Ill-Advised Bearing
Replacement
History
Corrective Measures
Comments
Root Cause Failure Analysis Example #2: Reciprocating Compressor Rod Failure
Background
Comments
RCFA Steps
Identifying the Physical Root Cause of the Primary Failure
Fatigue Example: Fin-Fan Cooler Shaft Failures
Preserving Machine Data
Causal Chains
Five Why RCFA Example
Cause Mapping
Cause Map Example #2
Single Root Cause Versus Multiple Causes
Cause Mapping Steps
Inhibitors to Effective Problem Solving
When is a Root Cause Failure Analysis Justified?
Time is Money
RCFA Levels
Closing Thoughts
References
Index
Back to Top
Preface
Acknowledgements
1. Overview of Rotating Machinery
By Robert X. Perez
Unspared versus Spared Machine Trains
Driven-Process Machines
Critical Machine Components
Bearing Life
Process Machinery
Pumps
Classification of Pumps
Dynamic (Centrifugal) Pumps
Vertical, Multistage Centrifugal Pumps
Positive Displacement (PD) Pumps
Rotary Positive Displacement Pumps
Screw Pumps
Comparison of Centrifugal and PD Pumps
Compressor Types
Multi-Staging
Drivers
Electric Motors
Steam Turbines
Speed Control
Gas Turbines
Natural Gas Engines
Closing
Part I: Fluid Movers
2. Positive Displacement Pumps
By Robert X. Perez
What is a Positive Displacement Pump?
Rotary Positive Displacement Pumps
Screw Pumps
Rotary Pump Design Limits
Safety Concerns
Reciprocating Positive Displacement Pumps
Classification of Reciprocating Pumps
Calculating the Required by a Reciprocating Pump Horsepower
Some Reciprocating Pumps Advice
Some Words of Caution
Pulsation and Surge Control
Comparison of Centrifugal and PD Pumps
Troubleshooting PD Pumps
References
3. Centrifugal Pumps: Part 1
By Robert X. Perez
Head Versus Pressure
Centrifugal Pump Performance
Determining the Minimum Safe Operating Point When You Know the Suction Specific Speed and the Best Efficiency Flow
Basic Centrifugal Pump Construction
Types of Centrifugal Pumps
Fixed Speed Versus Variable Speed Operation
Pumping Systems
The Importance of System Head Curve
Summary
References
4. Centrifugal Pumps: Part 2
By Robert X. Perez
Can I Use a Centrifugal Pump?
Net Positive Suction Head - NPSH
Summary
References
5. Sealless Centrifugal Pumps
By Robert X. Perez
Magnetic Drive Centrifugal Pumps
Bearings for Magnetic Drive Pumps
Internal Flush Flow
Advantages and Disadvantages of Mag Drive Pumps
Canned Motor Pumps
Comparing Canned Motor Pumps and Mag Drive Pumps
Monitoring Advice for Sealless Pumps
Monitoring Can Motor Pumps
References
6. Compressors
By Robert X. Perez
Commonly Used Compressor Flow Terms
Ideal Gas Law
Example of How to Convert from SCFM to ACFM
Visualizing Gas Flow
Compressibility Factor (Z)
Sizing Compressors
Compression Processes
Polytropic Compression
An Overview of Process Compressors
Compression Basics
Defining Gas Flow
Compressor Types
Multi-Staging
Key Reliability Indicators
Centrifugal Compressors
Centrifugal Compressor Piping Arrangements
Start-Up Configuration
Centrifugal Compressor Horsepower
How Process Changes Affect Centrifugal Compressor Performance
Baseball Pitcher Analogy
How Gas Density Affects Horsepower
Theory Versus Practice
How to Read a Centrifugal Compressor Performance Map
The Anatomy of a Compressor Map
Design Conditions
Keeping Your Centrifugal Compressor Out of Harm’s Way
Compressor Operating Limits
Compressor Flow Limits
Critical Speeds
Horsepower Limits
Temperatures
Reciprocating Compressors
Reciprocating Compressor Installations
Screw Compressors
Oil Injected Screw Compressors
Screw Compressor Modulation
Pressure Pulsation Issues
Troubleshooting Screw Compressors
References
Part II: Drivetrains, Foundations, and Piping
7. Introduction to Process Drivers and Drivetrains
By Robert X. Perez
Drivers, Speed Modifiers, and Driven Machines
Drivers
Selection Factors
Sizing
Signs of a Driver Problem
Closing Thoughts
References
8. Machinery Foundation and Baseplate Design Recommendations
By Robert X. Perez
Foundations
Foundation Rules of Thumb
Grouted Baseplates
Foundation Design Details
Grouting
Epoxy Pre-Filled Base Plates
Understanding the Importance of Machine Bases
Anchor Bolt Spacing
Bolt Preload
Foundation Design and Installation Standards
References
9. Process Piping Design and Installation Best Practices
By Robert X. Perez
Thermal Expansion
Effects of Piping Strain
Piping Flexibility
Elbows and Expansion Loops
Expansion Loop and Expansion Joint
Piping Installation Checks
Pump Piping Best Practices
Monitoring Pipe Stress While Bolting Up
Steam Turbine Piping
Dial Indicator Checks
Hot Alignment Checks
Final Advice
References
10. AC Induction Motors
By Robert X. Perez
Theory of Operation
Electric Motor Selection
Electric Motor Driver Enclosures
Open Drip Proof (ODP)
Totally Enclosed Fan Cooled (TEFC)
Totally Enclosed Air Over (TEAO)
Totally Enclosed Non-Ventilated (TENV)
Totally Enclosed Force Ventilated (TEFV)/ Totally Enclosed Blower Cooled (TEBC)
Weather Protective 1 (WP1)
Weather Protective 2 (WP2)
Totally Enclosed Air to Air Cooled (TEAAC)
Totally Enclosed Water to Air Cooled (TEWAC)
Explosion Proof (XP)
Motor Reliability Concerns
Controls
Instrumentation
Electrical Safety
The Effects of Voltage Unbalance
Insulation Classes & Their Thermal Ratings
Chapter 10, Addendum A: Reasons Why Motors Fail
Chapter 10, Addendum B: Using VFDs to Minimize Centrifugal Pump Power Usage
Flow Control Techniques
Energy Savings by Variable Frequency Drives
When VFDs Don’t Make Sense
VFD Advances
Chapter 10, Addendum C
References
11. General Purpose Back Pressure Steam Turbines
By Robert X. Perez and David W. Lawhon
Single-Stage Back Pressure Steam Turbine
Steam Flow Path
Mechanical Components in General Purpose Back-Pressure Steam Turbines
Bearing Lubrication
Force Lubrication Systems
Lubrication
Bearing Housing Seals
Lip Seals
Labyrinth Seals
Steam Packing Rings and Seals
Steam Turbine Speed Controls and Safety Systems
Introduction
Speed Controls
Governor Classes
Overspeed Trip System
Overpressure Protection
Parting Advice
References
12. Gas Turbine Drivers
By Robert X. Perez
Overview
Theory of Operation
Two Shaft Gas Turbine Design Details
Typical Conditions Inside an Industrial Gas Turbine
Effect of Atmospheric Conditions
Protection
Fuel and Fuel Treatment
Gas Fuels
Degradation and Water Washing
Advanced Materials for Land Based Gas Turbines
Condition Monitoring Approaches
Gas Turbine Maintenance Inspections
Final Words of Advice
References
13. Natural Gas Engine Drivers
By Robert X. Perez
Natural Gas Engines
2 Stoke Engines versus 4 Stoke Engines
The 4-Stroke Engine Cycle
The Differences Between 2-Stroke and 4-Stroke Engines
Turbochargers
Emissions Control
Rich versus Lean Burn Engines
Mechanical Condition Monitoring Techniques
Natural Gas Engine Lubrication and Oil Analysis
Engine Manufacturers’ Lubricant Recommendations
Maintenance and Reliability Recommendations
Oil Filtration
Engine Cooling Systems
Ensuring Engine Reliability
References
14. Turboexpanders for Gas Processing
By Robert X. Perez
Introduction
Turboexpanders in Gas Processing
The Benefits of a Turboexpander Over a J-T Valve
Preliminary Sizing of a Turboexpander
Basic Design and Special Features
Rotor
Bearings
Seals
Inlet Guide Vanes (IGVs)
Casings
Spare Parts
Potential Operating Issues
Control
Compressor Surge Control
Automatic Thrust Balancing System
Maintenance Requirements
Common Troubleshooting
Industry Specifications
Capacity Rerates
Inlet Guide Vane Open Area
Expander Wheel Outlet Area
Compressor Wheel Inlet Area
Bearings
Frame Size Increase
Repairs
Turboexpander Best Practices
Importance of Logging Field Data
Sample Data Log Sheet
Addition Information
Takeaway
References
Part III: Gearboxes, Couplings, and Seals
15. Gears and Gearboxes
By Robert X. Perez
Gears
Industrial Gearing Advice
Ways to Increase the Reliability of a Gearbox
Temperature of the Gear Teeth
Micro-Geometry of the Gear Teeth
Alignment
Surface Finish
Dynamic Loads
Vibration Analysis in Gearboxes
Other Predictive Technologies
Final Words
References
16. Industrial Drive Couplings
By Heinz P. Bloch and Robert X. Perez
Misalignment Concerns
Misalignment Results in Power Losses Across a Coupling
How Vibration Affects Bearing Life
Types of Flexible Couplings
Elastomeric Couplings
Tire Coupling
Gear Couplings
Gear Coupling Periodic Maintenance
Grid Couplings
Grid Couplings Periodic Maintenance
Disc Coupling
Operational Disc Coupling Inspection
Diaphragm Coupling
Couplings Design Considerations
Some Advantages of Diaphragm and Disc Coupling Designs
Advantages and Disadvantages of Gear Couplings
Advice for Users of Medium Horsepower Couplings
References
17. Seals
By Robert X. Perez
Mechanical Seal Configurations and Flush Plans
Practical Ways to Improve Mechanical Seal Reliability
Process Compressor Seals
References
Part IV: Bearings and Lubrication
18. Rolling Element Bearings
By Robert X. Perez
Bearing Element Bearings
Ball Bearings
Gear Drives
Notes
References
19. Hydrodynamic Bearings
By John K. Whalen, PE
API Mechanical Equipment Standards for Refinery Service
Bearings
Hydrodynamic Lubrication
Tower’s Experiments
Reynolds Equation
Journal Bearings
Thrust Bearings
Fixed Geometry Thrust Bearings
Babbitt
Current and Future Work
References
20. Introduction to Machinery Lubrication
By Robert X. Perez
Lubrication Regimes
Types of Lubricating Oils
Lubrication Methods
Splash Lubrication
Bearing Housing Protection
Contacting Bearing Protector Seals
Venting and Housing Pressurization Effects on Bearing Protector Seals
Oil Mist Lubrication
Fluid Film Bearing Lubrication
Plain Bearings
Oil Ring Lubrication
High-Speed Fluid Film Bearings
Fluid Film Bearing Lubrication
Closed-Loop Lubrication Systems
Assessing Lube Oil Cleanliness
Another ISO Cleanliness Code Example
Lubricant Storage and Handling
Lubrication Responsibilities of Operations, Maintenance, and Reliability
References
Part V: Condition Monitoring
21. Machinery Vibration Monitoring
By Robert X. Perez
Vibration Measurements and Monitoring Systems
Data Presentation
Data Collection Tips
Common Types of Field Sensors
What Vibration Sensor Should I Use?
What are the Components of Vibration?
Useable Frequency Spans for Accelerometer Mounting Methods
Measurement Locations
Machine Vibration Spectrums
Common Machinery Issues
Velocity Guidelines
Overall Vibration Levels
When Spectral Content is Known
Using the Commercial Standards (DLI Machinery Vibration Severity Chart)
Monitoring Critical Machinery with Fluid Film Bearings
Proximity Probe Benefits
Theory of Operation
Runout Concerns
Grounding and Noise
Shaft Orbits
General Machinery Monitoring Recommendations
Should You Use One or Two Probes?
Vibration Guidelines for Displacement Measurements in Fluid Film Bearings
For Other Centrifugal Compressors
For Other Centrifugal Machines, Such As Motors, Pumps, etc.
Rule of Thumb for Field Evaluations
Alternate Guidelines for Fluid Film Bearings
ISO 7919 Part 3 Shaft Vibration Guidelines
Managing Site Vibration Data
References
22. Centrifugal Pump Monitoring, Troubleshooting, and Diagnosis Using Vibration Technologies
William D. Marscher
Nomenclature
Introduction
Conclusions
Acknowledgments
References & Bibliography
23. Optimizing Lubrication and Lubricant Analysis
By Jim Fitch and Bennett Fitch Introduction
What You Might Not Know About Lubrication
Ensuring Reliable Testing
Determining the Optimum Course of Action
Noria Corporation
Bibliography
24. Troubleshooting Temperature Problems
By Robert X. Perez
Temperature Assessments
How Do Infrared Thermometers Work?
Bearing Temperature Trending
Rolling Element and Sleeve Bearing Temperature Guidelines
Bearing Temperature Guidelines for Instrumented Hydrodynamic Bearings
Recommended Guidelines for Babbitt Bearings*
Bearing Temperature Sensor Placement
Sleeve Bearings
Tilting Pad Journal (TPJ) Bearings—Load on Pad
Tilting Pad Journal Bearings—Load Between Pads
Thrust Bearings-Tilting Pad
General Temperature Probe Installation Guidelines
Compressor Discharge Temperature Assessments
Heat of Compression
Types of Compression Processes
Adiabatic Compression
Polytropic Compression
Why Compression Ratio Matters
What Role It Plays in Compressor Design and Selection
Compression Ratio versus Discharge Temperature
Design Temperature Margin
Design Trade-Offs
Reciprocating Compressor Temperature Monitoring
Valve temperature Monitoring
Temperature Monitoring Example
Summary
References
Part VI: Machinery Reliability
25. Machinery Reliability Management in a Nutshell
By Robert X. Perez
Criticality
Environmental Consequences
Safety Consequences
Equipment History
Safeguards
Compressor Operating Limits
Compressor Flow Limits
Critical Speeds
Horsepower Limits
Temperatures
Layers of Machinery Protection
Machinery Reliability Assessment Example
Background
History
Safeguards
Conclusion
Closing Remarks
References
26. Useful Analysis Tools for Tracking Machinery Reliability
By Robert X. Perez
Commonly Used Metrics for Spared Machinery
Mean Time to Repair (MTTR)
Mean Time Between Failure (MTBF)
Additional Reliability Assessment Tools for Spared Machines
Cumulative Failure Trends
Metrics for Critical Machines
Availability
An Alternative Means of Determining Availability is as Follows
Critical Machine Events
Process Outage Trends
Process Outage Related to Machinery Outages
Planned Maintenance Percentage (PMP)
Reliability Analysis Capabilities of Your CMMS Software
References
27. Improving the Effectiveness of Plant Operators
By Julien LeBleu
Items that will be covered in this chapter are the following
Look, Listen, and Feel
Applying Look, Listen, and Feel Techniques to Troubleshooting
Why the Operator’s Input is Important to the Troubleshooting
Process
Operator Tools
Understanding the Equipment – Pumps, Seals, and Sealing Support
Systems
Centrifugal Pump Relationships to Remember
Positive Displacement Pumps Relationships to Remember
Mechanical Seals
Capital Projects
Writing Quality Work Request
Procedures (Procedures and Decision Trees)
Must Give Operators Feedback
Must Be Required to Use Their Training
Discipline
Conclusion
References
28. Improving Machinery Reliability by Using Root Cause Failure Analysis Methods
By Robert X. Perez
Introduction
What is a Root Cause Failure Analysis?
Root Cause Failure Analysis Example #1: Ill-Advised Bearing
Replacement
History
Corrective Measures
Comments
Root Cause Failure Analysis Example #2: Reciprocating Compressor Rod Failure
Background
Comments
RCFA Steps
Identifying the Physical Root Cause of the Primary Failure
Fatigue Example: Fin-Fan Cooler Shaft Failures
Preserving Machine Data
Causal Chains
Five Why RCFA Example
Cause Mapping
Cause Map Example #2
Single Root Cause Versus Multiple Causes
Cause Mapping Steps
Inhibitors to Effective Problem Solving
When is a Root Cause Failure Analysis Justified?
Time is Money
RCFA Levels
Closing Thoughts
References
Index
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