Troubleshooting Rotating Machinery

Process machines are critical to the profitability of processes. Safe, efficient and reliable machines are required to maintain dependable manufacturing processes that can create saleable, on-spec product on time, and at the desired production rate. As the wards of process machinery, we wish to keep our equipment in serviceable condition. One of the most challenging aspects of a machinery professional or operator's job is deciding whether an operating machine should be shut down due to a perceived problem or be allowed to keep operating. If he or she wrongly recommends a repair be conducted, the remaining useful machine life is wasted, but if he or she is right, they can save the organization from severe consequences, such as product releases, fires, costly secondary machine damage, etc. This economic balancing act is at the heart of all machinery assessments. Troubleshooting is part science and part art. Simple troubleshooting tables or decision trees are rarely effective in solving complex, real-world machine problems. For this reason, the authors want to offer a novel way to attack machinery issues that can adversely affect the reliability and efficiency of your plant processes. The methodology presented in this book is not a rigid "e;cook book"e; approach but rather a flexible and dynamic process aimed at exploring process plant machines holistically, in order uncover the true nature the problem at hand.

Process machines are critical to the profitability of processes. Safe, efficient and reliable machines are required to maintain dependable manufacturing processes that can create saleable, on-spec product on time, and at the desired production rate. As the wards of process machinery, we wish to keep our equipment in serviceable condition.One of the most challenging aspects of a machinery professional or operator's job is deciding whether an operating machine should be shut down due to a perceived problem or be allowed to keep operating. If he or she wrongly recommends a repair be conducted, the remaining useful machine life is wasted, but if he or she is right, they can save the organization from severe consequences, such as product releases, fires, costly secondary machine damage, etc. This economic balancing act is at the heart of all machinery assessments.Troubleshooting is part science and part art. Simple troubleshooting tables or decision trees are rarely effective in solving complex, real-world machine problems. For this reason, the authors want to offer a novel way to attack machinery issues that can adversely affect the reliability and efficiency of your plant processes. The methodology presented in this book is not a rigid "cook book" approach but rather a flexible and dynamic process aimed at exploring process plant machines holistically, in order uncover the true nature the problem at hand.

Preface xiAcknowledgements xv1 Troubleshooting for Fun and Profit 11.1 Why Troubleshoot? 101.2 Traits of a Successful Troubleshooter 132 An Insight in Design: Machines and Their Components Serve a Function 192.1 An Overview of the Design Process 302.2 Complex Machine Element Environments 343 Machinery Design Issues and Failure Modes 373.1 Common Failure Modes 443.1.1 Pluggage 453.1.2 Erosive Wear 453.1.3 Fatigue 463.1.4 Compressor Blade Fatigue Example 473.1.5 Bearing Failure 493.1.6 Rubbing 503.1.7 Unique Failure Modes 504 Machinery in Process Services - The Big Picture 535 Causes Versus Symptoms 615.1 Causal Chains 665.2 Summary 716 Approach Field Troubleshooting Like a Reputable News Reporter 737 The "What" Questions 777.1 What is the Problem or What Are the Symptoms? 787.2 What Is Your Assessment of the Problem? 807.3 What Is at Stake? 857.4 What Risk Is at Hand? 867.5 What Additional Information Is Required? 878 Who Knows the Most About the Problem? 919 When Do the Symptoms Show Up? 979.1 "When" Questions to Ask 1009.2 Ways to Display Time Related Data 1019.3 Timelines 1029.4 Trend Plots 1069.5 Constant Amplitude Trends 1109.6 Step Changes 1109.7 Gradual Versus Rapidly Changing Trends 1119.8 Correlations 1139.9 Speed-Related Issues 1149.10 Erratic Amplitude 11710 Where Do the Symptoms Show Up? 12110.1 Locating a Machine-Train Problem 12210.2 Troubleshooting Problems Involving Multiple Machine-Trains 12810.3 Multiple Versus Single Machine Train Examples 13010.4 Analyzing Noises, Pings, and Knocks 13210.5 Seeing the Light at the End of the Tunnel 13511 Why Is the Problem Occurring? 13711.1 Fitting the Pieces Together 13911.2 Reciprocating Compressor Example 14211.3 Troubleshooting Matrices 14311.4 Assessing Machine with Multiple Symptoms 14412 Analyze, Test, Act, and Confirm (Repeat as Needed) 14712.1 The Iterative Path to the Final Solution 15013 Real-World Examples 15513.1 Case Study #1 15513.1.1 Closing Comments 15813.2 Case Study #2 15813.2.1 Closing Comments 16313.3 Case Study #3 16313.3.1 Closing Comments 17013.4 Case Study #4 17013.5 Case Study #5 17413.5.1 Closing Comments 17914 The "Hourglass" Approach to Troubleshooting 18114.1 Thinking and Acting Globally 18615 Vibration Analysis 18715.1 Vibration Analysis Primer 18815.2 Identifying Machine Vibration Characteristics 20116 Applying the 5Qs to Rotordynamic Investigations 20716.1 Introduction 20816.1.1 Rotordynamics: A Brief Overview 20816.2 Using Rotordynamic Results for Troubleshooting 21316.3 Closing 22217 Managing Critical Machinery Vibration Data 22717.1 Vibration Analysis Strategies 23018 Closing Remarks 23518.1 Practice the Method 23518.2 Provide Training on Fault Trees and Cause Mapping 23618.3 Employ Team Approach for Complex Problems 23618.4 Get Management's Support 237Appendix A: The Field Troubleshooting Process--Step by Step 239Appendix B: Troubleshooting Matrices and Tables 249Index 351