Cause Analysis by Pursuing the Cause-and-Effect Relationship 301 ing water has been demonstrated to cause the bearing outer ring to contract. The resulting increase in bearing preload will often reduce the bearing life expectancy. Similar distress may be introduced by moisture condensation attributable to cooling of air present in bearing housings. Deletion of cooling water is feasible if ISO Grade 68 or 100 mineral oils are chosen, Even better results have been obtained in installa- tions using oil mist lubrication or properly compounded synthetic oils of the diester and/or polyalpha-olefin variety, Many refineries have deleted cooling water from pumps with fluid temperatures around 740°F” Similarly, a large number of pump users have come to realize that water-cooled pump support pedestals represent a seri- ous liability at worst, and an unnecessary operating expense at best. Unforeseen cor- rosion incidents have led to the collapse of pedestals, in turn causing disastrous pump fires. Alignment of driver and driven shafts with predetermined offset values have proven fully satisfactory in every case. Assembly-induced bearing problems also deserve our attention. Rolling element bearings furnished with plastic cages can suffer damage when overheated in defec- tive heaters. They will be destroyed when heated by open flames, a practice observed on the assembly floor of a pump manufacturer in the 1980s! Do your main- tenance/technical work forces know which code letter identifies plastic cages? (Answer: P, for SKF bearings.) Do they know that the letter directly behind the bear- ing identification number identifies the load angle and that dimensionally inter- changeable angular contact bearings using the same number, but differing in just this one letter, may have allowable load ratings differing by a factor of 8-to-1? Com- pelling reasons for developing a purchase specification for your rolling element bearings and even more compelling reasons for workforce training! Troubleshooting Centrifugal Compressors, Blowers, and Fans Centrifugal compressors, blowers, and fans form the basic make-up of unspared machinery equipment in petrochemical process plants. Single, unspared centrifugal ‘compressor trains support the entire operation of steam crackers producing in excess of 1,000,000 metric tons (approximately 2.2 billion Ibs) of ethylene per year. When plants in this size range experience emergency shutdowns of a few hours’ duration, flare losses alone can amount to $400,000 or more. Timely recognition of centrifugal compressor troubles is therefore extremely important. Table 4-15 shows what is most likely to happen to a centrifugal compressor or blower. Table 4-16 presents a troubleshooting guide for centrifugal compressors and their lubrication systems. Similar guides may be constructed for other types of centrifugal machinery such as fans and blowers. Since Table 4-16 cannot possibly be all-encom- passing, refer to special sections in this book addressing such related topics as vibra- tion-causing syndromes and bearing, gear, and coupling failure analysis and trou- bleshooting,302 Machinery Failure Analysis & Troubleshooting Table 4-15 Typle: Distribution of Unscheduled Downtime Events for Major Turbocompressors in Process Plants ‘Approximate number of shutdowns per train per year: 2 Estimated Estimated Average Downtime Cause of Problem Frequency Hre/Event Events/Yr. = Hrs/Yr Rotor/shaft 2% 122 44 54 Instrumentation 21% 4 2 2 Radial bearings 13% 28 26 1 Blades/impelters 8% 10 16 18 Thrust bearings 6% 2 2 3 Compressor seals 6% 48 2 6 Motor windings 3% 200 06 2 Diaphragms 1% 350 2 7 Miscellaneous causes 20% 70 40 28 All causes, 100% 2.00 137 hours Table 4-16 Troubleshooting Guide—Centritugal Compressor and Lube System ‘Symptoms ‘Symptoms D Low Lube Oil Pressure| G Loss Of Disch. Pressure] Excessive Brg. Oil Drain Temp.E Compressor Surges kK Bixcessive Vibration Units Do Not Stay in Alignment F [ Water in Lube OT == G Possible Causes |#|A/B/C E|Fi\al# Possible Remedies Excenive Bearing 1 {3 1] * Replace bearings learance fiped Bearings 2 7 2| * Replace bearings E * Determine & correct 3 cause S @ \Rough Rotor Shaft |3 9 3.| * Stone or restore journals £ [Journal Surface * Replace shaft 3 & [Bent Rotor (Caused | 4 |8 4] * Turn rotor at low speed 5 [By Uneven Heating or until vibration stops, ten 2 \Cooling) gradually increase speed to operating speed. * If vibration continues, shut down, determine & correct the cause Possible Causes |# |A|B|C elFicl# Possible RemediesTable 4-16 (cont.) Machinery Troubleshooting 303 ‘Symptoms Symptoms Low Lube Oil Pressure] Loss Of Disch. Pressure] Excessive Brg. Oil Drain Temp.E ‘Compressor Surges] Units Do Not Stay in Alignment F Excessive Vibration| Water In Lube Oi 3 Possible Causes |# [A |B E[F[G]#] Possible Remedies lOperating In Critical | 5} 9 S| * Operate at other than [Speed Range critical speed [Build-Up of Deposits | 6 |10} 4 6 | * Clean deposits from rotor in Rotor * Check balance E |Build-Up Of Deposits |7] | 3 7| * Mechanically clean a lin Diffuser diffusers ® lUnbalanced Rotor [8 |11 8 | * Inspect rotor for signs of z rubbing 3 * Check rotor for g concentricity, cleanliness, loose parts 2 * Rebalance [Damaged Rotor 9 fiz 9.| * Replace or repair rotor * Rebalance rotor [Loose Rotor Parts |10|15 10| * Repair or replace loose parts [shaft Misalignment |11|5 11] * Check shaft alignment at operating temperatures 2 * Correct any misalignment S lDry Gear Coupling [12 [6 12| * Lubricate coupling 8 hom or Damaged [137 13] * Replace coupling |Coupting * Perform failure analysis Liquid “Stugging” [ia fia 14| * Locate & remove the source of liquid 2 5 * Drain compressor casing = of any accumulated liquids 2 & |Operating In Surge {15 [16 15] * Reduce or increase speed @ [Region until vibration stops = * Consult vibration analysis = guide g © Insufficient Flow ne} |i 16| * Increase recycle flow through machine Possible Causes |# [A |B e|F[G|#| Possible Remedies304 Machinery Failure Analysis & Troubleshooting Table 4-16 (cont.) ‘Symptoms ‘Symptoms Low Lube Oil Pressure| Loss Of Disch. Pressure] Excessive Brg. Oll Drain Temp. ‘Compressor Surges| Units Do Not Stay in Alignment F Excessive Vibration] Water in Lube Oi Gq Possible Causes [#[A|B|c[D|[E[F[a|#| Possible Remedios Change In System [17] | 2 17] * Check position of Resistance Due to inlet/discharge valves Obstructions or * Remove obstructions Improper Inlet or Disch. Valve Positions Compressor Not Up |18 1 18] * Increase to required ‘To Speed operating speed 5 Excessive Inlet 19 2 19] * Correct cause of high 5 Temperature inlet temperature 8 |Leak In Discharge [20 3 20] * Repair teak 2 Piping B | Vibration 21 1 21 | * Refer to “A” in symptom a column ° [Sympathetic Vibration |22] 4 22 | * Adjacent machinery can cause vibration even when the unit is shut down, or at certain speeds due to foundation or piping resonance. A detailed investigation is required in order to take corrective measures Improperly Assembled |23] 1 23] * Shut down, dismantle, Parts inspect, correct. Loose or Broken 24) 2 24] * Check bolting at support Bolting assemblies. * Check bed plate bolting * Tighten or replace * Analyze Assembly Piping Strain 25] 3 1] [25] * Inspect piping arrangements and proper installation of pipe hangers, springs, or expansion joints Bliclo|/elFlal# Possible Remedies Support System ey Possible Causes | # (table continued on next page)Machinery Troubleshooting 305 Table 4-16 (cont.) ‘Symptoms Symptoms Low Lube Oil Pressure] Loss Of Disch. Pressure| Excessive 6rg. Oil Drain Temp.E ompressor Surges] in Alignment F Excessive Vibration] Water in Lube Oil G Possible Causes |#]A|B|C|D||E/F/G|#| Possible Remedies |Warped Foundation or|26] 2| |26] * Check for possible E |Bedplate settling of the foundation 3 support ae * Correct footing as 5 required 2 * Check for uneven 3 temperatures surrounding the foundation causing [Faulty Lube Oil 27 1 [27] *Calibrate or replace [Pressure Gauge or Iswitch [Faulty Temperature |28 2 [28] * Calibrate or replace [Gauge or Switch [Oil Reservoir Low [29 By 29) * Add oil lLevel [Clogged Oil 30 5 30] * Clean or replace oil [Strainer/Filter strainer or filter cartridges i [Relief Valve 31 8 31 * Adjust relief valve limproperly Set or * Recondition or replace & |Stuck Open B|incorrect Pressure |32 9 32] * Check control valve for 5 |controt Valve Setting correct setting and Jon Operation operation Poor Oil 33 4 33] * Change oit \Condition/Gummy * Inspect and clean lube oil [Deposits On Bearings strainer or filter * Check and inspect bearings * Check with oil supplier to ascertain correct oil species being used Possible Causes _|# [a{B|c [0 Tete G Possible Remedies306 Machinery Failure Analysis & Troubleshooting Table 4-16 (cont.) ‘Symptoms ‘Symptoms o Low Lube Oil Pressure Loss Of Disch. Pressure] Excessive Brg. Oil Drain Temp.E B ‘Compressor Surges| Units Do Not Stay in Alignment F aA Excessive Vibration] Water in Lube Oi Gq Possible Causes |#[a|8|clo||e/F[G/#] Possible Remedies [Inadequate Cooling [34 34] * Increase cooling water |Water Supply supply to lube oil cooler * Check for above design cooling water inlet temperature [Fouled Lube Oil 35 35) * Clean or replace lube oil |Cooter cooler loperation at a Very |36 1 36] * Increase speed or operate lLow Speed Without aux. lube oil pump to [The Auxiliary Oil increase oil pressure Pump Running (If main L.O. pump is haft driven) g [Bearing Lube Oi 37 u 37] * Check to see that lube oil $ [Orifices Missing or orifices are installed and é Plugged are not obstructed I * Refer to lube oil system é schematic diagram for 8 orifice locations [Gi Pomp suaion fas 3 38] * Clear pump suction Plugged Leak In Oil Pump 39 4 39] * Tighten leaking suction Piping connections * Replace gaskets [Failure Of Both Main |40 6 40] * Repair or replace pumps \& Auxiliary Oil Pumps| |Oil Leakage ja 10 41] * Tighten flanged or threaded connections * Replace defective gaskets or parts [Clogged Or Restricted |42 42| * Clean or replace cooler [Oil Cooler Oil Side IE Possible Causes |# [A[B|c [D F[G/#| Possible Remedies {table continued on next page)Machinery Troubleshooting 307 Table 4-16 (cont.) ‘Symptoms Symptoms Low Lube Oil Pressure| Loss Of Disch. Pressure] Excessive Brg. Oil Drain Temp.E ‘Compressor Surges] Units Do Not Stay in Alignment F 7 Tn Lube Of Possible Causes |#|A|B|/C|D||E|F/G|#| Possible Remedies inadequate Flow Of [43 3 43| * Refer to “D” in symptom Lube Oil column * If pressure is satisfactory, check for restricted flow of lube oil to the affected bearings ater in Lube Oi (44 8 4a] * Refer to “G” in symptom column JLeak In Lube Oil 45, 1/45 * Hydrostatically test the {Cooler Tube(s) or tubes and repair as required [Tube Sheet * Replace zine protector rods (if installed) more frequently if leaks are due to electrolytic action of cooling water [Condensation in Oi1 [46 2|46| * During operation Reservoir maintain a minimum lube oil reservoir temperature of 120 deg. F to permit separation of entrained water * When shutting down, stop cooling water flow to oil cooler * Commission lube oil conditioning unit * Refer to lube oil management guide NOTE: Vibration may be transmitted from the coupled machine. To localize vibration, disconnect coupling and operate driver alone. This should help to indicate whether driver or driven machine is causing vibration. ElF|a|# Possible Remec Lube Oil System Possible Causes |#