Requireinents Specification

37

ments are often achieved at the expense of mechanical reliability. Specifically, tight labyrinth clearances may indicate high test-stand efficiency, but they are also prone to cause mechanical contact during operational upsets. Should this happen, the user is not only losing a fair measure of compressor efficiency, but is also running the risk of mechanical damage. Extra capacity looks good in light of future uprate potential, but it may cost in terms of requiring large recycle streams to avoid compressor surge during initial operation of the compressor. Similar concerns exist for centrifugal pumps operating at flows substantially below their best efficiency point (BEP). This element is further explained in Chapter 2, Selecting Major Machinery Vendors. In todays energy-conscious production and procurement environment, strong contractual safeguards are recommended. In virtually all cases, the user must be prepared to pay the cost of certified and witnessed performance tests. If these tests are to be conducted in the field, it is important for vendor and purchaser to agree beforehand on test-equipment types, test-equipment location, and applicable test procedures to be followed.

Assessing First Cost Versus Maintenance Cost

Typical maintenance costs for major equipment installed and operated in the continental United States are given in Chapter 4, Benchmarking Maintenance and Reliability. We have arranged the text in this sequence because maintenance costs generally tend to emerge into real focus after the plant has started up. However, from the point of view of the engineer who specifies machinery or selects machinery from among several competing offers, the future cost of maintenance should be of concern now. An example will illustrate why this is significant. Let us assume a plant can satisfy a given compression service by using either a single electric-motor-driven centrifugal compressor sized for 100% capacity, or three gas-engine-driven reciprocating compressors sized for 50% capacity. The process engineers, cost estimators, and project engineers have developed data showing the foundation requirements, plot-plan arrangement, piping complexity, and utility costs for the two different approaches. Their balance sheet reflects the principal elements and is given in Table 1-2. The initial judgment might favor integral gas-engine reciprocating compressors for this service. However, the picture may change when we apply current maintenance statistics for motor-driven centrifugal compressors and integral gas-enginedriven compressors, Table 1-3, and project these costs over the next few years. The importance of paying attention to future maintenance cost is further illustrated in Chapter 5, dealing with life-cycle costs studies.
Specifying Machinery Documentation Requirements

Safe operation, proper surveillance, and cost-optimized maintenance of machinery requires that a good deal of machinery-related data be available and made accessible

38

Improving Machinery Reliability

Table 1-2 C o s t Analysis for Compression Systems

Motor-Driven Centrifugal
Horsepower input Piping system Foundation 3-year cost of power Barrel compressor Reciprocating compressor Driver and gear Switchgear Fuel-supply facilities Total
9200 k5760 404 14904 2464 -

Three Gas-Engine Driven Reciprocating Compressors

7400 (2 machines running) k$ I384 1390 11888

4440
Included/NA

I582
400 k520.5 14

400 k$19,502

Maintenance: See Table 1-3 or use plant data New Total

to the plant's technical staff in advance of plant startup. Machinery data and documentation packages often arrive too late to contribute to a successful plant startup. Machinery then has to be commissioned, maintained, or repaired without proper guidance and with inadequate planning. Startup planning also involves installation completeness reviews." These reviews are critically important in the chain of pre-commissioning events leading to successful startup. They must be executed by following a checklist-type outline which allows the reviewer to ascertain that all installation-related items defined in the job specification have been furnished or executed. Unless the reviewer is following a written checklist, the installation completeness review may be hit-and-miss, and startup delays or costly failures could result. Finally, there is documentation which is, indeed, needed only after the plant is on stream. However, this documentation, too, should be obtained before the equipment vendor is paid his final retention payment. Attempts to gather up the data sometime later have often proven to be expensive, frustrating, or unsuccessful. Based on actual experience, it is concluded that project teams should be given the responsibility of obtaining these data. Representing the owner of the plant, the project team may elect to have the design contractor put equipment vendors under contractual obligation to provide important data on time and in usable format. What Each Machinery Data File Should Contain Efficient and accurate repair and troubleshooting of machinery requires good documentation. Also, it is important that plant maintenance and technical service personnel are given ready access to this documentation, be it in paper or electronic format.
*For coiiiprehensive information on this topic, see Bloch and Geitner, hfrodtctiori fo Mrrchirtery Relinhilify Assessnienf, 2nd ed. Houston: Gulf Publishing Company.

Requirements Specification

39

Table 1-3 Estimated Average Maintenance Cost for U.S. Process Plants (1997)
Electric Motors * Mean time between failures: 50 operating months * Average overall maintenance cost for plants with 50,000-150,000 installed motor horsepower: $2.75/hp/yr Centrifugal Pumps Mean time between failures: 56 operating months (good plant) Average cost of shop materials and labor, exclusive of field, technical support, and overhead charges for plants with 50,000 to 150,000installed motor horsepower: $9.70/hp/yr Probable actual cost of average pump repair, exclusive (inclusive) of burden, field labor, and technical support expenses: $2000/event ($9000/event) Motor-Driven Reciprocating Compressors in Clean Service * Mean expenditure: $9.20/hp/yr, in approx. 1000 hp size machines $20.00/hp/yr, in approx. 300 hp size machines Motor-Driven Reciprocating Compressorsin Severe Service
* Mean expenditure: $25.00/hp/yr, over 1000 hp size machines

$37.90/hp/yr, up to 1000 hp size machines

Integral Gas-Engine Reciprocating Compressors For plants with installed total horsepower in the 10,000 to 30,000 hp range: $45,00/hp/yr Motor-Driven Centrifugal Compressor Trains (Clean Service) Average overall maintenance cost for plants ranging from 60,000-1 80,000 installed hp: $6.40/hp/yr
9

Steam Turbine-Driven Centrifugal Compressor Trains * Average overall turbomachinery train maintenance cost for plants ranging from 60,000- 180,000 installed hp: $9.20/hp/yr
Gas Turbines Average overall maintenance cost: $13,lO/hp/yr, 4-10 gas turbines, gas-fired, 6,000-18,000 hp range $lO.OO/hp/yr, 4-10 gas turbines, gas-fired, 25,000 hp and higher
0

Gas Turbine-Driven Centrifugal Compressor Trains Average overall maintenance cost, trains in 40,000 hp range, natural gas-fired, clean compression service: $35/hp/yr

Diesel Engines Average overall maintenance cost, diesel engines only: $42/hp/yr

Experience slhows that major contractors and owners project engineers orient their initial data-collection efforts primarily toward construction-related documentation. As the project progresses, more emphasis is placed on obtaining design-related machinery documentation as listed in the appendixes of API specifications for major machinery. These requirements are generally understood by contractors and machinery manufacturers. Before the project is closed out, this collection of data is assembled in many volumes of mechanical catalogs.

40

Improving Machinery Reliability

Unfortunately, data collection using API guidelines alone does not result in a complete data package or in an adequate data format. Moreover, data collection in itself does not automatically provide plant maintenance and technical personnel ready access to all pertinent machinery data. This is where machinery data-file folders and their electronic equivalents fit in. Machinery data-file folders, manual, as shown in Figure 1-25, or computer-based as available from CMMS (Computerization Maintenance Management System) suppliers, should contain nine key items:

1. Installation, operating-surveillance, and maintenance instructions. These could be instruction manuals routinely available from equipment vendors, or instruction sheets and illustrations specially prepared for a given machine. All of this information is generally intended to become part of the plants equipment reference data library. However, some specific instructions may also be required for field posting.

( ) 1.
( ) 2. ( ) 3.

MACHINERY DATA FILES I n s t a l l a t i o n , Operating, & Maintenance Manual ( I n s t r u c t ions) S p e c i f i c a t i o n Sheet Cross Sectional Drawings ( i f n o t included i n Mafntenance Manual) O u t l i n e (Dimensional), e t c .

( ) 4. ( ) 5.
( ) 6.
( ) 7.

B i l l o f M a t e r l a l (complete p a r t s l i s t )
RPL (Required P a r t s L i s t ) by s t o r e s o r l o c a l vendor

- minimum t o be stocked

Performance Curve ( i f a p p l i c a b l e ) Mechanical Seal I n f o r m a t i o n (Drawings, e t c . ) Design Change Data Computer I n p u t Form
/
/

( ) 8.

( ) 9.

/
/

Figure 1-25. Machinery data files.

Requirements Specijication

41

For example, Figure 1-26 represents one of many steam-turbine latching and startup instructions that was developed for both purposes, that is, reference information and field-posted instructions. The vendor should be contractually obligated to prepare these and similar illustrated instructions. Figure 1-27 belongs in the surveillance data category. This tabulation provides key input for vibration spectrum analysis techniques that are an indispensable troubleshooting tool for modern process plants. Again, the data should be provided by the equipment vendor before plant startup. Efforts to acquire this information after the equipment vendor has received full payment for machinery and services are usually quite costly and frustrating.
2. Equipment specification sheets, such as API data sheets and supplementary data used at time of purchase. 3. Cross-section drawings showing the equipment assembly. These drawings must be dimensionally accurate. Dimensional outline drawings should also be included. 4. Bill of materials or complete parts list identifying components and materials of construction.

ET-IIB STEAM TURBINE, LATCHING AND STARTUP INSTRUCTIONS

42

Improving Machinery Reliability

Figure 1-27. Machinery vibration spectrum analysis data.

5. Tabulation of minimum number of parts to be kept on hand by storehouse or local vendor. 6. Performance curve, if applicable. 7. Mechanical seal and seal-gland drawings, if applicable. 8. Design-change data. A typical design-change form is shown in Figure 1-28. It is used to document one of the many minor modifications which will inevitably be made after the machinery reaches the plant. This example shows a change which had to be implemented on oil-mist-lubricated motor bearings. After modifying the upper bearing retainer to provide oil mist flow through the bearing instead of past the bearing, the design-change form is placed in the file folder and a notation made on the front of the cover to let the user know how many design-change forms he should find inside. 9. Computer input forms. These forms should be given to the equipment vendor as part of the specification package for pumps, motors, and small steam turbines. Providing basic equipment data should be part of the vendor's contractual requirements. Some elements of a typical computer input form for pumps are highlighted in Figure 1-29. In addition to information given in the API data sheets, the equipment vendor must provide such important maintenance information as impeller and bushing clearances, manufacturing tolerances, and asbuilt internal dimensions. The computer input forms can serve as the nucleus of a computerized failure-report system for a given plant. As a minimum, properly

Requirements Specification

43

Figure 1-28. Rotating equipment correctionlchange.

Figure 1-29. Process equipment computer input form.

filled-in forms represent a databank of valuable maintenance and interchangeability information. Large petrochemical companies may derive additional benefits from using these computerized data sheets for intra-affiliate analyses of cominon~ality spare parts, etc. of

44

Improving Machinery Reliability

Major Machinery Turnaround Documentation

Efficient and effective future machinery maintenance should be planned at the inception of any given project. While this statement holds true in any industry, it takes on added importance in the petrochemical plant environment where downtime for unspared major machinery can cost staggering amounts of money. Assembly and disassembly procedures for machinery or critical machine subassemblies and tabulations of critical machine dimensions will have to be acquired well before turnaround maintenance can be performed. The logical time for defining and assembling all these data is prior to equipment delivery. The critical-dimension diagram shown in Figure 1-30 is typical of size and tolerance information which must be cataloged for axial as well as radial dimensions of turbomachinery rotors, bearings, seals, admission valves, governors, etc. Many of these data must be obtained during initial assembly of the equipment and cannot be retrieved once the machine leaves the manufacturers facilities. This makes it again appropriate to require the equipment vendor to carefully record these dimensions at initial assembly and to furnish these data to the contractor and ultimate owner before the machinery is commissioned at the plant.

A photographic record of machinery assembly and disassembly is of similar importance to process plants. Figure 1-31 depicts a random page taken from the illustrated reassembly manual developed for a large mechanical-drive steam turbine. Each step is documented both pictorially and in writing. A margin column lists the time it takes a designated maintenance crew to perform the task. The number in parentheses gives the cumulative total crew-hours expended.

TURNAROUND k WllHlLNANCE INFOIW\lION

ROTOR CLEAFANCEI
MACHINETAQNO

C-103 (Ethylene)

Figure 1-30. Turnaround and maintenance information: rotor clearances.

Requirements Specification
~

45

REASSEMBLY PROCEDURES
MACHINE TAQ NO.

FOR MAJOR H.P. STEAM TURBINES El-201 Propane Rdrigera~ion

hrs

(35) l'he low pressure side ceaing bolts are tightened with a h o m e r or extension wrench until the specified torque values are reached. Exhaust casing connection bolting must be loose before the horizontal joint bolts are tightened. Only then can the attaching bolts be tightened.

3
IbZ)

(36) Inspection before assembling the governor-aide bearing. After cleaning the upper bearing housing, the bearing liner la fitted, and plastigage placed on the bearing liner.
OAT
5/9/80

2
1bS)

FILE REFERENCE

MACHINERY RELIABILITY PROGRAM

M-80.4-C2Ol

Figure 1-31. Reassembly procedures for major HP steam turbines. Illustrated instructions of this type also serve as training material for personnel involved in turnaround execution. A copy of the manual belongs on the compressor deck for the duration of the machinery turnaround. Its conscientious use cannot help but reduce the risk of oversights and delayed restarts of major machinery. This illustrated manual is also highly useful to planners whose detailed turnaround scheduling

46

Improving Machinery Reliability

efforts will become more precise if actual times-to-perform-tasks are catalogued in this fashion. Fully illustrated assembly and disassembly manuals are often routinely furnished by first-class overseas machinery manufacturers. There should be ample incentive for reputable vendors to express willingness to make similar instructions available to interested users. By the same token, project staff representing the ultimate owner of large, unspared turbomachinery should arrange for these illustrated manuals to be produced.
Spare Parts Identification Sheets

Most major contractors are experienced in advising their clients on recommended levels of spare parts procurement. These recommendations are generally reviewed and translated into a spare parts warehousing system that assigns to all spares such data as symbol numbers, reordering information, bin location, etc. Among etc., we found quality-control information most helpful. Critical spare parts are identified with code letters indicating that the users inspectors should check the parts at the point of origin or upon receipt at the users warehouse. This procedure is bound to reduce the number of unpleasant surprises reported by petrochemical plants embarking on major tnachinery turnaround only to discover that spare parts errors were about to delay completion of machinery turnarounds. Spare parts identification sheets differ from conventional spare parts documentation or traditional storehouse information in a number of ways. They are primarily intended as an aid to mechanics, machinists, and turnaround planners. These persons require that spare parts information be contained on a single sheet, not in separate catalogs or on computer printouts. In many cases, illustrations are required for positive identification of parts by personnel unfamiliar with either the machinery or the storehouse routine. To satisfy all of these needs, process plants should require machinery spare parts information to be displayed as shown in the spare parts documentation sheet represented in Figure 1-32. Major machinery spare parts documentation sheets must contain all the information needed by the mechanical work forces to locate the parts in the storehouse. These documentation sheets must allow mechanics, turnaround planners, and inspectors to verify stock levels, critical dimensions, and suitability of parts. Cross references and design-change and inspection information complete the sheet and make it a stand-alone, highly useful document.
Lubrication Data

Pertinent data on manual as well as automated equipment lubrication must be available well in advance of plant startup. Lubrication summaries are routinely prepared by the contractor and range in format from simply restating the original equipment manufacturers recommended lubricants to an intelligent consolidation of

.NOllVlN3Wfl30a S1YWd PYVdS AN3NIH3WW UOWW

48

Improving Machinery Reliability

7th S T R E E T E A S T /
7

BLOCK 7 AREA 0

0P - 6 A

0 -68 P
W
W

0 -

3
4 >

I3

m E

L 3 P-17A
P-178

Figure 1-33. Equipment lubrication plot plan.

EQUIPMEN1 L U B R l C A l I O N SUMMARY

LOCATION OATA/

LUBRICATION DATA

SCHEDULI I

REMRKS

(SPECIAL QUANTITY,
DIFFERENT LUBE REOUIREO INBOARD VS; OUTBOARD, ETC.)

Add Grease While Running Only

Replace O i l OnceIMonth
150 G a l l o n Capacity 150 G a l l o n Capacity

Y:

LUBRICANTS EN-100 = ENMIST-100

UX-2 = UNIREX-2 T-32 = T e r e s s t i c - 3 2 G-90 = Gear O i l - 9 0 SY-32 = Synesstic-32

APPLICATION

OM = O i l M i s t GG = Grease Gun GC = Grease C e n t r a l BO = B o t t l e O i l e r C I = C i r c u l a t i n g System

Figure 1-34. Equipment lubrication summary.

Requirements Specijkntion

49

Figure 1-35.Oil-mist lubrication summary.

installation Completeness Checklists

Rotating equipment has to be thoroughly checked out before it is ready for startup. These completeness checks, customarily called but-listing, will ensure that the actual installation complies with all applicable equipment specifications. For instance, on a motor-driven centrifugal pump, completeness checks would incEude installation-related items such as coupling alignment, baseplate grouting, seal flush piping, and lubrication, and exclude design-related items such as impeller diameters or seal material. An installation completeness checklist must be reviewed and finally signed off by the engineer, technician, or field inspector responsible for a given checkout task. This list should take the place of more superficial hit-and-miss review efforts that have traditionally resulted from verbal instructions and checkout from memory. The development of written installation completeness checklists should be handled by the engineering contractor or the owners project engineer. This task should not prove difficult because virtually every checklist item can be picked off the detailed job specifications used for a given project. Essentially, the task requires that these job specifications be reviewed item by item and that requirements dealing with field instulfufionof rotating machinery be transferred to the checklist in tabular format. An example will serve to illustrate how installation completeness checklists were developed for a major grassroots petrochemical project. Without these checklists, it would not have been possible to entrust completeness reviews to contract millwrights unfamiliar with the owners general practices and installation requirements.

50

Improving Machinery Reliability

For instance, the job specifications for centrifugal pumps were examined and construction elements relating to casings, seals, guards, strainers, piping, and pipe supports tabulated in checklist form. Whenever necessary for clarity, illustration, remarks, or sometimes cross references were added to the tabulations. These cross references would point to standardized small-bore (auxiliary) piping or standardized lubrication specifications, as shown in Figure 1-36. Similar installation completeness checklists were developed for general-purpose steam turbines, centrifugal fans, and equipment baseplates. In each case, the end product was an installation or construction-related tabulation that reduced the contractor's job specification to 10% or 20% of its initial bulk and restated only those

IN5TALLATIOFI COMPLETEIIEL;

R E V I E W FOR ROTATING
MACHINERY MACHINERY TYPE: TOPIC OF REVIEW: All L u b r i c a t i o n and Bearing Types

Page No. 1 0 1 5 Rev./Oate 0:3-2-79 Reference Stdnddrd: P l a n t Spec. Exclusions:

18-3.2

P-202. P - 3 2 3

The i l l u s t r a t i o n s used i n t h i s s e c t i o n cover b e a r i n g arrangement and l u b r i c a t f o n f o r F l e c t r i c motors, b u t t h e b e a r i n g types and p r i n c i p l e s a p p l y t o a l l o i l o r grease l u h r i i a t r d bearings. LUBRICATION

I.
2.

Ory Sump O i l M i s t L u b r i c a t i o n : Wet O i l Sump o r "Purge M i s t " : Grease L u b r i c a t e d Bearings:

S h a l l be a p p l i e d t o machinery w i t h r o l l i n q e l e m P n s x ings only. S h a l l be a p p l i e d t o machinery w i t h sleeve b e a r i n g s o n l y . Uhere s p e c i f i e d , s h a l l have accessible grease f l t t i n g s f o r standard grease guns. F i t t i n g s must be accessible r l t h o u t r e q u i r i n g removal o f guards or covers.

3.

ALL ROLLING ELEMENT BEARINGS

1.

A.

2.

Double s h i e l d e d b e a r i n g s s h a l l n o t be used w i t h d r y sump o i l m i s t lubrication. Double s h i e l d e d b e a r i n g s are n o r m a l l y used with grease l u b r i c a t e d b e a r i n g s . Double s h i e l d e d b e a r i n g s are i n d i c a t e d b y t h e b e a r i n g i d e n t i f i c a t i o n code l e t t e r s "PP" on e l e c t r i c motor nameplates. S i n l e s h i e l d e d b e a r i n s are s u i t a b l e f o r d r y sump o i l m i s t l u b r i c a t i o n on w y Loaaed ea?,n s . The h i e ded' i d e o f the b e a r i n g s h a l l be t u r n e d away from t h e m i s t cavxf.----~ k h l y l o ~ d e d ' m o t o f b e a r i n g s are i n d i c a t e d b y t h e b e a r i n g i d e n t i f i c a t i o n code l e t t e r s "lp" "" 8. S i n g l e s h i e l d e d b e a r i n g s are i n d i c a t e d b y t h e b e a r i n g i d e n t i f i c a t i o n code l e t t e r " P " o n e l e c t r i c motor nameplates. I n l e t and o u t l e t connections s h a l l be a t the t o p and bottom housing c o v e r .

B.

THRUST BEARINGS ONLY

I. Nan-Shield t h r u s t b e a r i n g s s h a l l be used w i t h d r y sump o i l m i s t l u b r i i a t i o z .

F A n t i f r i c t i o n t h r u s t b e a r i n g s are i n d i c a t e d b y the b e a r i n g i d e n t i f i c a t i v code ! e t t e r 5 BN. BA, BT. BS, BK, o r BG on e l e c t r i c motor nameplates. B. No l e t t e r s "P" are allowed i n t h e t h r u s t b e a r i n g i d e n t i f i c a t i o n code ri11 r.1ec.l-i~ ,rioter nameplates. A n t i f r i c t i o n t h r u s t b e a r i n g s s h a l l not be used as c o u p l i n g end b e a r i n g s on v e r t i c a l e!pcIt-i: motors d r i v i n g pumps i n hydrocarbon s e r v i c e . A. O i l m i s t i n l e t and vent connections on v e r t i c a l e l e c t r i c motors: S h a l l be u ~ r r n d n e n l l i marked w i t h l e t t e r punches. I f b e a r i n g s h i e l d s are removed i n order t o b r i n g equipment i n t o compliance w i t h any o f t h e above g u i d e l i n e s , t h e l e t t e r ( s ) "P" must be o b l i t e r a t e d from the b e a r i n g i d e n t i f i c a t i o n code on t h e motor nameplate.

2.

NOTE: -

Figure 1-36. Illustration completeness review for rotating machinery.

Requirenients Specification

51

Table 1-4 Machinery Documentation Summary*

Responsibility Submit to Owner Before

c
0

8
2
E

Document Title

Machinery data fill folder (All documents are to be submitted in both paper and electronic format) Installation, surveillance and maintenance instructions Special instructions and illustrations Commissioning instructions Machinery vibration analysis data Equipment specification sheets Dimensionally accurate cross sections Bill of materials Tabulation of minimum spares Performance curves Mechanical-seal tabulation Mechanical-seal and gland drawings Design change form Computer input form Critical dimension sketch Assembly/disassembly manual Spare parts identification sheet Lubrication plot plan Lubrication summary Oil-mist lubrication summary Installation comoleteness checklist
*This docuruetitdon shall be furtiistied by coritrnctor nrid/or veiidor urd is iri ndditioti l o ~Iociirneiifatiori reqiiirertierits itidicnterl in the lotest revisiori of qqdicable API Starirlnrds 610 ttirorrgh 686.

areas which field personnel could reasonably be expected to review and ascertain. However, the tabulation contained enough information in narrative or illustrated form to convey the full meaning of all relevant checkout tasks.
Conclusion

Relevant documentation as compiled in Table 1-4 must be made available to engineers, maintenance work forces, and technical service personnel responsible for costeffective, reliable operation of process plant machinery. The most appropriate time for acquiring this documentation is before the plant enters the startup phase. Documentation requirements written into the procurement specification are more likely fulfilled than documentation requests made at a later date.

52

Improving Machinery Reliability

In fact, Best-of-Class companies stipulate in their purchase orders that 10-1 5 percent of the negotiated cost of the entire order will be withheld until the vendor has provided all specified documents. Finally, the job of machinery engineers, maintenance workforces, and technical service personnel will be further facilitated and cost savings realized if requisite documentation is presented in useful paper or electronic format. The foregoing examples were found to represent this format in paper form.