Acknowledgements

This series is a result of interactions with literally thousands of dedicated

engineers, machinists, operators, vendors, contractors and students who
have been an integral part of my career.
I consider myself very fortunate to have been associated with the best of
the best mentors, business associates and dear friends throughout my
career. Most especially, in chronological order Dick Salzmann, Bob
Aimone, Merle Crane, Walt Neibel, the late Murray Rost, Mike
Sweeney and Jimmy Trice. Bob, Merle, Murray and Mike have
contributed specifically to the material in this series while Dick, Walt
and Jimmy have tactfully kept me on track when necessary.
Special thanks to all of the global machinery vendors who have allowed
me to use their material for my training manuals and now this
publication.
Last but certainly not least; my career would not have been possible
without the support, encouragement and assistance from my wife Doris
and our children Jennifer, Brian, Eric, Michael and Dara.
A special additional note of thanks to Michael who helped assemble the
material, and hopefully learned some in doing so, since he has elected
to pursue a career in rotating machinery.

XV
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 About the
author

Bill Forsthoffer began his life-time career in rotating machinery in 1962

with De Laval Turbine Inc. as a summer trainee. After obtaining a
Bachelor of Arts degree in Mathematics and Bachelor of Science degree
in Mechanical Engineering, during which time he worked for De Laval
part time in the Test, Compressor and Steam Turbine Departments, he
joined De Laval fiill time in the Compressor Engineering Department
in 1968. He was responsible for all phases of centrifugal compressor
component and auxiliary design and also made many site visits to
provide field engineering assistance for start up and problem resolution.
Bill joined Mobil Oil Corporate Engineering in 1974 and was
responsible for all aspects of rotating equipment specification, technical
procurement, design audits, test, field construction, commissioning,
start-up and troubleshooting.
After 15 years at Mobil, Bill founded his own consulting company in
1990 and has provided rotating equipment consulting services to over
100 companies. Services include: project reliability assurance, training
(over 7,000 people trained) and troubleshooting.
Bill is active in the industry as President of Forsthoffer Associates Inc.,
frequently writes articles for Turbo Machinery International Magazine
and conducts many site specific and public workshops each year.
He can be contacted at bill@forsthofferassociates.com

XVII
 DEDICATION

TO DORIS AND OUR CHILDREN

FOR THEIR TOTAL FAITH
IN MY ENDEAVORS
 Rotating
equipment
overview

Introduction
Definition of rotating equipment
Classifications of rotating equipment
Site equipment examples
Performance and mechanical design similarities
The equipment 'train' or 'unit'
Important fundamentals

Introduction

Take a minute and list all the different types and kinds of rotating
equipment you can think of. Even if you have not been involved with
rotating equipment for a long time, when you consider the types of
equipment that you come in contact with every day, your list will be
sizeable. Imagine if we pursued our objectives by looking at each
individual piece of equipment. You would never remember all the
aspects and the book would be long and very boring. We will not
attempt this approach. Rather, this section will divide all types of
rotating equipment into four major classifications. The function of each
individual classification will be defined. Throughout this book we will
cover many types of rotating equipment.
One good thing to remember is to always ask yourself what the
function of this particular type is, what does it do.^ We will find that
many aspects covered in this book will have the same common
function.
Our approach therefore, will be to observe the similarities in both
Principles of Rotating Equipment

performance and mechanical aspects of various types of equipment. We

will see that many of these relationships apply regardless of the type of
equipment that is considered.
Now think of any rotating equipment unit that you have come in
contact with and review that unit considering the different components
that comprise it. You will find that every unit of rotating equipment
consists of a driven machine, driver, transmission device and is
supported by auxiliary equipment. That is, each unit is made up of all
the classifications of rotating equipment that are described in this
section. This is an important fact to remember in troubleshooting
equipment. In essence then, each unit is a system.

Definition of rotating equipment

DEFINITION

Rotating equipment moves products

Products = solids, liquids, gases

Figure 1.1 Definition

Figure 1.1 presents a basic definition of rotating equipment.

As we shall see, there are different classifications of rotating equipment.
Regardless of the classification, rotating equipment moves product.
More properly stated:

Rotating equipment moves money!!

Stop the equipment and the source of revenue stops! This is a very
important fact to remember. If you want management to approve your
recommendation, you must be able to justify it economically! The form
of any recommendation to management should be as shown in Figure
1.2.
 Rotating Equipment Overview

A successful recommendation

Must state clearly and simply:

The problem
The problems' cost to the company (parts, labor and loss revenue)
The recommended solution
Its' cost
Proof that the solution will work (has it worked somewhere else?)
Savings to company by implementing proposed solution

Figure 1.2 A successful recommendation

If you proceed as shown in Figure 1.2 you will be able to obtain and
maintain management support. Remember, you can learn a great deal
in this book. However, if you cannot implement what you have learned
the information is totally useless to the company. If you cannot obtain
management support, you will never implement any action plan.

Classifications of rotating equipment

There are four (4) basic function classifications of rotating equipment.
Refer to Figure 1.3 which defines the classifications of rotating
equipment.

Classifications of rotating equipment

Driven
Drivers or prime movers (provide power)
Transmission devices
Auxiliary equipment

Figure 1.3 Classifications of rotating equipment

Figure 1.4 is a partial listing of some rotating equipment types grouped

according to fijnction.
Principles of Rotating Equipment

MaJ(3r types of rotating equipment

1. Driven equipment 11. Drivers - prime movers

A. Compressors A. Steam turbines
1. Dynamic 2 Positive displacement B. Gas turbines
Centrifugal Screw C. Motors
Axial Rotary lobe Induction
Integral Gear Reciprocating Synchronous
Diaphragm Vari-speed
Liquid Ring
D. Engines
B. Pumps Internal combustion
1. Dynamic 2. Positive displacement Diesel
Centrifugal Plunger Gas
Axial Diaphragm
Slurry Gear
Integral Gear Screw
Progressive cavity

C. Extruders
D. Mixers
E. Fans

III.Transmission devices IV.Auxiliary equipment

A. Gears A. Lube and seal systems
Helical B. Buffer gas systems
Double helical C. Cooling systems
B. Clutches
C. Couplings

Figure 1.4 Major types of rotating equipment

Site equipment examples

Following is an example of typical site rotating equipment.

Figures 1.5, 1.6, 1.7, 1.8 show examples of each rotating equipment
classification.
 Rotating Equipment Overview

Figure 1.5 High pressure centrifugal compressor (Courtesy of Dresser Rand)

Figure 1.6 Extraction - condensing steam turbine (Courtesy of MHI)

Principles of Rotating Equipment

Bolted Connections Diaphragm Pack Sub-assembiy

OD Bolts Spacer Bolts Diaphragm Pack (Shaded Area)

Rigid Hub

HP Series Coupling and Sub-assembly U.S. Patent No. 3,808,83"

Figure 1.7 Multiple, convoluted diaphragm-spacer coupling (Courtesy of Zurn Industries)

Figure 1.8 Horizontal oil console arrangement (Courtesy of Oltechnique

Performance and mechanical design similarities

During this book we will be examining many different types of rotating

equipment. However, the task will be a lot easier if we begin our study
by first focusing on the similarities of the equipment and then the
specific differences.
 Rotating Equipment Overview

As an example, we have chosen to first present pumps then compressors

as topics. As was just discussed, both pumps and compressors are driven
types of equipment and move product. Regardless of the product phase
or state, their functions are identical. Refer to Figure 1.9 which
compares dynamic pump and compressor performance.

Pumps and compressors

Both pumps and compressors move a fluid from one energy level to
another.
A pump moves an incompressible fluid - a liquid. For our purposes, the
volume of a liquid does not change with pressure and temperature.
A compressor moves a compressible fluid - a gas. The volume of a gas
changes with pressure, temperature and gas composition.
The principles of dynamic machines apply both to pumps and compressors.
However, since gases are compressible, the volume flow rate and hence the
gas velocity in a passage is affected.

Figure 1.9 Pumps and compressors

The same comments can be made concerning mechanical components.

Refer back to Figures 1.5 and 1.6 and ask are the functions of the
casings, internal seals, shaft end seals and bearings the same.^
Absolutely! A bearing performs the same ftinction whether it is in a
pump, compressor, gearbox, etc.
Figure 1.10 shows how both performance and mechanical ftinctions are
similar regardless of the classification or type of equipment.
Principles of Rotating Equipment

Classifications of rotating equipment

Driven Drivers Transmission Auxiliary

device system

P.D. P.D. P.D. P.D.

Dynamic Dynamic Dynamic Dynamic

Perf Perf Perf Perf Perf Perf Perf Perf

Mech Mech Mech Mech Mech Mech Mech Mech

Key: P.D. = Positive displacement

Perf = Performance design
Mech = Mechanical design

Figure 1.10 Classifications of rotating equipment

As we proceed through this book, we will discover that positive

displacement or dynamic performance principles will be the same
regardless of the type of equipment (pump, compressor or turbine).
Also, the mechanical principles presented for bearings, seals, etc. will
apply whether the component is in a pump, turbine, gear, etc.

The equipment 'train' or 'unit'

As stated, the objective is to learn the functions of equipment and

major components so that they can be effectively condition-monitored
to maximize site safety and reliability. Having defined the four (4)
classifications of equipment, how many of these classifications are
present in a pump unit or compressor train.^ ... All four (4)!!
Regardless of the type of unit or train, a driven, driver, transmission(s)
and auxiliary system(s) must always be present. When you are asked to
inspect G-301 or K-101 you are actually inspecting G-301 pump unit
or K-101 compressor train. Failure to recognize this fact will severely
limit your troubleshooting scope and ability.

8
 Rotating Equipment Overview

As an example, a call from the unit shift manager may state that G-301
discharge pressure is zero - what are possible causes? A few are:
• Process change
• Pump wear
• Coupling failure
• Pump shaft failure
• Driver shaft failure
• Pump or driver shaft seizure (no oil)
• Pump seal failure
• Process valve closed
• Steam inlet valve closed (if driver is a steam turbine)
Do you get the point! ... The entire unit or train, all four machinery
classifications must always be considered in rotating equipment design,
revamps and troubleshooting.

Important fundamentals
Before discussing specific facts concerning all the rotating equipment
on site, some important ftindamentals need to be presented. The
environment or surroundings for any piece of rotating equipment play
an important part in determining the availability of that particular item
(Refer to Figure 1.11).
This figure shows that the rotating equipment environment is the
process unit in which the equipment is installed. The surroundings of
the equipment will be defined early in the project. Proper design of
process conditions, piping and foundations, selection of other
components (drivers, transmission devices and auxiliaries) and proper
specification of ambient conditions all must be considered. If any of
these items are not taken into account, the end user of the equipment
will be faced with a history of an unreliable process and will pay dearly
in terms of lost product revenue.
Principles of Rotating Equipment

The rotating equipment environment

Process condition change

Piping and foundation change
'Unit' (driven, driver,
transmission, auxiliaries)
Ambient conditions

Figure 1.11 The rotating equipment environment

It is important to understand that the life span of rotating equipment is

extremely long compared to the specification, design and installation
phase. Refer to Figure 1.12. A typical installation will have a
specification design and installation phase of only approximately 10% of
the total life of the process unit. Improper specification, design or
installation will significantly impact the maintenance requirements,
maintenance cost and availability of a particular piece of machinery.

The life span of rotating equipment

IShip
Install
«-»-«|
1 ^'^'^ 1 Plant Preventive and Predictive
L
start-up iVIaintenance

1 1 i t 1
0 1 :> :) 10 20 30

Time—Years

® = Process Unit Turnaround

Figure 1.12 The life span of rotating equipment

10
 Rotating Equipment Overview

The objectives of the end user are shown in Figure 1.13.

The objectives

• Maximum reliability (on stream time)

r^
^^^ B.E.P.

• Maximum product throughput ^

• Minimum operating costs ^
g 100
UJ HI
oc oc
UJ 3 - ^
U. (/>
it (0

°s 100
% FLOW

Figure 1.13 The objectives

In order to maximize the profit, a piece of machinery must have

maximum reliability, maximum product throughput and minimum
operating cost (maximum efficiency). In order to achieve these
objectives, the end user must play a significant part in the project
during the specification and design phase and not only after the
installation of the equipment in the field. Effective field maintenance
starts with the specification phase of a project. Inadequate specifications
in terms of equipment operating conditions, mechanical design,
instrumentation and the location of the instrumentations will reduce
equipment availability.
The definitions of reliability and availability are shown in Figure 1.14.

Definitions: Reliability and availability

Reliability The amount of time eguipment operates in one (1) year

Operating hours per year
Reliability (o/o) =
8700 hours
Availability The amount of time equipment operates in one (1) year -
the planned downtime
Operating hours per year
Availability (%)
8700 - planned downtime (hours)
Note: The values should be greater than 95%.

Figure 1.14 Definitions: Reliability and availability

11