Troubleshooting Rotating Machinery – Including Centrifugal Pumps and Compressors, Reciprocating Pumps and Compressors, Fans, Steam Turbines,

<p>Preface xi</p>
<p>Acknowledgements xv</p>
<p>1 Troubleshooting for Fun and Profit 1</p>
<p>1.1 Why Troubleshoot? 10</p>
<p>1.2 Traits of a Successful Troubleshooter 13</p>
<p>2 An Insight in Design: Machines and Their Components Serve a Function 19</p>
<p>2.1 An Overview of the Design Process 30</p>
<p>2.2 Complex Machine Element Environments 34</p>
<p>3 Machinery Design Issues and Failure Modes 37</p>
<p>3.1 Common Failure Modes 44</p>
<p>3.1.1 Pluggage 45</p>
<p>3.1.2 Erosive Wear 45</p>
<p>3.1.3 Fatigue 46</p>
<p>3.1.4 Compressor Blade Fatigue Example 47</p>
<p>3.1.5 Bearing Failure 49</p>
<p>3.1.6 Rubbing 50</p>
<p>3.1.7 Unique Failure Modes 50</p>
<p>4 Machinery in Process Services The Big Picture 53</p>
<p>5 Causes Versus Symptoms 61</p>
<p>5.1 Causal Chains 66</p>
<p>5.2 Summary 71</p>
<p>6 Approach Field Troubleshooting Like a Reputable News Reporter 73</p>
<p>7 The What Questions 77</p>
<p>7.1 What is the Problem or What Are the Symptoms? 78</p>
<p>7.2 What Is Your Assessment of the Problem? 80</p>
<p>7.3 What Is at Stake? 85</p>
<p>7.4 What Risk Is at Hand? 86</p>
<p>7.5 What Additional Information Is Required? 87</p>
<p>8 Who Knows the Most About the Problem? 91</p>
<p>9 When Do the Symptoms Show Up? 97</p>
<p>9.1 When Questions to Ask 100</p>
<p>9.2 Ways to Display Time Related Data 101</p>
<p>9.3 Timelines 102</p>
<p>9.4 Trend Plots 106</p>
<p>9.5 Constant Amplitude Trends 110</p>
<p>9.6 Step Changes 110</p>
<p>9.7 Gradual Versus Rapidly Changing Trends 111</p>
<p>9.8 Correlations 113</p>
<p>9.9 Speed–Related Issues 114</p>
<p>9.10 Erratic Amplitude 117</p>
<p>10 Where Do the Symptoms Show Up? 121</p>
<p>10.1 Locating a Machine–Train Problem 122</p>
<p>10.2 Troubleshooting Problems Involving Multiple Machine–Trains 128</p>
<p>10.3 Multiple Versus Single Machine Train Examples 130</p>
<p>10.4 Analyzing Noises, Pings, and Knocks 132</p>
<p>10.5 Seeing the Light at the End of the Tunnel 135</p>
<p>11 Why Is the Problem Occurring? 137</p>
<p>11.1 Fitting the Pieces Together 139</p>
<p>11.2 Reciprocating Compressor Example 142</p>
<p>11.3 Troubleshooting Matrices 143</p>
<p>11.4 Assessing Machine with Multiple Symptoms 144</p>
<p>12 Analyze, Test, Act, and Confirm (Repeat as Needed) 147</p>
<p>12.1 The Iterative Path to the Final Solution 150</p>
<p>13 Real–World Examples 155</p>
<p>13.1 Case Study #1 155</p>
<p>13.1.1 Closing Comments 158</p>
<p>13.2 Case Study #2 158</p>
<p>13.2.1 Closing Comments 163</p>
<p>13.3 Case Study #3 163</p>
<p>13.3.1 Closing Comments 170</p>
<p>13.4 Case Study #4 170</p>
<p>13.5 Case Study #5 174</p>
<p>13.5.1 Closing Comments 179</p>
<p>14 The Hourglass Approach to Troubleshooting 181</p>
<p>14.1 Thinking and Acting Globally 186</p>
<p>15 Vibration Analysis 187</p>
<p>15.1 Vibration Analysis Primer 188</p>
<p>15.2 Identifying Machine Vibration Characteristics 201</p>
<p>16 Applying the 5Qs to Rotordynamic Investigations 207</p>
<p>16.1 Introduction 208</p>
<p>16.1.1 Rotordynamics: A Brief Overview 208</p>
<p>16.2 Using Rotordynamic Results for Troubleshooting 213</p>
<p>16.3 Closing 222</p>
<p>17 Managing Critical Machinery Vibration Data 227</p>
<p>17.1 Vibration Analysis Strategies 230</p>
<p>18 Closing Remarks 235</p>
<p>18.1 Practice the Method 235</p>
<p>18.2 Provide Training on Fault Trees and Cause Mapping 236</p>
<p>18.3 Employ Team Approach for Complex Problems 236</p>
<p>18.4 Get Management s Support 237</p>
<p>Appendix A: The Field Troubleshooting Process Step by Step 239</p>
<p>Appendix B: Troubleshooting Matrices and Tables 249</p>
<p>Index 351</p>