Power Plant Equipment Operation And Maintenance Guide

Maximizing Efficiency and Profitability

Kiameh, Philip

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Bindwijze:	Boek, Gebonden
Genre:	Elektrotechniek

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Beschrijving

THE DEFINITIVE GUIDE TO SELECTING, OPERATING, AND MAINTAINING POWER PLANT EQUIPMENT

Power Plant Equipment Operation and Maintenance Guide provides detailed coverage of different types of power plants such as modern co-generation, combined-cycle, and integrated gasification combined cycle (IGCC) plants. The book describes the design, selection, operation, maintenance, and economics of all these power plants. The best available power enhancement options are discussed, including duct burners, evaporative cooling, inlet-air chilling, absorption chilling, steam and water injection, and peak firing.

This in-depth resource addresses the sizing, selection, calculations, operation, diagnostic testing, troubleshooting, maintenance, and refurbishment of all power plant equipment, including steam turbines, steam generators, boilers, condensers, heat exchangers, gas turbines, compressors, pumps, advanced sealing mechanisms, magnetic bearings, and advanced generators.

Coverage includes:

Methods for enhancing the reliability and maintainability of all power plants
Economic analysis of modern co-generation and combined-cycle plants
Selection of the best emission-reduction method for power plants
Preventive and predictive maintenance required for power plants
Gas turbine applications in power plants, protective systems, and tests

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Details

Titel:	Power Plant Equipment Operation And Maintenance Guide
Auteur:	Kiameh, Philip
Mediatype:	Boek
Bindwijze:	Gebonden
Taal:	Engels
Aantal pagina's:	768
Uitgever:	Mcgraw-hill Education - Europe
Plaats van publicatie:	01
NUR:	Elektrotechniek
Afmetingen:	246 x 190 x 45
Gewicht:	1428 gr
ISBN/ISBN13:	9780071772211
Intern nummer:	18074862

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Biografie (woord)

Philip Kiameh, M.A.Sc., B.Eng., D.Eng., P.Eng., has been a teacher at the University of Toronto, Canada, for 18 years. He also teaches courses and seminars worldwide to more than 4,000 engineers across Europe, North America, and the Middle East. Professor Kiameh has written four books for working engineers and has won excellence in teaching awards from the Professional Development Center at the University of Toronto and TUV Akademie. He performed research on power generation equipment with Atomic Energy of Canada Limited and has more than 26 years of practical engineering experience with Ontario Power Generation, formerly, Ontario Hydro, the largest electric utility in North America.

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Inhoudsopgave

Preface

xxv

Acknowledgments

xxix

1 Gas Turbine Applications in Power Stations, Gas Turbine Protective Systems, and Tests

(10)

1.1 Introduction

(3)

1.2 Working Cycle

(2)

1.2.1 Starting

(2)

1.2.2 Shutdown

(1)

1.3 Protection

(1)

1.4 Black Start

(1)

1.5 Routine Tests

(1)

1.6 Bibliography

(2)

2 Steam Turbine Selection for Combined-Cycle Power Systems

(20)

2.1 Abstract

(1)

2.2 Introduction

(1)

2.3 Steam Turbine Application to Steam and Gas Plants

(6)

2.3.1 Steam and Gas Plants Structure

(1)

2.3.2 Steam Turbine Exhaust Size Selection

(1)

2.3.3 Non-Exhaust Cycle-Steam Conditions

(4)

2.3.4 Reheat Cycle Steam Condition

(1)

2.4 Steam Turbine Product Structure

(12)

2.4.1 Performance

(2)

2.4.2 Casing Arrangements

(10)

2.4.3 Cogeneration Applications

(1)

2.5 Bibliography

(2)

3 Steam Turbine Maintenance

(10)

3.1 Life Cycle Operating Cost of a Steam Turbine

(1)

3.2 Steam Turbine Reliability

(1)

3.3 Boroscopic Inspection

(1)

3.4 Major Cause of Steam Turbine Repair and Maintenance

(1)

3.5 Maintenance Activities

(2)

3.6 Advanced Design Features for Steam Turbines

(5)

3.7 Bibliography

(2)

4 Frequently Asked Questions About Turbine-Generator Balancing, Vibration Analysis, and Maintenance

(4)

4.1 Balancing

(1)

4.2 Vibration Analysis---Cam Bell Diagram

(1)

4.3 Turbine-Generator Maintenance

(3)

5 Features Enhancing the Reliability and Maintainability of Steam Turbines

(18)

5.1 Steam Turbine Design Philosophy

(1)

5.2 Measures of Reliability, Availability, and Maintainability

(1)

5.3 Design Attributes Enhancing Reliability

(6)

5.3.1 Overall Mechanical Design Approach

(1)

5.3.2 Modern Steam Turbine Design Features

(5)

5.4 Design Attributes Enhancing Maintainability

(8)

5.4.1 Maintainability Features

(7)

5.4.2 Maintenance Recommendations

(1)

5.5 Cost/Benefit Analysis of High Reliability, Availability, and Maintenance Performance

(1)

5.5.1 Reliability, Availability, and Maintainability Value Calculation

(1)

5.6 Conclusion

(1)

5.7 Bibliography

(2)

6 Steam Generators

(30)

6.1 Introduction

(1)

6.2 The Fire-Tube Boiler

(2)

6.3 The Water-Tube Boiler

(3)

6.3.1 The Straight-Tube Boiler

(2)

6.3.2 The Bent-Tube Boiler

(1)

6.4 The Water-Tube Boiler: Recent Developments

(3)

6.4.1 The Boiler Walls

(2)

6.4.2 The Radiant Boiler

(1)

6.5 Water Circulation

(2)

6.6 The Steam Drum

(1)

6.7 Superheaters and Reheaters

(3)

6.7.1 Convection Superheater

(1)

6.7.2 Radiant Superheater

(2)

6.8 Once-Through Boilers

(1)

6.9 Economizers

(1)

6.10 Air Preheaters

(3)

6.11 Fans

(5)

6.11.1 Fan Control

(1)

6.11.2 The Stack

(2)

6.12 Steam Generator Control

(3)

6.12.1 Feedwater and Drum-Level Control

(1)

6.12.2 Steam-Pressure Control

(1)

6.12.3 Steam-Temperature Control

(2)

6.13 Bibliography

(2)

7 Boilers (Steam Generators), Heat Exchangers, and Condensers

(14)

7.1 Heat Transfer

(2)

7.1.1 Steady-State Conduction

(2)

7.2 Thermal Conductivities

(1)

7.2.1 Conduction Through Cylindrical Walls

(1)

7.3 Combination Heat-Transfer Effects

(1)

7.4 Convection Heat-Transfer Coefficients

(2)

7.4.1 Turbulent Forced-Convection Flow Inside Long Circular Tubes

(1)

7.4.2 Streamlined Forced-Convection Flow Inside Tubes (Water and Oils)

(1)

7.4.3 Turbulent Forced-Convection Flow Across N Onbaffled Tube Banks with Circular Tubes

(1)

7.5 Boiling Liquids and Condensing Vapors

(1)

7.6 Heat Exchangers

(8)

7.6.1 Shell-and-Tube Heat Exchangers

101

(6)

8 Integrated Gasification Combined Cycles

107

(4)

8.1 Introduction

107

(1)

8.2 IGCC Processes

107

(1)

8.3 IGCC Plant Considerations

108

(1)

8.3.1 Turnkey Cost

108

(1)

8.3.2 Size of IGCC

109

(1)

8.3.3 Output Enhancement

109

(1)

8.4 Emission Reduction

109

(1)

8.4.1 Nitrogen Oxides

109

(1)

8.4.2 Air Pollutants

109

(1)

8.4.3 Mercury

109

(1)

8.4.4 Carbon Dioxide

109

(1)

8.5 Reliability, Availability, and Maintenance

110

(1)

8.6 Bibliography

110

(1)

9 Single-Shaft Combined-Cycle Power Generation Plants

111

(8)

9.1 Introduction

111

(1)

9.2 Performance of Single-Shaft Combined-Cycle Plants

112

(2)

9.3 Environmental Impact

114

(1)

9.4 Equipment Configurations

115

(1)

9.5 Starting Systems

116

(1)

9.6 Auxiliary Steam Supply

116

(1)

9.7 Plant Arrangement

116

(1)

9.8 Maintenance

117

(1)

9.9 Advantages of Single-Shaft Combined-Cycle Plants

117

(1)

9.10 Bibliography

118

(1)

10 Selection of the Best Power Enhancement Option for Combined-Cycle Plants

119

(6)

10.1 Plant Description

119

(1)

10.2 Evaluation of Inlet-Air Pre-Cooling Option

119

(3)

10.3 Evaluation of Inlet-Air Chilling Option

122

(1)

10.4 Evaluation of Absorption Chilling System

123

(1)

10.5 Evaluation of the Steam and Water Injection Options

123

(1)

10.6 Evaluation of Supplementary Firing in HRSG Option

124

(1)

10.7 Comparison of All the Power Enhancement Options

124

(1)

10.8 Bibliography

124

(1)

11 Economics of Combined-Cycle and Cogeneration Plants

125

(42)

11.1 Introduction

125

(1)

11.2 Natural Gas Prices

125

(1)

11.3 Economic Growth

126

(1)

11.4 Financial Analysis

127

(1)

11.5 Base Case

127

(1)

11.6 Combined-Cycle Configuration

128

(1)

11.7 Capital Cost

128

(1)

11.8 Operating and Maintenance Cost

128

(7)

11.9 Economic Evaluation of Different Combined-Cycle Configurations

135

(5)

11.10 Electricity Purchase Rate

140

(1)

11.11 Economic Consideration

140

(1)

11.12 Conclusions

140

(1)

11.13 Bibliography

141

(1)

11.14 Appendix: Definitions of Terms Used in the Tables

141

(1)

11.15 Appendix: Financial Analysis of the Different Configurations of Combined-Cycle Plants

142

(25)

12 Wind Power Turbine Generators---Brushless Double-Feed Generators

167

(8)

12.1 Introduction

167

(1)

12.2 Basic System Configuration

168

(1)

12.3 Equivalent Circuit for the Brushless Double-Fed Machine

169

(2)

12.4 Parameter Extraction

171

(1)

12.5 Generator Operation

171

(1)

12.6 Converter Rating

172

(2)

12.7 Machine Control

174

(1)

12.8 Conclusions

174

(1)

12.9 Bibliography

174

(1)

13 Gas Laws and Compression Principles

175

(28)

13.1 Introduction

175

(1)

13.2 Symbols

175

(4)

13.2.1 Compressor Operation

175

(4)

13.3 First Law of Thermodynamics

179

(1)

13.4 Second Law of Thermodynamics

179

(22)

13.4.1 Ideal or Perfect Gas Laws

179

(3)

13.4.2 Property Relationships

182

(3)

13.4.3 Vapor Pressure

185

(1)

13.4.4 Partial Pressures

186

(1)

13.4.5 Critical Conditions

187

(1)

13.4.6 Gas Mixtures

187

(1)

13.4.7 The Mole

187

(1)

13.4.8 Volume Percent of Constituents

188

(1)

13.4.9 Molecular Weight of a Mixture

188

(1)

13.4.10 Specific Gravity and Partial Pressure

188

(1)

13.4.11 Specific Heats

189

(1)

13.4.12 Pseudo-Critical Conditions and Compressibility

190

(1)

13.4.13 Weight-Basis Item

191

(1)

13.4.14 Compression Cycles

191

(2)

13.4.15 Compressor Polytropic Efficiency

193

(1)

13.4.16 Compressor Power Requirement

194

(1)

13.4.17 Compressibility Correction

195

(1)

13.4.18 Multiple Staging

196

(1)

13.4.19 Compressor Volumetric Flow Rate

197

(1)

13.4.20 Cylinder Clearance and Volumetric Efficiency

198

(3)

13.4.21 Cylinder Clearance and Compression Efficiency

201

(1)

13.5 Bibliography

201

(1)

13.6 Appendix: List of Symbols

201

(2)

14 Compressor Types and Applications

203

(16)

14.1 Introduction

203

(1)

14.2 Positive Displacement Compressors

204

(6)

14.2.1 Rotary Compressors

204

(4)

14.2.2 Reciprocating Compressors

208

(2)

14.3 Dynamic Compressors

210

(8)

14.3.1 Centrifugal Compressors

210

(7)

14.3.2 Axial Flow Compressors

217

(1)

14.4 Bibliography

218

(1)

15 Compressors

219

(18)

15.1 Compressor Types

219

(1)

15.2 Compressor Operation

219

(1)

15.3 Gas Laws

219

(1)

15.4 Compressor Performance Measurement

220

(13)

15.4.1 Inlet Conditions

222

(1)

15.4.2 Compressor Performance

222

(1)

15.4.3 Energy Available for Recovery

222

(1)

15.4.4 Positive Displacement Compressors

223

(1)

15.4.5 Reciprocating Compressors

223

(1)

15.4.6 Trunk Piston Compressors

224

(1)

15.4.7 Sliding Crosshead Piston Compressors

225

(1)

15.4.8 Diaphragm Compressors

226

(1)

15.4.9 Bellows Compressors

227

(1)

15.4.10 Rotary Compressors

227

(1)

15.4.11 Rotary Screw Compressors

228

(1)

15.4.12 Lobe-Type Air Compressors

229

(1)

15.4.13 Sliding Vane Compressors

230

(1)

15.4.14 Liquid Ring Compressors

230

(1)

15.4.15 Dynamic Compressors

231

(1)

15.4.16 Centrifugal Compressors

231

(1)

15.4.17 Axial Compressors

232

(1)

15.4.18 Air Receivers

233

(1)

15.5 Compressor Control

233

(1)

15.6 Compressor Unloading System

233

(1)

15.7 Intercooler and Aftercoolers

234

(1)

15.8 Filters and Air Intake Screens

235

(1)

15.9 Preventive Maintenance and Housekeeping

235

(1)

15.10 Bibliography

236

(1)

16 Performance of Positive Displacement Compressors

237

(16)

16.1 Compressor Performance

237

(9)

16.1.1 Positive Displacement Compressors

237

(1)

16.1.2 Reciprocating Compressor Rating

237

(1)

16.1.3 Reciprocating Compressor Sizing

237

(3)

16.1.4 Capacity Control

240

(6)

16.1.5 Compressor Performance

246

(1)

16.2 Reciprocating Compressors

246

(5)

16.2.1 Compressor Valves

246

(2)

16.2.2 Reciprocating Compressors Leakage

248

(1)

16.2.3 Screw Compressors Leakage

249

(2)

16.3 Bibliography

251

(2)

17 Reciprocating Compressors

253

(34)

17.1 Introduction

253

(3)

17.2 Crankshaft Design

256

(3)

17.3 Bearings and Lubrication Systems

259

(3)

17.4 Connecting Rods

262

(1)

17.5 Crossheads

263

(1)

17.6 Frames and Cylinders

264

(5)

17.7 Compressor Cooling

269

(3)

17.8 Pistons

272

(1)

17.9 Piston and Rider Rings

272

(2)

17.10 Valves

274

(6)

17.11 Piston Rods

280

(1)

17.12 Packings

281

(1)

17.13 Cylinder Lubrication

282

(1)

17.14 Distance Pieces

282

(4)

17.15 Bibliography

286

(1)

18 Reciprocating Air Compressors Troubleshooting and Maintenance

287

(14)

18.1 Introduction

287

(1)

18.2 Location

287

(1)

18.3 Foundation

287

(2)

18.4 Air Filters and Suction Lines

289

(1)

18.5 Air Receiver Location and Capacity

289

(1)

18.6 Starting a New Compressor

290

(2)

18.7 Lubrication

292

(1)

18.8 Non-Lubricated Cylinders

293

(1)

18.9 Valves

293

(3)

18.10 Piston Rings

296

(1)

18.11 Intercoolers and Aftercoolers

296

(1)

18.12 Cleaning

297

(1)

18.13 Packing

297

(3)

18.14 Bibliography

300

(1)

19 Diaphragm Compressors

301

(16)

19.1 Introduction

301

(1)

19.2 Theory of Operation

301

(3)

19.3 Compressor Design

304

(4)

19.4 Materials of Construction

308

(1)

19.5 Accessories

309

(1)

19.6 Cleaning and Testing

310

(1)

19.7 Applications

311

(1)

19.7.1 Automotive Air Bag Filling

312

(1)

19.7.2 Petrochemical Industries

312

(1)

19.8 Limitations

312

(1)

19.9 Installation and Maintenance

312

(3)

19.10 Diaphragm Compressor Specification

315

(1)

19.11 Bibliography

315

(2)

20 Rotary Screw Compressors and Filter Separators

317

(32)

20.1 Twin-Screw Machines

317

(22)

20.1.1 Compressor Operation

317

(1)

20.1.2 Applications of Rotary Screw Compressors

318

(3)

20.1.3 Dry and Liquid Injected Compressors

321

(1)

20.1.4 Operating Principles

322

(2)

20.1.5 Flow Calculation

324

(1)

20.1.6 Power Calculation

324

(4)

20.1.7 Temperature Rise

328

(1)

20.1.8 Capacity Control

328

(4)

20.1.9 Mechanical Construction

332

(2)

20.1.10 Industry Experience

334

(3)

20.1.11 Maintenance History

337

(1)

20.1.12 Performance Summary

338

(1)

20.2 Oil-Flooded Single-Screw Compressors

339

(4)

20.3 Selection of Modern Reverse-Flow Filter Separators

343

(4)

20.3.1 Conventional Filter Separators and Self-Cleaning Coalescers

343

(1)

20.3.2 Removal Efficiencies

344

(1)

20.3.3 Filter Quality

344

(1)

20.3.4 Selection of the Most Suitable Gas Filtration Equipment

345

(1)

20.3.5 Evaluation of the Proposed Filtration Configurations

346

(1)

20.3.6 Life-Cycle-Cost Calculations

346

(1)

20.4 Conclusions

347

(1)

20.5 Bibliography

347

(1)

20.6 Appendix: Coke Fuel

348

(1)

20.6.1 Introduction

348

(1)

20.6.2 Properties and Usage

348

(1)

20.6.3 Other Coking Processes

348

(1)

20.6.4 Bibliography

348

(1)

21 Straight Lobe Compressors

349

(8)

21.1 Applications

349

(1)

21.1.1 Operating Characteristics

349

(1)

21.2 Operating Principle

349

(2)

21.3 Pulsation Characteristics

351

(1)

21.4 Noise Characteristics

351

(1)

21.5 Torque Characteristics

352

(1)

21.6 Construction

352

(1)

21.6.1 Rotors

352

(1)

21.6.2 Casing

352

(1)

21.6.3 Timing Gears

352

(1)

21.6.4 Bearings

353

(1)

21.7 Staging

353

(1)

21.7.1 Higher Compression Ratios

353

(1)

21.7.2 Power Reduction

353

(1)

21.8 Installation

354

(1)

21.9 Bibliography

355

(2)

22 Recent Developments in Separating Liquid from Gases

357

(8)

22.1 Introduction

357

(1)

22.2 Removal Mechanisms

358

(1)

22.3 Liquid/Gas Separation Technologies

359

(2)

22.3.1 Gravity Separators

359

(1)

22.3.2 Centrifugal Separators

359

(1)

22.3.3 Mist Eliminators

359

(1)

22.3.4 Filter Vane Separators

359

(1)

22.3.5 Liquid/Gas Coalescers

359

(2)

22.3.6 Selection of Liquid/Gas Separation Equipment

361

(1)

22.4 Formation of Fine Aerosols

361

(1)

22.5 Ratings and Sizing of Separation Equipment

361

(2)

22.6 Bibliography

363

(2)

23 Dynamic Compressors Technology

365

(8)

23.1 Introduction

365

(1)

23.2 Centrifugal Compressor Overview

365

(3)

23.3 Axial Compressors Overview

368

(3)

23.4 Bibliography

371

(2)

24 Simplified Equations for Determining the Performance of Dynamic Compressors

373

(8)

24.1 Nonoverloading Characteristics of Centrifugal Compressors

373

(1)

24.2 Stability

373

(1)

24.3 Speedy Change

373

(2)

24.4 Compressor Drive

375

(1)

24.5 Calculations

376

(3)

24.6 Bibliography

379

(2)

25 Centrifugal Compressors---Components, Performance Characteristics, Balancing, Surge Prevention Systems, and Testing

381

(38)

25.1 Introduction

381

(1)

25.2 Casing Configuration

381

(1)

25.3 Construction Features

381

(15)

25.3.1 Diaphragms

383

(8)

25.3.2 Interstage Seals

391

(4)

25.3.3 Balance Piston Seal

395

(1)

25.3.4 Impeller Thrust

396

(1)

25.4 Performance Characteristics

396

(10)

25.4.1 Slope of the Centrifugal Compressor Head Curve

397

(2)

25.4.2 Stonewall

399

(2)

25.4.3 Surge

401

(3)

25.4.4 Off-Design Operation

404

(2)

25.5 Rotor Dynamics

406

(1)

25.6 Rotor Balancing

406

(2)

25.7 Surge Prevention Systems

408

(4)

25.8 Surge Identification

412

(1)

25.9 Liquid Entrainment

412

(1)

25.10 Instrumentation

413

(1)

25.11 Cleaning Centrifugal Compressors

413

(2)

25.12 Bibliography

415

(1)

25.13 Appendix: Boundary Layer

415

(4)

25.13.1 Definition

415

(1)

25.13.2 Description of the Boundary Layer

415

(1)

25.13.3 Separation: Wake

416

(1)

25.13.4 Bibliography

417

(2)

26 Compressor Auxiliaries, Off-Design Performance, Stall, and Surge

419

(6)

26.1 Introduction

419

(1)

26.2 Compressor Auxiliaries

419

(1)

26.3 Compressor Off-Design Performance

419

(4)

26.3.1 Low Rotational Speeds

422

(1)

26.3.2 High Rotational Speeds

423

(1)

26.4 Performance Degradation

423

(1)

26.5 Bibliography

424

(1)

27 Dynamic Compressors Performance

425

(16)

27.1 Description of a Centrifugal Compressor

425

(5)

27.2 Centrifugal Compressor Types

430

(5)

27.2.1 Compressors with Horizontally Split Casings

430

(1)

27.2.2 Centrifugal Compressors with Vertically Split Casings

430

(3)

27.2.3 Compressors with Bell Casings

433

(1)

27.2.4 Pipeline Compressors

433

(1)

27.2.5 SR Compressors

434

(1)

27.3 Performance Limitations

435

(5)

27.3.1 Surge Limit

436

(2)

27.3.2 Stonewall

438

(1)

27.3.3 Prevention of Surge

438

(1)

27.3.4 Anti-Surge Control Systems

438

(2)

27.4 Bibliography

440

(1)

28 Compressor Seal Systems

441

(12)

28.1 Introduction

441

(1)

28.2 The Supply System

441

(1)

28.3 The Seal Housing System

442

(1)

28.4 The Atmospheric Draining System

443

(1)

28.5 The Seal Leakage System

443

(2)

28.6 Gas Seals

445

(1)

28.7 Liquid Seals

446

(1)

28.8 Liquid Bushing Seals

446

(2)

28.9 Contact Seals

448

(1)

28.10 Restricted Bushing Seals

449

(1)

28.11 Seal Supply Systems

450

(2)

28.11.1 Flow Through the Gas Side Contact Seal

451

(1)

28.11.2 Flow Through the Atmospheric Side Bushing Seal

451

(1)

28.11.3 Flow Through the Seal Chamber

452

(1)

28.12 Seal Liquid Leakage System

452

(1)

28.13 Bibliography

452

(1)

29 Dry Seals, Advanced Sealing Mechanisms, and Magnetic Bearings

453

(20)

29.1 Introduction

453

(1)

29.2 Background

453

(1)

29.3 Dry Seals

454

(7)

29.3.1 Operating Principles

454

(3)

29.3.2 Operating Experience

457

(1)

29.3.3 Problems and Solutions

457

(1)

29.3.4 Upgrade Developments of Dry Seals

458

(1)

29.3.5 Prevention of Dry Gas Seal Failures by Gas Conditioning

459

(2)

29.4 Magnetic Bearings

461

(4)

29.4.1 Operating Principles

461

(3)

29.4.2 Operating Experience and Benefits

464

(1)

29.4.3 Problems and Solutions

465

(1)

29.4.4 Development Efforts

465

(1)

29.5 Thrust-Reducing Seals

465

(2)

29.6 Integrated Design

467

(4)

29.7 Bibliography

471

(2)

30 Compressor System Calculations

473

(12)

30.1 Calculations of Air Leaks from Compressed-Air Systems

473

(2)

30.1.1 Annual Cost of Air Leakage

474

(1)

30.2 Centrifugal Compressor Power Requirement

475

(9)

30.2.1 Compressor Selection

476

(3)

30.2.2 Selection of Compressor Drive

479

(2)

30.2.3 Selection of Air Distribution System

481

(1)

30.2.4 Water Cooling Requirements for Compressors

481

(1)

30.2.5 Variation of Compressor Delivery with Inlet Air Temperature

481

(1)

30.2.6 Sizing of Compressor System Components

482

(1)

30.2.7 Calculation of Receiver Pump-Up Time

483

(1)

30.3 Bibliography

484

(1)

31 Pumps

485

(32)

31.1 Introduction

485

(1)

31.2 Centrifugal Pumps

485

(19)

31.2.1 Theory of Operation of a Centrifugal Pump

487

(2)

31.2.2 Casings and Diffusers

489

(3)

31.2.3 Radial Thrust

492

(3)

31.2.4 Hydrostatic Pressure Tests

495

(1)

31.2.5 Impeller

496

(4)

31.2.6 Axial Thrust

500

(1)

31.2.7 Axial Thrust in Multistage Pumps

500

(1)

31.2.8 Hydraulic Balancing Devices

501

(3)

31.3 Mechanical Seals

504

(1)

31.4 Bearings

504

(1)

31.5 Couplings

504

(1)

31.6 Bedplates

504

(2)

31.7 Minimum Flow Requirement

506

(1)

31.8 Centrifugal Pumps: General Performance Characteristics

506

(2)

31.9 Cavitation

508

(1)

31.10 Net Positive Suction Head

509

(1)

31.11 Maintenance Recommended on Centrifugal Pumps

510

(1)

31.12 Recommended Pump Maintenance

511

(2)

31.13 Vibration Analysis

513

(2)

31.14 Bibliography

515

(2)

32 Centrifugal Pump Mechanical Seal

517

(38)

32.1 Introduction

517

(1)

32.2 Basic Components

517

(38)

32.2.1 Seal Balance

518

(1)

32.2.2 Face Pressure

519

(2)

32.2.3 Pressure-Velocity

521

(1)

32.2.4 Power Consumption

521

(1)

32.2.5 Temperature Control

522

(5)

32.2.6 Seal Lubrication/Leakage

527

(28)

33 Positive Displacement Pumps

555

(16)

33.1 Reciprocating Pumps

555

(7)

33.1.1 Piston Pumps

555

(2)

33.1.2 Plunger Pumps

557

(3)

33.1.3 Diaphragm Pumps

560

(2)

33.2 Rotary Pumps

562

(8)

33.2.1 Gear Pumps

562

(1)

33.2.2 Screw Pumps

563

(1)

33.2.3 Two-or Three-Lobe Pumps

564

(1)

33.2.4 Cam Pumps

564

(1)

33.2.5 Vane Pumps

565

(5)

33.3 Bibliography

570

(1)

34 Diaphragm Pumps

571

(8)

34.1 Introduction

571

(1)

34.2 Mechanically Driven Diaphragm Pumps

571

(2)

34.3 Hydraulically Actuated Diaphragm Pumps

573

(1)

34.4 Pneumatically Powered Diaphragm Pumps

573

(3)

34.5 Materials of Construction

576

(2)

34.5.1 Advantages and Limitations

577

(1)

34.5.2 Limitations of Diaphragm Pumps

577

(1)

34.5.3 Advantages of Diaphragm Pumps

578

(1)

34.6 Bibliography

578

(1)

35 Canned Motor Pumps

579

(4)

35.1 Canned Motor Pumps Design and Applications

579

(3)

35.2 Seal-Less Pump Motors

582

(1)

35.3 Bibliography

582

(1)

36 Troubleshooting of Pumps

583

(20)

36.1 Pump Maintenance

583

(3)

36.1.1 Daily Observations of Pump Operation

583

(1)

36.1.2 Semiannual Inspection

583

(1)

36.1.3 Annual Inspection

584

(1)

36.1.4 Complete Overhaul

584

(1)

36.1.5 Spare and Repair Parts

585

(1)

36.1.6 Record of Inspections and Repairs

585

(1)

36.1.7 Diagnoses of Pump Troubles

586

(1)

36.2 Troubleshooting of Centrifugal Pumps

586

(1)

36.3 Troubleshooting of Rotary Pumps

586

(1)

36.4 Troubleshooting of Reciprocating Pumps

586

(1)

36.5 Troubleshooting of Steam Pumps

586

(2)

36.6 Vibration Diagnostics

588

(14)

36.6.1 Analysis Symptoms

588

(13)

36.6.2 Impeller Unbalance

601

(1)

36.6.3 Hydraulic Unbalance

602

(1)

36.7 Bibliography

602

(1)

37 Water Hammer

603

(16)

37.1 Introduction

603

(1)

37.2 Nomenclature

603

(1)

37.3 Basic Assumptions

604

(1)

37.4 Effects of Water Hammer in High- and Low-Head Pumping Systems

605

(2)

37.4.1 Magnitude of the Pulse

605

(1)

37.4.2 Possible Causes of Water Hammer

606

(1)

37.4.3 Mitigating Measures to Water Hammer

606

(1)

37.4.4 Applications of Water Hammer

606

(1)

37.5 Power Failure at Pump Motors

607

(8)

37.5.1 Pumps with No Valves at the Pump

607

(3)

37.5.2 Pumps Equipped with Check Valves

610

(2)

37.5.3 Controlled Valve Closure

612

(1)

37.5.4 Surge Suppressors

612

(1)

37.5.5 Water Column Separation

613

(1)

37.5.6 Quick-Opening, Slow-Closing Valves

613

(1)

37.5.7 One-Way Surge Tanks

613

(1)

37.5.8 Air Chambers

614

(1)

37.5.9 Surge Tanks

614

(1)

37.5.10 Nonreverse Ratchets

614

(1)

37.6 Normal Pump Shutdown

615

(1)

37.7 Water Hammer Example

615

(2)

37.8 Steam Hammer

617

(1)

37.9 Bibliography

617

(2)

38 Selection and Procurement of Pumps

619

(18)

38.1 Introduction

619

(1)

38.2 Engineering of System Requirements

619

(1)

38.2.1 Fluid Type

619

(1)

38.2.2 System-Head Curves

619

(1)

38.3 Alternate Modes of Operation

620

(1)

38.4 Margins

620

(1)

38.5 Wear

621

(1)

38.6 Future System Changes

621

(1)

38.7 Selection of Pump and Driver

621

(2)

38.7.1 Pump Characteristics

622

(1)

38.7.2 Code Requirements

622

(1)

38.7.3 Fluid Characteristics

622

(1)

38.7.4 Pump Materials

623

(1)

38.7.5 Driver Type

623

(1)

38.8 Pump Specifications

623

(5)

38.8.1 Specification Types

623

(1)

38.8.2 Data Sheet

624

(1)

38.8.3 Codes and Standards

624

(2)

38.8.4 Bidding Documents

626

(1)

38.8.5 Technical Specification

626

(1)

38.8.6 Commercial Terms

627

(1)

38.9 Special Considerations

628

(2)

38.9.1 Performance Testing

628

(1)

38.9.2 Pump Drivers

628

(1)

38.9.3 Special Control Requirements

629

(1)

38.9.4 Drawing and Data Requirements Form

629

(1)

38.9.5 Quality Assurance and Quality Control

629

(1)

38.10 Bidding and Negotiation

630

(5)

38.10.1 Public and Private Sector

630

(1)

38.10.2 Bid List

631

(1)

38.10.3 Evaluation of Bids

631

(1)

38.10.4 Cost

631

(1)

38.10.5 Efficiency

631

(1)

38.10.6 Economic Life

631

(1)

38.10.7 Spare Parts

631

(1)

38.10.8 Guarantee/Warranty

631

(1)

38.10.9 Sample Bid Evaluation

632

(3)

38.11 Bibliography

635

(2)

39 Pumping System Calculations

637

(26)

39.1 Analysis of Pumps Installed in Series

637

(1)

39.2 Analysis of Pumps Installed in Parallel

637

(5)

39.3 Selection of Pump Driver Speed

642

(1)

39.4 Affinity Laws for Centrifugal Pumps

643

(1)

39.5 Centrifugal Pump Selection Using Similarity or Affinity Laws

644

(2)

39.6 Determination of Centrifugal Pump Capacity and Efficiency

646

(2)

39.7 Selection of the Best Operating Speed for a Centrifugal Pump

648

(2)

39.8 Calculate the Total Head of the Pump

650

(5)

39.9 Pump Selection Procedure

655

(7)

39.9.1 Draw the Proposed Piping Layout of the Pumping System

655

(1)

39.9.2 Determine the Required Pump Capacity

655

(1)

39.9.3 Determine the Total Head on the Pump

656

(1)

39.9.4 Obtain the Physical and Chemical Data of the Liquid Being Pumped

656

(1)

39.9.5 Select the Category and Type of Pump

657

(3)

39.9.6 Evaluate the Selected Pump

660

(2)

39.10 Bibliography

662

(1)

40 Bearings

663

(8)

40.1 Types of Bearings

663

(1)

40.1.1 Ball and Roller Bearings

663

(1)

40.2 Stresses During Rolling Contact

664

(1)

40.3 Statistical Nature of Bearing Life

665

(1)

40.4 Materials and Finish

666

(1)

40.5 Sizes of Bearings

666

(1)

40.6 Types of Rolling Bearings

666

(5)

40.6.1 Thrust Bearings

669

(2)

41 Lubrication

671

(10)

41.1 The Viscosity of Lubricants

671

(3)

41.1.1 Viscosity Units

671

(1)

41.1.2 Significance of Viscosity

672

(1)

41.1.3 Flow Through Pipes

673

(1)

41.2 Variation of Viscosity with Temperature and Pressure

674

(1)

41.2.1 Temperature Effect

674

(1)

41.2.2 Viscosity Index

674

(1)

41.2.3 Effect of Pressure on Viscosity

674

(1)

41.3 Non-Newtonian Fluids

674

(1)

41.3.1 Greases

674

(1)

41.3.2 VI-Improved Oils

674

(1)

41.3.3 Oils at Low Temperatures

675

(1)

41.4 Variation of Lubricant Viscosity with Use

675

(1)

41.4.1 Oxidation Reactions

675

(1)

41.4.2 Physical Reactions

675

(1)

41.5 Housing and Lubrication

675

(2)

41.6 Lubrication of Antifriction Bearings

677

(2)

41.7 Bibliography

679

(2)

42 Used Oil Analysis---A Vital Part of Maintenance

681

(10)

42.1 Proper Lube Oil Sampling Technique

681

(8)

42.1.1 Test Description and Significance

681

(1)

42.1.2 Visual and Sensory Inspections

681

(2)

42.1.3 Chemical and Physical Tests

683

(6)

42.2 Summary

689

(1)

42.3 Bibliography

689

(2)

43 Vibration Analysis

691

(16)

43.1 The Application of Sine Waves to Vibration

691

(12)

43.1.1 Multimass Systems

693

(1)

43.1.2 Resonance

693

(2)

43.1.3 Logarithms and Decibels

695

(1)

43.1.4 The Use of Filtering

695

(1)

43.1.5 Vibration Instrumentation

695

(2)

43.1.6 Transducer Selection

697

(2)

43.1.7 Machinery Example

699

(1)

43.1.8 Vibration Analysis

699

(1)

43.1.9 Vibration Causes

699

(1)

43.1.10 Forcing Frequency Causes

699

(3)

43.1.11 Vibration Severity

702

(1)

43.2 Appendix: A Case History (Condensate Pump Misalignment)

703

(4)

43.2.1 Problem

703

(1)

43.2.2 Test Data and Observations

703

(1)

43.2.3 Corrective Actions

703

(1)

43.2.4 Final Results

703

(1)

43.2.5 Conclusion

703

(4)

Index

707

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Power Plant Equipment Operation And Maintenance Guide

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THE DEFINITIVE GUIDE TO SELECTING, OPERATING, AND MAINTAINING POWER PLANT EQUIPMENT

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