Beruflich Dokumente
Kultur Dokumente
INDUSTRIAL EQUIPMENT
An Introduction to
Rotating Equipment
Maintenance
Objectives
Basics of Rotating Industrial Equipment
Equipment
Compressors
Fans,
Lubrication
Bearing
Seals
Alignment
Vibration
Analysis
Thermal Analysis
1.
2.
3.
4.
5.
6.
7.
5.
6.
7.
Safety Meetings
The
Accident Causes
10
Whenever
Unsafe Conditions
Unsafe Acts
Unsafe Conditions
11
Unsafe
Unsafe Acts
12
What
Hazard Awareness
13
The
Safety Meetings
Toolbox Meetings
Procedure Warnings and Cautions
System and Work Site Familiarity
14
15
Maintain
If
16
Beware
17
Do
18
Promptly
19
If
Leave
20
All
21
Bypassing
22
It
23
Be
24
25
Before
Signs
26
The
Prohibition Signs
27
28
Warehouses
materials
Explosion hazardous areas
Locations with toxic materials
Areas where different activities with flammable
materials are carried out
Mandatory Signs
29
Attention,
Warning Signs
30
Warning
signs mean
Caution
Risk of Danger
Hazard ahead
Warning
Safety Signs
31
First
32
Fire
Traffic Signs
33
Speed
Limit
It is prohibited to exceed the
speed specified on the sign
15
Traffic Signs
34
Pedestrian
Crossing
Traffic Signs
35
Priority
Fire Safety
36
Obey
Report
37
To
LOCKOUT
38
DISCONNECT SWITCH
LOCKOUT IF WORKING
ON CONTROL PANEL
OR ON ELECTRICAL
CONTROL CIRCUIT
INCOMING
POWER
LOCKOUT TERMS
39
LOCKOUT
LOCKOUT
DEVICE
ENERGY SOURCE
ENERGY ISOLATING DEVICE
SHALL
SHOULD
Definitions
40
Lock Definitions
41
Instrumentation/Electrical
Tagout Definitions
42
Tagout
Summary
43
Potential
Electrical Regulations
Electrical PPE
Safety Codes
Lock Out
Precautions
44
Personal
Definitions
45
Personal
Protective Equipment
Impervious Clothing and Gloves
Safety Equipment
46
Comply
47
Make
48
The
Hard Hat
Safety Glasses
Safety or Sturdy Shoes
Mini Filter in some areas
Head Protection
49
Hard
50
Face Shields
51
Face
52
Goggles
Hand Protection
53
Gloves
Glove Inspection
54
Impervious
Body Protection
55
Appropriate
Aprons
56
Aprons
Foot Protection
57
Employees
Definitions
58
Air
Line Respirator
Breathing Air Equipment
Cartridge Respirator
Face Piece-to-Face Seal
Hazard Assessment
Hazardous Atmosphere
Definitions
59
IDLH
Atmosphere
Qualitative Fit Test
Self Contained Breathing Apparatus (SCBA)
Single-Use Disposable Dust Respirator
Tolerance Test
Summary
60
Review
COMPRESSORS
61
Main Topics
62
Introduction
to compressors
Centrifugal
Reciprocating
Screw
Introduction
63
Compression
Gas Lift
Gas Gathering
Helium Recovery
Condensate Recovery
Transmission
Distribution
Types
64
Reciprocating
Centrifugal
Sliding
Vane
Rotary
Screw
Reciprocating Compressor
Suction
Valve
Piston Rod
Cylinder
Head
Cylinder
65
Piston
Discharge
Valve
SUCTION VALVE
DISCHARGE VALVE
66
DISCHARGE
Stages
67
68
Sliding Vane
Rotor
Inlet Port
Discharge
Port
Screw Compressors
69
Centrifugal Compressor
Fundamentals
70
Gas
flow path
Stage
Process stage
Velocity Energy to Pressure
Centrifugal Compressor
71
Gas Suction
Torque
Discharge
72
Axial,
or horizontally
split
Radial,
or
vertically split
JOINT
JOINT
JOINT
73
Surge
74
Surge
Causes/Effects of Surge
75
Restricted
Rotating
Face
76
Stationary
Face
Summary
Review
77
PUMPS
78
Course Objectives
79
At
Major Topics
80
Pumps
General
Positive Displacement Pumps
Centrifugal Pumps
Pumps
81
Types
Pumps
Gear Pumps
Piston Pumps
Plunger Pumps
Centrifugal - Overview
82
Screw
Pumps
Gear pumps
Piston pumps
Rotating gears
Centrifugal pumps
Screw Pumps
83
Screw
three-screw
two- screw
single-screw
Screw Pumps
84
INLET
INLET
OUTLET
OUTLET
Gear Pumps
85
External Gear
Internal Gear
Lobe
Counter-rotating gears
86
87
88
Piston Pumps
89
Piston
Pump Diagram
Major Component Review
Operation and Application
Maintenance and Troubleshooting
Piston Pump
90
Major Components
Basics of Rotating Industrial Equipment
Inlet
Check Ball
Cam Plate
Outlet
Check Ball
Outlet
Inlet
SUCTION
COMPRESSION
DISCHARGE
Drive Shaft
Pumping
Chamber
Spring
Piston
91
92
SUCTION
COMPRESSION
DISCHARGE
Plunger Pumps
93
Plunger
Pump Diagram
Major Component Review
Operation and Application
94
95
96
OUTLET CHECK
VALVE
LUBE INLET
LUBE OUTLET
PRIMER/REGULATING
ASSEMBLY
FRONT OF
RESERVOIR
INLET CHECK
VALVE
ROCKER
ARM
ASSEMBLY
CAM
Centrifugal Pumps
97
Centrifugal
Pump Diagram
Major Component Review
Operation and Application
Pump Laws
Centrifugal Pumps
Maintenance and Troubleshooting
Fundamentals
Impeller Vanes
Tongue
Eye
98
Volute
99
Sleeve/Coupling/Bearings
100
Shaft
Sleeve
Coupling
Bearings
Impeller Types
101
102
103
Valves
104
Single
105
High
Flow-rate requirements
Low Differential Pressure (Lift) requirements
Low Fluid Viscosity
106
Conversion
energy
Work on the fluid is performed by impeller and
Volute (higher flow, lower pressure) or Diffuser
(lower flow, higher pressure)
Centrifugal Flow
107
Centrifugal
flow
Mixed flow
Axial flow
108
Flow
Path
Precautions
Prevent Cavitation
Avoid Low Flow Conditions
Cavitation
109
Loss of capacity
Lowered Discharge Pressure
Lower Efficiency
Noise, Vibration, and Damage to Pump components.
Cavitation
110
Cavitation
is Caused by:
Vaporization
Air ingestion
Internal recirculation
Flow turbulence
Vane Passing Syndrome
Vaporization
111
Air Ingestion
112
Air
Turbulence
113
We
114
You
Pump Laws
115
Velocity
V flow N
Discharge
H pump N2
Pump
P pump N3
Pump Laws
116
Example:
N = 1450 RPM
V = 400 m3 / hr
H = 100 Barg
P = 45 kW
Summary
Review
117
TURBINES
118
Objectives
119
Define
Brayton Cycle.
Turbine Theory of Operation
Define major components used in a Gas Turbine
system.
Identify Gas Turbine auxiliary systems.
Define Gas Turbine Maintenance requirements.
Gas Turbine
120
Function
/ Purpose
Process Flow
Gas Turbine
121
Basic Configuration
Air
Compressor
Combustor
Turbine
Gas Turbine
122
Brayton Cycle
Basics of Rotating Industrial Equipment
123
124
Performance parameters
125
Speed
of rotation
Oil Temperature
Oil Pressure
Fuel gas pressure
Rotor axial displacement
Bearing vibrations
Exhaust temperature
Main Components
126
Turbine
Casing
Compressor Section
Combustion Chamber
Bearings
Turbine Rotors
Auxiliary Systems
Turbine Casing
127
Compressor Section
128
Combustion Chamber
129
Combustion
chamber
Axial
Compressor
Air inlet
130
Exhaust
Gas
H.P.
Shaft
Assy
L.P.
Shaft
Assy
Load
Combustor
131
Can-annular
Bearings
132
Turbine Rotors
133
Rotors/Buckets
Split
shaft design
Variable Nozzle
Rotors/Buckets
134
Variable Nozzle
135
Shutdown Sequence
136
Normal
Shutdown
Emergency Stop
Normal Shutdown
137
Emergency Stop
138
Can
Filters
139
Lube
oil filter
Fuel oil filters
Hydraulic supply filters
Air filters
Shutdown Maintenance
140
Major
Inspection
Borescope Inspections
Combustion Inspection
Hot Gas Path Inspection
Major Inspection
141
Turbine
Disassembly
Initial Alignment Checks
Component Inspections
Wear component replacement
Reassembly
Final Alignment Checks
Borescope Inspections
142
Overview
and Purpose
Summary
Review
143
144
Course Objectives
145
Define
Course Objectives
146
Discuss
Fan Safety
147
Rotating
Equipment
Elevation
High Temperature
H2S
LEADING
EDGE
148
Rotors
149
Fan Checks
150
151
Driver
152
Variable
Belts
153
HTD Belts
154
HTD Belts
155
Synchronous Belt
10.7 mm 14 mm Pitch
156
V-belts
V-Belt
Tensile Members
Matrix
157
Powerband V-belts
158
Powerband V
-Belt
Cog Belts
159
Cog Belt
(Side View)
Belt Alignment
160
Example
mis-alignment of belts
Belt Alignment
161
Four
Belt Tensioning
Too tight
Slight bow
Too loose
162
Changing Belts
163
Never
Bearing
164
Louvres
165
Louvres
166
Cylinder Actuator
167
6 7
Supply
Exh.
Out 1
5 4 Signal 2
3 10 11 12 9
Exh.
Out 2
Vibration Switch
168
Lubrication System
169
Lubrication System
170
Maintenance Requirements
171
General
Inspections
Blade Angle Adjustment
Blade Tip Clearance Adjustment
Bearing Lubrication
Maintenance Requirements
172
Vibration
Monitoring
Fan Belt Tensioning
Fan Belt Alignment
General Inspections
173
24000
174
175
176
177
Unscrew
Vibration Monitoring
178
179
Caution:
180
With
181
Fill
182
Review
183
Axial
Troubleshooting
184
Excessive
Vibration
Improper Louvre Operation
Fan Vibration
185
Imbalanced
Blade
Excessive Blade Pitch Variance
Misalignment
Worn Components
Resonance
Structural Integrity
186
Cylinder
signal
187
Cylinder
signal
Summary
Review
Question
188
LUBRICATION REQUIREMENTS
189
Objectives
190
Define
types of lubrication
Distinguish the difference between grease and oil
Discuss the hazards of mixing different
lubrications
Describe the proper handling of lubrication
Describe replacement of Lube Oil filters
Main Topics
191
Define
types of lubricants
Oil
Grease
ISO and SAE specifications
Distinguish
Main Topics
Describe
192
Contamination
Storage
Methods of application
Disposal
Describe
Filter redundancy
Flow characteristics,
DP = Differential Pressure
Replace with disposable cartridge
Introduction to Lubrication
193
Why
use lubricants?
Reduce Friction
Increase Cooling
Lubrication Functions
194
Form
Lubrication
195
Friction
196
Grease
197
198
199
Bearings
Gears
Couplings
Pumps
200
Engine
components
Hydraulic pumps
Gas and Steam Turbines
Any moving parts
201
Inhibiting
202
YES!!
THE
Lubricant Selection
203
Operating
temperature
Load
Speed
Environment
Grease
Lubrication
Oil Lubrication
Grease
204
Grease
Oil
205
Oil
206
How
oil is used:
207
Grease or Oil?
208
What
Viscosity
209
210
Viscosity
211
Consistency
212
Fundamental
principle
Thickener
Operating
temperature
Mechanical conditions
Low temperature effect
High temperature effect
Grease Lubrication
213
Thickening
agent
Properties
Where
used
214
Reduction
215
Load condition
Speed range
Operating conditions
Temperature conditions
Sealing efficiency
External environment
Oil Types
216
Two
Mineral-Based Oil
217
Mineral-based
hydrocarbons
Mineral-based oil has 2 types of base:
Naphtha Base
A
Paraffin Base
A
Mineral-Based Oil
218
Naphtha
Base
Mineral-Based Oil
219
Paraffinic
Base
Mineral-Based Oil
220
Mineral-based
synthetics.
Mineral-based oils can contain traces of
sulfur and nitrogen. These impurities can
cause oil to form sludge.
Synthetic Oil
221
Synthetic
Synthetic Oil
222
Synthetic
Synthetic Oil
223
Synthetic
oil is less flammable than mineralbased oil at low pressure. (Pressure causes
most oils to become more flammable)
Synthetic oils are generally more expensive
than mineral based oils
Lubricant Specifications
224
ISO
SAE
225
ISO
ISO Lubricants
226
ISO GRADE
32
46
68
100
Viscosity
40C
100C
30.4
5.2
43.7
6.6
64.6
8.5
30.4
5.2
Flash Point
222(432)
224(435)
245(473)
262(504)
-36(-33)
-36(-33)
-33(-27)
-30(-22)
C(F)
Pour Point
C(F)
227
Why
Mixing Lubricants
228
Consequences
are:
Change of viscosity
Stripping of machines internal coatings,
damage to seals
Reduced flash point, risk of fire
Mixing Lubricants
229
Loss
of corrosion protection
Poor water separation
Foaming
Thermal instability
230
Equipment
Specified Lubricant
Chevron
Equivalent
Consumption Rate
Service
Interval
ISO VG 32
GST ISO 32
Based on oil
analysis
Grease
negligible
1750 Hours
Grease
negligible
11500 Hours
Grease
negligible
3000 Hours
Grease
negligible
1000 Hours
231
Equipment
Specified Lubricant
Chevron
Equivalent
Texaco Ursatex
SAE 20/20W
.5L
Yearly
Esso Unirex N3
Chevron SRI
Grease 2
50g
2 years
Demineralised Water
Pump Motor
Texaco Ursatex
SAE 20/20W
100L
Yearly
Texaco Ursatex
SAE 20/20W
.5L
Yearly
Esso Unirex N3
Chevron SRI
Grease 2
50g
2 Years
232
Equipment
Specified Lubricant
Chevron
Equivalent
Consumption
Rate g/year
Service
Interval
Texaco
Multi-purpose
AP EP2
Chevron Dura-Lith
EP #2
200
Yearly
Shell Alvania G3
100
3 Years
Chevron
Delo 400 15W-40
100
3 Years
233
Equipment
Specified Lubricant
Chevron Equivalent
Service
Interval
Total Dacnis VS 32
4000 hours
73-MGC-9251 A/B
Bearings
Total MultiElf
4500 hours
73-MEA-9202A/B-01/02
Bearings
234
Equipment
Specified Lubricant
ISO VG 46
Shell
Alvania R3
Shell
Alvania R3
Monitor and
service if out of
spec
235
Equipment
Specified Lubricant
ISO VG 46
Shell
Alvania R3
Shell
Alvania R3
Monitor and
service if out of
spec
Fundamentals of Lubrication
236
Equipment
lubrication
Bearings
Gears
Couplings
Pumps
Engine components
Hydraulic pumps
237
Force
Feed Lubricant
Oil Mist
Constant Circulation
Oil Slinger
Zerk Fittings
Surface Application (brush or spray)
238
239
240
Centralized
241
Constant Circulation
242
243
Hand
grease
square slide
shaft and
worm shaft
(Monthly)
1 to 2
pumps per
shaft of
(Mobil
XHP222)
Grease
support
wheel
bearings
(Quarterly)
1 to 2
pumps with
(Mobil
XHP222)
Check
Windup
Gear Boxes
(Quarterly)
Oil type
ISO360
(Mobil Gear
636)
Oil Slinger
244
Zerk Fittings
245
Zerk
Surface Application
246
Sometimes
Pump System
247
248
Temperature
Light
Water
Particulate
Contamination
Atmospheric Contamination
Oil Separation
Storage - Temperature
249
250
Light
Storage - Contamination
251
252
Oil
253
Product
Shelf Life In
Years
Base Oils
5+
Lube Oils
(Mineral or Synthetic)
Greases
(Mineral or Synthetic)
Rust Preventatives
Summary
Review
Question
254
BEARINGS
255
Introduction
256
Purpose
of a bearing
Friction bearing
Antifriction bearing
Bearings
Basics of Rotating Industrial Equipment
SEPARATOR/CAGE
BALL
ROLLER
Ball Bearing
Roller Bearing
Sleeve Bearing
257
258
Friction
bearings
Journal and Sleeve
Lubrication
Rotational Speed
Highest friction point.
259
Rolling
contact bearings
Starting friction
Cages/Seperators
Lubrication
Tapered Rollers
Spherical Rollers
Needle Rollers
Ball Rollers
260
Cylindrical Rollers
Thrust Bearings
261
Spherical Roller
Tapered Roller
Bearing Loads
262
Thrust Load
Radial Load
Example of Loads
Thrust Load
Tapered
Roller
Bearings
Radial Load
263
Bearing Contact
Ball
264
Roller
265
266
Types of Failure
267
Spalling.
Fretting.
Types of Failure
268
Brinelling
Types of Failure
269
Vibration
Electric Currents.
270
Bearing Lubrication
271
All
Summary
Review
Question
272
SEALS
273
Major Topics
274
Seals
Seal
Types
Dry Gas Seals
Labyrinth Seals
Firewater Pump Packing Seals
Support Systems Seal Flushing
Troubleshooting
Purpose
275
Shaft
Shaft
276
Packing
chamber or
box
Packing
rings
Gland follower
or stuffing
gland
Gland Packing
277
Used
in Firewater pumps
Fluid not toxic or flammable
Leak rate not critical
Mechanical Seals
278
Fluid
is Toxic or Flammable
Leak
rate is critical
Gland Packing
279
Description
Application
Advantages
Disadvantages
Operation
Gland Packing
280
Adjustment
Nut
Seal Flush
Pump Casing
Gland
Follower
Packing
Lantern Ring
Shaft
Gland Packing
281
Mechanical Seals
282
Pusher
Seals
Bellows Seals
Metal
Elastomer
Cartridge
Seals
Advantages
283
Advantages
Pusher Seal
284
Pusher Seal
285
Bellows Seals
286
287
288
289
290
Cartridge Seals
291
A
F
B
C
D
Impeller
End
E
Cartridge Seals
292
General Terminology
293
Rotating
Seal
Stationary Seal
Balanced Seal
Unbalanced Seal
Stationary Seal
Basics of Rotating Industrial Equipment
End Plate
294
Rotating
Impeller
End
C
D
Stationary Seal Design
Unbalanced
U nbalanced
P ressure
A tm osphere
295
Balanced
296
B alanced
P ressure
B alanced
S houlder
A tm osphere
297
Description
Location
Maintenance
298
Description
299
300
Labyrinth Seals
301
Description
Location
Maintenance
Description
Impeller
Shaft
Internal
Labyrinth Seals
302
Lantern ring
303
Gland packing
Packing Construction
304
Lattyflon
2790AL
PTFE Impregnanted
Polyacrylic Yarns
Silicone Lubricant
Packing Replacement
305
Packing Replacement
306
Packing Replacement
Packing
Dummy shaft
307
Packing Replacement
308
45
309
310
Description
Maintenance
Flushing
311
312
LPG,
Flush Plans
313
Plan 11
inlet
Seal end
view
orifice
Flush Plans
Basics of Rotating Industrial Equipment
314
Plan 21
inlet
Coolant
out
Seal end
view
orifice
Temperature
sensor
cooler
Coolant
in
Flush Plans
315
Plan 31
inlet
Seal end
view
Cyclone
separator
Cyclone Separator
316
B. To mechanical seal
A.
Discharge
in
Quenching
317
Flush
Quench
Impeller end
Stationary
face
Gland gasket
groove
Fixed throttle
bushing
Drain
Water Quenching
318
319
Cooling
Pressurization
Pressurization
320
321
Loss
of Face Lubrication
Bellows cracking
Corrosion
322
Corrosion
323
Review
Operating Data
Review Maintenance History
324
Inspect
Mechanical Condition
325
Inspect
Mechanical Seal
Seal Chamber
326
Causes
Summary
Review
Question
327
ALIGNMENT
328
Major Topics
329
Alignment
Overview
Methods of Alignment
Use of the Rotalign Pro System
Alignment of Simple Driver/Load Systems
Soft Foot
Alignment of Equipment Trains
Sheave Alignment
Alignment Troubleshooting
Thermal Growth
Alignment Overview
330
Reasons
Time
Cost
Effort
Alignment Terminology
331
Offset
Side View
Motor
Vertical
Pump
Top View
Motor
Horizontal
Pump
Alignment Terminology
Angularity
Side View
Motor
Pump
Top View
Motor
332
Vertical
Horizontal
Pump
Methods of Alignment
333
Straight Edge
Dial Indicator
Laser Alignment
Dial Indicator
334
Rim
Alignment
Side View
Motor
Vertical
Pump
Top View
Motor
Horizontal
Pump
Dial Indicator
Face
Alignment
Side View
Motor
Pump
Top View
Motor
335
Vertical
Horizontal
Pump
Dial Indicator
336
Bar Sag
337
Dial Indicator
Caution: If the Coupling faces appear
as below, it will be necessary to replace
Laser Alignment
338
Soft Foot
339
Any
Internal Misalignment
340
Soft Foot
341
Causes
Bent legs/feet
Deformed shims
Dirt or debris
Strain from attached components
Machine frame distortion
Soft Foot
342
Effects
Vibration
Strain and Deformation
Bearing Wear/Distortion
Premature Equipment Failure
343
344
Bent
345
Squishy
346
Induced
Strain
Induced
Soft Foot
Indicator
Parallel
Angular
Soft Foot
347
348
Feeler Gauges
25
15
25
25
25
25
12
25
8
10
349
Soft Foot
Soft
Foot Correction
Parallel
Angular
Soft Foot
350
Step Shimming
351
Sheave Alignment
352
Alignment Troubleshooting
Shaft
Cause:
Weight
of Coupling
Shaft Run out
Test:
Use
Caution:
353
Deflection
Alignment Troubleshooting
354
Solution:
Alignment Troubleshooting
355
Solution:
Alignment Troubleshooting
356
Shaft
Deflection (Continued)
Affect on Alignment
Alignment
coupling
No indication what the alignment will be while the machine is
in operation
Alignment Troubleshooting
357
Bolt
Bound
Affect on Alignment
Motor
will not move far enough to bring the motor and pump
back into alignment
Alignment Troubleshooting
358
Bolt
Bound
Alignment Troubleshooting
359
Bolt
Bound
Pipe Strain
Correct
machine on Skid
Piping mis-alignment
Incorrect Part
Alignment Troubleshooting
360
Coupling
Lateral Clearance
Cause:
Wrong
Coupling
Improper machine position
Excessive Axial Shaft movement
Alignment Troubleshooting
361
Solution:
Loosen the Shaft grub screws and move the coupling flange(s)
as necessary to establish the correct clearance
If excessive shaft axial play was present, repair the cause for this
play.
Consult the equipment manufacturer
Thermal Growth
Side View
Motor
Top View
Motor
362
Pump
Pump
Summary
Review
363
VIBRATION ANALYSIS
364
Course Objectives
365
Define
Introduction
366
Method
What is vibration?
367
Motion
Vibration
368
Vibration
Spring or Elasticity
Mass or Inertia
External Force
50 mm
1.2 m
369
Oscillatory Motion
External force causes the
system to oscillate as the
spring stores and
releases energy
50 mm
1.2 m
A
O
A sin w
=w
370
Vibration
371
Vibrations may:
Repetitive Vibrations
372
The
Normal Vibrations
Machines
G PK
0
-20
0
373
0.80000
Resonance
374
The
375
Efficiency
loss
Wear acceleration
Machine failure
Personnel injury
376
Normal
Causes of Unbalance
377
Deposit
and Build-Up
Corrosion and Wear
Eccentricity
Keys And Keyways
Clearance Tolerances
Misalignment
378
Parallel
Offset Misalignment
Angular Misalignment
Combination
Tolerances
Eccentricity
379
Vibration From:
380
Bent
Shafts
Faulty Anti-Friction Bearings
Faulty Journal Bearings
Belt Drive Problems
Bad Gears
Vibration Sensors
381
Sensors
Velocity Transducer
382
383
Axial Position
384
Key Phasor
385
Proximity Probes
386
387
Basics of Rotating Industrial Equipment
388
Basics of Rotating Industrial Equipment
Summary
Review
Question
389
THERMAL ANALYSIS
390
Introduction
391
Purpose
of thermal analysis
Types of equipment used
Antifriction bearing
Temperature Measurement
392
393
Bimetallic Thermometers
Back
Bi-metallic Spring
394
Bottom
Thermocouples:
395
DIGITAL THERMOMETER
74.0F
-20 TO 70
0 TO 160F
Thermographic Instruments:
396
249
397
398
399
400
401
402
403
404
405
Real
Apparent
I2R Loss
-increased Resistance
-load fluctuations
Emittance
Harmonics
Reflectance
Induced heating
Transmittance
Convection
Geometric Variations
Thermal capacitance
406
407
408
409
410
P = IR
Where P = Power and is the rate of
doing work or the rate at which heat is
produced. It can see from the equation
that the amount of thermal energy
produced is increased or decreased by
increasing or decreasing the current or
resistance.
412
414
415
Basics of Rotating Industrial Equipment
416
This hot bus stab to the back of the breaker represents an extremely
serious problem. Why?
First because of its location in the system. A failure here will typically
have significant consequences! Second, the heat appears to be
generated inside the breaker. This means the thermal pattern we see is
greatly diminished by comparison to the actual point of contact that is
inside the breaker. Lastly, the material we are looking at has a very low
emissivity, so if it looks at all warm or hot, it is extremely hot! This
type of problem should generally be checked and repaired immediately.
If this is not possible, it should be monitored closely until the next
repair opportunity.
417
418
419
Problem
Classification
Phase to Phase
Temperature Rise
Comments
Minor
1 - 10 C
Intermediate
10 - 30 C
Serious
30 - 70 C
Critical
above 70 C
420
421
Correction Factor
2
4
6
8
10
12
14
16
18
1.00
1.30
1.60
1.68
1.96
2.10
2.25
2.42
2.60
422
423
424
425
Harmonics problems
on circuit
426
427
Summary
Review
Question
428
PREVENTATIVE MAINTENANCE
429
Main Topics
430
Preventive
Maintenance Programs
Maintenance problems
Maintenance Problems
431
Wear
and tear
Careless or untrained personnel
Improper lubrication
Excessive loads and speeds
Incorrect alignment practices
Vibration
Prevention Troubleshooting
432
Troubleshooting
of a problem
The need to troubleshoot can be minimized by
an effective maintenance programs
Types of Maintenance
433
Preventative
maintenance
Condition based maintenance
Proactive maintenance
Failure history based maintenance
Preventive Maintenance
434
Condition Monitoring
435
Temperature
Vibration
Changes
in noise or sound
Visually observed changes and problems
Sound/Noise
436
Listening
Sound
Measurements
Preventative Maintenance
Preparations
437
Preparation
Precautions
438
439
Summary
Review
Question
440
FAULT RECOGNITION
441
Course Objectives
442
Identify
Main Topics
443
Predictive
Maintenance
Condition Monitoring
Predictive Maintenance
444
Predictive Maintenance
445
List
Condition Monitoring
446
Temperature
Vibration
Changes
in noise or sound
Visually observed changes and problems
Temperature
447
Surface
Temperature
Vibration
448
Screwdriver
Listen
Vibration
Probe
Sound/Noise
449
Listening
Sound
Measurements
Sight
Loose
Bearing
Housing
Loose
Bolts
Cracked
Housing
450
Seal
Problem
Leaking
Lubrication
451
Talk to operators
Ensure other system components are
working properly
Timing of symptoms
-Sudden symptoms indicate complete
failure of parts
-Gradual symptoms indicate gradual
wearing out of parts
Changes in pumps operating
characteristics
452
Loud
453
Abnormal
pressure Readings
Leakage from stuffing box
Leakage from casing flange
Lubricant leak from bearing housing
454
Bearing
Lubrication Leak
Bearings Damaged
Bearings Worn
Casing Flange Bolts Loose
Casing Flange Gasket Worn
Casing Wearing Ring Damaged
Casing Wearing Rings Worn
Cavitation
Discharge Strainer Clogged
455
Excessive
Vibration
Overheating
Summary
Review
Question
456