Design, Modeling and Reliability in Rotating Machinery

✍ Scribed by Robert X. Perez (editor)

• Publisher: Wiley-Scrivener
• Year: 2022
• Tongue: English
• Leaves: 367
• Edition: 1
• Category: Library

✦ Synopsis

Design, Modeling, and Reliability in ROTATING MACHINERY

This broad collection of current rotating machinery topics, written by industry experts, is a must-have for rotating equipment engineers, maintenance personnel, students, and anyone else wanting to stay abreast with current rotating machinery concepts and technology.

Rotating machinery represents a broad category of equipment, which includes pumps, compressors, fans, gas turbines, electric motors, internal combustion engines, and other equipment, that are critical to the efficient operation of process facilities around the world. These machines must be designed to move gases and liquids safely, reliably, and in an environmentally friendly manner. To fully understand rotating machinery, owners must be familiar with their associated technologies, such as machine design, lubrication, fluid dynamics, thermodynamics, rotordynamics, vibration analysis, condition monitoring, maintenance practices, reliability theory, and other topics.

The goal of the “Advances in Rotating Machinery” book series is to provide industry practitioners a time-savings means of learning about the most up-to-date rotating machinery ideas and best practices. This three-book series will cover industry-relevant topics, such as design assessments, modeling, reliability improvements, maintenance methods and best practices, reliability audits, data collection, data analysis, condition monitoring, and more.

This first volume begins the series by focusing on rotating machinery design assessments, modeling and analysis, and reliability improvement ideas. This broad collection of current rotating machinery topics, written by industry experts, is a must-have for rotating equipment engineers, maintenance personnel, students, and anyone else wanting to stay abreast with current rotating machinery concepts and technology.

Design, Modeling, and Reliability in Rotating Machinery covers, among many other topics:

• Rotordynamics and torsional vibration modeling
• Hydrodynamic bearing design theory and current practices
• Centrifugal and reciprocating compressor design and analysis
• Centrifugal pump design, selection, and monitoring
• General purpose steam turbine sizing

✦ Table of Contents

Cover
Half-Title Page
Series Page
Title Page
Copyright Page
Dedication
Contents
Preface
Acknowledgements
Part 1: Design and Analysis
1 Rotordynamic Analysis
Introduction
Rotor Vibration – General Physical Concepts
Rotor Vibration – Mathematical Description
Natural Frequencies and Resonance
Critical Speed Analysis
Phase Angle, and Its Relationship to Natural Frequency
Gyroscopic Effects
Accounting for Bearings
Cross-Coupling Versus Damping and “Log Dec”
Annular Seal “Lomakin Effect”
Fluid “Added Mass”
Casing and Foundation Effects
Lateral Vibration Analysis Methods for Turbomachinery and Pump Rotor Systems
Manual Methods Single Stage
Computer Methods
Forced Response Analysis:
Mechanical Excitation Forces
Balance
Fluid Excitation Forces
Impeller Reaction Forces
Impeller Active Forces
Rotordynamic Stability
Subsynchronous Whirl & Whip
Stabilizing Component Modifications
Vertical Turbine Pump Rotor Evaluation
Conclusions
Nomenclature
Acknowledgements
References
2 Torsional Analysis
Introduction
General Concerns in the Torsional Vibration Analysis of Pump and Turbomachinery Rotor Assemblies
Predicting Torsional Natural Frequencies
Torsional Excitations
Torsional Forced Response
Case History
Conclusions
Nomenclature
Acknowledgements
References
3 Hydrodynamic Bearings
API Mechanical Equipment Standards for Refinery Service
Bearings
Hydrodynamic Lubrication
Tower’s Experiments
Reynolds Equation
Stribeck Curve
Journal Bearings
Dynamic Coefficients
Tilting Pad Journal Bearings
Pivot Types
Lubrication Methods
Thrust Bearings
A Note on Thrust Bearing Diameters
Fixed Geometry Thrust Bearings
Pivot Types
Lubrication
Increasing Load Capacity
Babbitt
Polymer-Lined Bearings
Current and Future Work
References
4 Understanding Rotating Machinery Data Trends and Correlations
Pattern Recognition
Static Versus Dynamic Data
Trends
Flat Trends
Trends with Step Changes
Upward and Downward Trends
Cyclic Trends
Is It the Machine or the Process?
Correlations
“Correlation Does Not Imply Causation”
Combination Trends
Exponential Growth Trends
Erratic Trends
5 An Introduction to Sizing General Purpose Steam Turbines
Why Do We Use Steam Turbines?
How Steam Turbines Work
Steam Generation
Waste Heat Utilization
The Rankine Cycle
General Purpose Steam Turbine Sizing
General Purpose, Back Pressure, Steam Turbines
Single Stage Back Pressure Steam Turbine
Sizing Procedure
Closing Comments
6 Making the Business Case for Machinery Upgrades
Payback Time Examples
Closing Thoughts
Part 2: Compressors
7 Selecting the Best Type of Compressor for Your Application
Example of How to Convert from SCFM to ACFM
Compressibility Factor (Z)
Compressor Selection Example
Summary
Addendum
Demystifying Compressor Flow Terms
Ideal Gas Law
Examples of How to Convert from SCFM to ACFM
Visualizing Gas Flow
Compressibility Factor (Z)
8 Compressor Design: Range versus Efficiency
Introduction
Critical Parameters/Nomenclature
Operating Requirements
Critical Components
Impellers
Inlet Guides
Diffusers
Return Channels
Other Components
Aerodynamic Matching
Stage Components
Stage to Stage
Operating Conditions
Movable Geometry – Optimizing Range and Efficiency
Concluding Remarks
Disclaimer
Acknowledgements
References
9 Understanding Reciprocating Compressor Rod Load Ratings
Introduction
Basic Theory
Gas Loads
Piston Rod Loads
Crosshead Pin Loads
Crankpin Loads
History of “Rod Loads”
Glossary of Terms
User’s Perspective
Performance Study to Evaluate Compressor Re-Rate
Combined Load Exceeds Gas Load
Distorted Pressure Measurements = Distorted Rod Loads
Conclusions
Reference
10 How Internal Gas Forces Affect the Reliability of Reciprocating Compressors
Gas Loads
Non-Reversing Gas Loads
Non-Reversing Rod Conditions Matrix
Non-Reversing Gas Load Examples
“One Failure from Disaster”
Ways to Protect Your Compressor
Closing Remarks
Robert Akins
Acknowledgements
Part 3: Pumps
11 Should You Use a Centrifugal Pump?
Net Positive Suction Head NPSH
Ways to Increase the Margin Between the NPSHa and the NPSHr
Summary
12 Practical Ways to Monitor Centrifugal Pump Performance
Why Use Centrifugal Pumps?
Head Versus Pressure
Centrifugal Pump Performance
Assessing Centrifugal Pump Performance
Summary
Addendum
Determining the Best Two-Parameter Analysis Method for a Centrifugal Pump
13 Using Electric Motor Horsepower to Protect Centrifugal Pumps Operating in Parallel Flow Applications: A Case Study
The Problem
Solution
Results
Conclusions
Addendum
A Simplified Method of Determining the Efficiency of a Motor-Driven Centrifugal Pump
The Traditional Analysis Method
A Simplified Alternative Assessment Method
Example
14 Mechanical Seals and Flush Plans
Recommendations for Optimizing the Service Lives of Mechanical Seals
Liquid Properties
Expected Seal Cavity Pressure
Sealing Temperature
Liquid Characteristics
Reliability and Emission Concerns
Single or Double Seal?
Seal Flush Plans
Parting Advice
About the Editor
About the Contributors
Index
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