2/5/2019 Maintenance: Pursuing Improvements in Rotating Machinery - Chemical Engineering | Page 1

OPERATIONS & MAINTENANCE PDF

MAINTENANCE: PURSUING IMPROVEMENTS IN ROTATING

MACHINERY
By Kirill Grebinnyk and Bob Krusemark, Sulzer | May 1, 2019

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The variety of rotating equipment used in chemical manufacturing creates the need for diverse maintenance methods. Using new techniques can
greatly improve the reliability and performance of all types of rotating machines

The processes that are required to manufacture chemicals on an industrial scale rely on a large variety of rotating equipment to deliver the end
product. From steam turbines and electric motors to compressors, expanders and pumps, every machine has a vital role to play. Keeping the
manufacturing process running requires dedicated maintenance teams and expert knowledge to deliver reliability and performance.

Installed pieces of rotating equipment are operated for numerous years — decades in many cases — and at some point, will begin showing signs of
age. In some cases, the original equipment manufacturer (OEM) may no longer support the older models or may even have ceased to exist. In other
situations, the lead time for a major overhaul may not match the expectations of the plant owner. Whatever the case, modern design and
manufacturing processes can be applied to time-served equipment and deliver cost-e ective improvements.

MANAGING POWER AND EFFICIENCY

From onsite generators to the numerous electric motors, reliable operation of electrical assets within a manufacturing plant in the chemical
process industries (CPI) is vital. Unexpected failures can cause considerable inconvenience and lost production, which will impact revenue. So, once
again, a preventative maintenance program can provide signi cant bene ts by reducing downtime and improving operational e ciency.

The use of vibration analysis, combined with thermal imaging, which is used to identify imminent bearing failure, poor electrical connections and
the imbalance of phase loadings, can produce an accurate indication of the overall status of the equipment. Additional testing of the electrical
winding, especially partial-discharge analysis above 6,000 V, can also provide very useful information on the overall condition of the equipment,
as well as an indication of its remaining lifetime. For larger electrical assets, a repair will usually be more cost-e ective than replacement, while
still o ering the opportunity to improve on the original design.

Continuous advancements are being made in insulation technology, and they have allowed the same insulating properties to be delivered by a
thinner layer of material than in the past. Using thinner insulation, engineers must apply good design practices to keep voltage stresses to
acceptable levels, which helps to extend the operating life of the motor. When the insulation is optimized, the percentage of copper in the winding
can be increased, which, in turn, can reduce operating temperatures or improve output, as well as energy e ciency.

Using the information gathered from the preventative maintenance routines, it is possible to plan repairs so that they coincide with planned
shutdowns or outages. Working with independent repair specialists, new windings can be designed, manufactured and tested ahead of time,
minimizing project duration and delivering longterm reliability.

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OPTIMIZING ELECTRICAL PERFORMANCE

In the case of electrical assets, such as generators and motors, monitoring the condition of the stator and the insulation on the windings provides
vital information about the future reliability of the machine. Electrical insulation degrades over time, and the speed of its deterioration is a ected
by the operating temperatures and stresses that it is subject to.

Situations of voltage imbalance, over- and under-voltage, voltage disturbance and operating temperature all play a role, so a proactive approach
can o er considerable bene ts. Optimizing supply characteristics can extend the service life of the equipment, while using advanced techniques,
such as partial-discharge analysis on high-voltage machines, can provide vital information about the condition of the stator.

Since the breakdown of electrical-equipment insulation is a very gradual process, implementing a condition-monitoring program is an ideal
method for optimizing asset performance. Data from resistance temperature detectors (RTDs), metering devices and partial-discharge couplers
enable the operator of the machine to extend its service life to the optimal point where the windings need to be replaced. This “inside information”
helps to avoid unexpected failures and allows the coil replacement to be scheduled along with other planned maintenance activities, minimizing
disruption (Figure 1).

FIGURE 1. Electrical testing of new coils ensures optimum performance

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