Introduction to Rotating Equipment Maintenance

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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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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Auxiliary and Support Systems

LubricationBearingSealsAlignmentVibration AnalysisThermal Analysis

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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Summary

Review

CLICK TO RETURN TO TOPICS

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Introduction

COMPRESSORS

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Main Topics

Introduction to compressorsCentrifugalReciprocatingScrew

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Introduction

Compression is used in all aspects of gasprocessing such as:

Gas LiftGas GatheringHelium RecoveryCondensate RecoveryTransmissionDistribution

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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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Sliding Vane CompressorSliding VaneRotor

Inlet PortDischargePort

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Screw Compressors

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Centrifugal CompressorFundamentals

Gas flow pathStageProcess stageVelocity Energy to Pressure

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Centrifugal CompressorBasics of Rotating Industrial Equipment

Gas Suction

Discharge

Torque

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Centrifugal Compressor Types

Axial, or horizontallysplit

JOINT

JOINT

JOINT

Radial, orvertically split

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Centrifugal Compressor StageComponents

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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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Dry Gas SealsFace Rotation

RotatingFace

StationaryFace

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Summary

Review Question and Answer Session


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PUMPS

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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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Major Topics

Pumps GeneralPositive Displacement PumpsCentrifugal Pumps

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PumpsBasics of Rotating Industrial Equipment

Types

Positive Displacement - Overview

Screw PumpsGear PumpsPiston PumpsPlunger Pumps

Centrifugal - Overview

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Positive Displacement Pumps

Screw PumpsGear pumpsPiston pumpsRotating gearsCentrifugal pumps

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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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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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External Gear Pump

Counter-rotating gears

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External Gear Pumps

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Internal Gear Pump

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Piston Pumps

Piston Pump DiagramMajor Component ReviewOperation and ApplicationMaintenance and Troubleshooting

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Piston Pump

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Major ComponentsInletCheck BallCam Plate

OutletCheck BallOutlet

Inlet

SUCTION

COMPRESSION

DISCHARGE

Drive Shaft

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PumpingChamber

SpringPiston


Operation and Application

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Plunger Pumps

Plunger Pump DiagramMajor Component ReviewOperation and Application

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Packed Plunger Pump

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Diaphragm Plunger Pump

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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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FundamentalsImpeller VanesTongue

Eye

Volute

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Centrifugal Pump Diagram

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Sleeve/Coupling/Bearings

Shaft SleeveCoupling

Elastomeric couplings (having properties thatresemble rubber)Non-elastomeric

Bearings

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Impeller Types

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Suction and Discharge

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Swing Type Check Valve

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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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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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Flow PathPrecautions

Prevent CavitationAvoid Low Flow Conditions

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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



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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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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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Main Components

Turbine CasingCompressor SectionCombustion ChamberBearingsTurbine RotorsAuxiliary Systems

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Turbine Casing

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Compressor Section

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Combustion Chamber

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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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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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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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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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Borescope Inspections

Overview and Purpose

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Summary



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FANS AND LOUVERS

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Course Objectives

Define the steps necessary to maintain andreplace fan bearingsDiscuss characteristics of BeltsState the steps necessary to remove, replaceand adjust drive belts

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Course Objectives

Discuss methods of determining cause basedupon effect

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Fan Safety

Rotating EquipmentElevationHigh TemperatureH2S

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Rotor and Hub Assembly ExampleTRAILINGEDGE

LEADINGEDGE

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Rotors

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Fan Checks

Adjust the pitch of eachblade to the vendorsspecified angleVerify blades rotatefreelyVerify proper motorrotation

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Fin Fan Tip ClearanceBasics of Rotating Industrial Equipment

Blade Tip Clearance

Adjust each bladeassembly to the vendorsspecified tip clearance

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Driver

Variable Speed Drive (VSD) Electric MotorTotally Enclosed Fan Cooled (TEFC)Explosion Proof

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Belts

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HTD Belts

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HTD Belts

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Synchronous Belt

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V-belts

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Powerband V-belts

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Cog BeltsCog Belt(Side View)

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Belt Alignment

Example mis-alignment of belts

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Belt Alignment

Four Point Touch AlignmentCord tied toshaft

Cord touching sheave at pointsindicated by arrows

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Belt Tensioning

Too tight

Slight bowToo loose

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Changing Belts

Never lever or pry belts onto sheaves orsprockets

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Bearing

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Louvres

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Louvres

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Cylinder Actuator6 7

Supply

Exh.Out 1

5 4 Signal 2

3 10 11 12 9

Exh.Out 2

8

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Vibration Switch

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Lubrication System

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Lubrication System

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Maintenance Requirements

General InspectionsBlade Angle AdjustmentBlade Tip Clearance AdjustmentBearing Lubrication

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Maintenance Requirements

Vibration MonitoringFan Belt TensioningFan Belt Alignment

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General Inspections

24000 Hours - General Inspection and Cleaning90 Days Vibration Monitoring90 Days Belt Maintenance

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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

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Blade Tip Clearance Adjustment

Unscrew all the positioning boltsPull each blade out so that the head seatsfirmly against the internal rim of the hubassembly

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Vibration Monitoring

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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.

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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

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Fill Set Level Screw cavity with Silicone greaseandReplace cap

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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

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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

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Troubleshooting

Excessive VibrationImproper Louvre Operation

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Fan Vibration

Imbalanced BladeExcessive Blade Pitch VarianceMisalignmentWorn ComponentsResonanceStructural Integrity

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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

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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.

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Summary

ReviewQuestion and Answer Session


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LUBRICATION REQUIREMENTS

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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

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Main Topics

Define types of lubricants

OilGreaseISO and SAE specifications

Distinguish the difference between grease andoilDiscuss the hazards of mixing differentlubrications

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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

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Introduction to Lubrication

Why use lubricants?

Reduce FrictionIncrease Cooling

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Lubrication Functions

Form a lubricant film between components.Reduce the effect of frictionProtect against corrosionSeal against contaminantsCool moving parts

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Lubrication

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Friction

Grease and oil lubricate the moving parts of amachineGrease and oil reduce friction, heat, and wear ofmoving machine parts

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Oil = Low Friction and Heat

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No Oil = High Friction and Heat

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Lubrication Prevents Failure of:

BearingsGearsCouplingsPumps

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Lubrication Prevents Failure of:

Engine componentsHydraulic pumpsGas and Steam TurbinesAny moving parts

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Lubricants prevent failure by:

Inhibiting rust and corrosionAbsorbing contaminatesDisplacing moistureFlushing away particles

201


Can lubricants cause damage?

YES!!THE WRONG LUBRICANT CAN CAUSEMACHINE FAILURE!

202

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Introduction


Lubricant SelectionOperating temperatureLoadSpeedEnvironmentGrease LubricationOil Lubrication

203


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

204

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Page 102


Introduction


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


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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Page 103


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


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

RWD

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Introduction


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


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


Consistency

Fundamental principleThickenerOperating temperatureMechanical conditionsLow temperature effectHigh temperature effect

212

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Introduction


Grease Lubrication

Thickening agentPropertiesWhere used

213


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


Grease Selection Factors

Load conditionSpeed rangeOperating conditionsTemperature conditionsSealing efficiencyExternal environment

215


Oil Types

Two types of lubrication oil are:Mineral-basedSynthetic

216

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Page 108


Introduction


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


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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Introduction


Mineral-Based Oil

Paraffinic Base

Higher viscosity index (>95cs)Higher pour pointVery resistant to changes in viscosity index andoxidationThicken at low temperatures

219


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


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


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


Lubricant Specifications

ISO = International Standards Organization

SAE = Society of Automotive Engineers

224

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Introduction


ISO Lubricant Specifications

ISO Grade lubricants are for industrial use.ISO specifications exist for lubricants inextreme industrial environments.

225


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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Introduction


Using Different Lubricants

Why do we use different lubricants?What happens if oils are mixed?

227


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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Introduction


Mixing Lubricants

Loss of corrosion protectionPoor water separationFoamingThermal instability

229


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

Page 115


Introduction


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



100L

Yearly

Fire Water JockeyPump



.5L

Yearly

Fire Water JockeyPump Motor

Esso Unirex N3

Chevron SRIGrease 2

50g

2 Years


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


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


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


234

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Introduction


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


MEA-708 A1/2/3 oil coolerdrive

ShellAlvania R3

Chevron SRIGrease 2


235


Fundamentals of Lubrication

Equipment lubrication

BearingsGearsCouplingsPumpsEngine componentsHydraulic pumps

236

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Introduction


Lubricant Delivery Methods

Force Feed LubricantOil MistConstant CirculationOil SlingerZerk FittingsSurface Application (brush or spray)

237


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


Oil Mist Lubrication

This method keeps rotating machinery operatingeffectively for extended time periods.

239


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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Introduction


Benefits - Oil Mist Lubrication

Bearing failures reducedLubricant consumption reduce by 40%Equipment runs cooler Saves energyContaminants are excludedMore efficient lubrication

241


Constant Circulation

A Constant Circulation system re-circulates oil ina closed system like your heart circulates bloodin your body.

242

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Page 121


Introduction

Lubrication Check ExampleHandgreasesquare slideshaft andworm shaft(Monthly)1 to 2pumps pershaft of(MobilXHP222)


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)


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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Introduction


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


Surface Application

Sometimes lubricants are painted on with abrush, sprayed from an aerosol can, or wipedonto the part.

246

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Introduction


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


Lubricant Storage Factors

TemperatureLightWaterParticulate ContaminationAtmospheric ContaminationOil Separation

248

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Introduction


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


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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Introduction

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


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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Introduction


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


Summary



254

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Page 127


Introduction

BEARINGS

255


IntroductionPurpose

of a bearingFriction bearingAntifriction bearing

256

RWD

Page 128


Introduction

BearingsBasics of Rotating Industrial Equipment

SEPARATOR/CAGEBALLROLLER

Ball Bearing

Roller Bearing

Sleeve Bearing

257


Sleeves and JournalsFriction

bearingsJournal and SleeveLubricationRotational SpeedHighest friction point.

258

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Introduction


Balls and RollersRolling

contact bearingsStarting frictionCages/SeperatorsLubrication

259


Anti-Friction Bearing Types

Tapered RollersSpherical RollersNeedle Rollers

Ball Rollers

Cylindrical Rollers

260

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Introduction


Thrust Bearings

261

Ball Thrust Bearing

Spherical Roller

Roller Thrust Bearing

Tapered Roller


Bearing LoadsThrust LoadRadial Load

262

RWD

Page 131


Introduction


Example of LoadsThrust Load

TaperedRollerBearingsRadial Load

263


Bearing Contact

Ball

Roller

264

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Page 132


Introduction


Tapered Roller Bearings

265


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


Types of Failure

Spalling.Fretting.

Spalling on inner ring

267


Types of Failure

Brinelling

268

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Page 134


Introduction


Types of Failure

VibrationElectric Currents.

Pitting from largeelectrical current.False Brinelling

269


Types of Failure - Misalignment

270

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Page 135


Introduction

Bearing LubricationBasics of Rotating Industrial Equipment

All bearings need lubrication to preventmetal-to-metal contact between components.Lubrication PracticesToo Much LubricationInadequate LubricationSmearing

271


Summary



272

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Page 136


Introduction

SEALS

273


Major Topics

SealsSeal TypesDry Gas SealsLabyrinth SealsFirewater Pump Packing SealsSupport Systems Seal FlushingTroubleshooting

274

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Page 137


Introduction


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


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


Introduction


Gland Packing

Used in Firewater pumpsFluid not toxic or flammableLeak rate not critical

277


Mechanical Seals

Fluid is Toxic or FlammableLeak rate is critical

278

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Page 139


Introduction


Gland Packing

DescriptionApplicationAdvantagesDisadvantagesOperation

279


Gland Packing

AdjustmentNutSeal Flush

Pump CasingGlandFollower

Packing

Lantern RingShaft

280

RWD

Page 140


Introduction


Gland Packing

281


Mechanical Seals

Pusher SealsBellows Seals

MetalElastomer

Cartridge Seals

282

RWD

Page 141


Introduction


Advantages

Advantages

Extremely low leakage rates can be attained withproper selection and implementationReduced Preventative Maintenancerequirements with proper selection andimplementation

283


Pusher Seal

284

RWD

Page 142


Introduction


Pusher Seal

285


Bellows Seals

286

RWD

Page 143


Introduction


Bellows Seal (Elastomeric)

287


Bellows Seal (Elastomeric)

288

RWD

Page 144


Introduction


Bellows Seal (Metallic)

289


Bellows Seal (Metallic)

290

RWD

Page 145


Introduction


Cartridge Seals

291


Cartridge Seals

292

RWD

Page 146


Introduction


General Terminology

Rotating SealStationary SealBalanced SealUnbalanced Seal

293


Stationary Seal

294

RWD

Page 147


Introduction


Unbalanced

295


Balanced

296

RWD

Page 148


Introduction


Dry Gas Seals

DescriptionLocationMaintenance

297


Dry Gas Seal

298

RWD

Page 149


Introduction


Description

299


Gas Seal Description

300

RWD

Page 150


Introduction


Labyrinth Seals

DescriptionLocationMaintenance

301


Description

302

RWD

Impeller

Shaft

InternalLabyrinth Seals

Page 151


Introduction

Firewater Pump DiagramBasics of Rotating Industrial Equipment

Seal flush

Gland packing

Lantern ring

303


Packing Construction

Lattyflon 2790AL

PTFE ImpregnantedPolyacrylic YarnsSilicone Lubricant

304

RWD

Page 152


Introduction


Packing Replacement

305


Packing Replacement

306

RWD

Page 153


Introduction


Packing ReplacementPacking

Dummy shaft

307


Packing Replacement

45

308

RWD

Page 154


Introduction


Mechanical Seal Service

Flowserve Single Pusher Cartridge Seal Type CSCPX

309


Support Systems - Seal Flush

DescriptionMaintenance

310

RWD

Page 155


Introduction


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


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

RWD

Page 156


Introduction


Flush Plansinlet

Plan 11

Seal endview

orifice

313

Flush PlansBasics of Rotating Industrial Equipment

Plan 21

inletCoolantout

Seal endvieworifice

Temperaturesensor

coolerCoolantin

314

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Page 157


Introduction


Flush Plansinlet

Plan 31Seal endview

Cycloneseparator

315


Cyclone Separator

316

RWD

B. To mechanical seal

A.Dischargein

C. Return to pump suction

Page 158


Introduction


Quenching

317

FlushQuench

Impeller endStationaryfaceGland gasketgroove

Fixed throttlebushing

Drain


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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Page 159


Introduction


Other Support Systems

CoolingPressurization

319


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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Introduction

Overview of Seal FailuresBasics of Rotating Industrial Equipment

Loss of Face LubricationBellows crackingCorrosion

321


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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Page 161


Introduction


Causes of Seal Failures

Review Operating DataReview Maintenance History

323



Inspect Mechanical Condition

324

RWD

Page 162


Introduction



Inspect Mechanical Seal

325


Seal Chamber

Causes for a reduction in sealchamber pressureCauses for a temperature increaseat the seal faces

326

RWD

Page 163


Introduction


Summary



327

ALIGNMENT

328

RWD

Page 164


Introduction


Major Topics

Alignment OverviewMethods of AlignmentUse of the Rotalign Pro SystemAlignment of Simple Driver/Load SystemsSoft FootAlignment of Equipment TrainsSheave AlignmentAlignment TroubleshootingThermal Growth

329


Alignment Overview

Reasons for Proper Alignment

TimeCostEffort

330

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Page 165


Introduction


Alignment Terminology

Offset

Side View

Motor

Vertical

Pump

Top View

Motor

331

Horizontal

Pump


Alignment Terminology

Angularity

Side View

Motor

Vertical

Pump

Top View

Motor

Horizontal

Pump

332

RWD

Page 166


Introduction


Methods of Alignment

Straight Edge

Dial Indicator

Laser Alignment

333


Dial Indicator

Rim Alignment

Side View

Motor

RWD

Pump

Top View

Motor

334

Vertical

Horizontal

Pump

Page 167


Introduction


Dial Indicator

Face Alignment

Side View

Motor

Vertical

Pump

Top View

Motor

Horizontal

Pump

335


Dial Indicator

Bar Sag

336

RWD

Page 168


Introduction


Dial Indicator Caution: If the Coupling faces appearas below, it will be necessary to replace

337


Laser Alignment

338

RWD

Page 169


Introduction


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


Internal Misalignment

340

RWD

Page 170


Introduction


Soft Foot

Causes

Bent legs/feetDeformed shimsDirt or debrisStrain from attached componentsMachine frame distortion

341


Soft Foot

Effects

VibrationStrain and DeformationBearing Wear/DistortionPremature Equipment Failure

342

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Page 171


Introduction


Soft Foot - Types

Parallel Air Gap

343


Soft Foot - Types

Bent

344

RWD

Page 172


Introduction


Soft Foot - Types

Squishy

345


Soft Foot - Types

Induced

Strain

InducedSoft Foot

346

RWD

Page 173


Introduction


Soft Foot Detection

Dial Indicator

Parallel

Angular

Soft Foot

347


Soft Foot Detection

Feeler Gauges

348

RWD

Page 174


Introduction


Soft Foot DetectionTypical Soft FootReadings

0

0

0

1525

25

10

8

256

25

5

25

12

0

25

349


Soft Foot

Soft Foot Correction

Parallel

Angular

Soft Foot

350

RWD

Page 175


Introduction


Step Shimming

351


Sheave Alignment

352

RWD

Page 176


Introduction


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



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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Introduction



Solution:

Replace the machine shaft if necessaryConsult the equipment manufacturer

355



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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Introduction



Bolt Bound

Affect on Alignment

Motor will not move far enough to bring the motor and pumpback into alignment

357



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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Introduction



Bolt Bound

Bolts in improper position

Pipe Strain

Re-position machine on SkidCorrect Piping mis-alignment

Wrong Motor / Pump

Replace Incorrect Part

359



Coupling Lateral Clearance

Cause:

Wrong CouplingImproper machine positionExcessive Axial Shaft movement

360

RWD

Page 180


Introduction



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


Thermal GrowthSide View

Motor

Top View

Motor

362

RWD

Pump

Pump

Page 181


Introduction


Summary



363

VIBRATION ANALYSIS

364

RWD

Page 182


Introduction


Course Objectives

Define the need for analysisDefine the cause and effects of equipmentvibrationState how vibration is measured

365


Introduction

Method to detect and control the mechanicalcondition of rotating equipment.

366

RWD

Page 183


Introduction


What is vibration?

Motion of a machine from rest.Method to detect and control the mechanicalcondition of rotating equipment.Vibration amplitude.Vibration facts.

367


VibrationVibration is the mechanical oscillation or motionabout a reference point of equilibrium- Violin string- Rotating machinery

368

RWD

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Introduction


Vibration

Vibratory system includes:

Spring or ElasticityMass or InertiaExternal Force

50 mm

1.2 m

369


Oscillatory MotionExternal force causes thesystem to oscillate as thespring stores andreleases energy50 mm

1.2 m

pAO

A sin wAw

=w

2

370

RWD

Page 185


Introduction


VibrationVibrations may:

Repeat (reciprocating machinery)Occur at specific times (impact)

371


Repetitive Vibrations

The period of repetition may be measured asfrequencyMost equipment vibrations occur between 10 and2000Hz

372

RWD

Page 186


Introduction


Normal Vibrations

Machines will have a characteristic vibrationsignature during normal operation20

G PK0

-200

T

0.80000

373


Resonance

The resonance combines with the naturalfrequency of the system resulting in an amplifiedvibration. This can lead to destruction.

Example: Bridge resonance

374

RWD

Page 187


Introduction


Effects of Machine Vibration

Efficiency lossWear accelerationMachine failurePersonnel injury

375


Source of Equipment Vibration

Normal motion of machine operationUnbalanced partsWorn bearingsLoose mountingExternal impact

376

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Page 188


Introduction


Causes of Unbalance

Deposit

Introduction to Rotating Equipment Maintenance

Documents

auxiliary equipment

equipment operation

defective orbroken equipment

rwd page

unsafe practices

safety needs

safety devices

unsafe conditionsunsafe