Professional Documents
Culture Documents
September 2004
COMPARED TO STEEL,
ZANITE IS FLAT OUT THE BEST.
Zanite is a
proprietary formula
combining Epoxy resins
with quartz aggregate
Stainless Steel
Baseplate
Integrated Drip Custom Designs Inserts for all ANSI for exceptional
strength and corrosion
Flatness
Pan and Drain and materials
pump and NEMA
available.
motor frame sizes. resistance throughout.
at 0.001"/ft. Connection.
FAX: 216-274-9296
Scope of Work
EMEs GE 7E and 6B gas turbines are proven
performers, and the DLN units (Dry Low NOx)
can achieve very low nitrogen oxide emissions,
which help keep the environment clean. Ensuring
that these turbines and other operating components stay at peak efficiency demands high-quality
procedures and personnel.
From the outset of the contract, Thomasons
work has been marked by careful attention to the
customers outage schedules and timeframes, including review of the units operation and maintenance documents. Major inspections cover the turbines to be disassembled, to determine necessary
repairs or component replacements, if any.
Thomason also has performed refurbishments at
each facilitys site with OEM components. All
maintenance and repairs are done to OEM specifications. Depending on the condition of each GE
turbine, Thomason work crews and Wood Group
project engineers have refurbished them (with generator refurbishment conducted, in one case, by a
responsible third party).
In addition, Thomason has been conducting
all combustion, hot gas path, and major inspections, and has helped insure that State of California
and OSHA requirements for process safety and
mechanical integrity are met.
SEPTEMBER 2004
Teamwork Delivers
STANDARD ALLOYS
OUR FEATURES re
a
Certified to ISO 9001
Since
Since 1926
1926
YOUR BENEFITS
Quality Parts
Competitive Prices
Quick Delivery
Hydraulic Upgrades/
Re-Rates
Metallurgical Upgrades
Obsolete Parts Solutions
Ingersoll Rand
Pacific
Worthington
United
Byron Jackson
Wilson Snyder
Goulds
Union
Stratco
Johnston
Delaval
Allis Chalmers
and more
Phone: 800-231-8240
Fax: 409-983-7837
Email:
sales@standardalloys.com
Website:
www.standardalloys.com
SEPTEMBER 2004
37
Company Profile
New Motor
Efficiency
Audit Tool
To control profit-draining
energy costs, you first
must identify and
quantify them.
efficient solutions and/or improvements that can provide dramatic savings within a short period of time.
At this particular facility, one
of the evaluations was done on
an application in which a
700 hp motor was driving a compressor. Testing with the Motor
Efficiency Wizard demonstrated
that the efficiency of this motor
was 91.2 %. With a new premium efficient motor, the energy
efficiency could be improved to
96.4%. Based on the service
teams calculations, the savings
associated with replacing the
existing motor with a premium
efficient model would come to
$10,903.00 annually. Armed
with this new information, the
plant engineers replaced the
motor and were able to eliminate
thousands of dollars from their
overall operating expenses each
year.
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SEPTEMBER 2004
The Wizard
Time-Saving
mined by putting the unit in question on a dyno; loading it up; measuring the input power, output torque
and speed at six points; and then calculating the efficiency.
While this is a very simple procedure, it also is an
extremely costly one, especially in a plant environment
where operation or production must be stopped for
extended periods while the motor is off-site. In nearly
all cases, the expense and downtime related to this type
of testing is prohibitive. Plus, with laboratory testing,
actual operating conditions of the motor in its application cannot be duplicated. Consequently, true efficiency at the in-service motor output horsepower,
operating temperature and plant supply voltage, is difficult, if not impossible, to determine.
In contrast, the Motor Efficiency Wizard provides
accurate testing in a very short timeframewithout
disconnecting the motor from the load. In fact, the motor
can remain in service at its operating temperature
while supplying power to its driven load.
Figure 3.
Efficiency
versus
horsepower
plot
generated
by the
Wizard
Figure 4.
Motor
output
torque
versus
speed
generated
by the
Wizard
SEPTEMBER 2004
39
Who Needs an
Energy Audit?
40
SEPTEMBER 2004
41
42
SEPTEMBER 2004
A: Certainly, there are some high-quality conventional, mineral-based oils available. Typical conventional lubricants for air compressors, however, will
need to be changed on average every 500 to 1,000
hours. Lubricants formulated with synthetic
diesters and PAOs are capable of achieving drain
intervals of up to 8,000 hours.
Also, with conventional oils in reciprocating
compressors, there is a faster rate of hard carbon
deposits forming in the valve area. Carbon deposits
allow recompression, potentially leading to fires
and/or explosions.
When using mineral oils, special care should be
given to routinely inspect the compressor and
lubricant condition.
Just like in the automotive market, where synthetics offer superior performance and protection
compared to conventional oils, the same is true
when dealing with air compressors. Compared to
conventional lubricants, synthetic oils deliver better
oxidation and thermal stability. The high resistance
of synthetic lubricants to deposit formation enables
them to be used over extended periods in bearing
lubrication systems.
Synthetics can help reduce the cost and time
needed for maintenance items such as cleaning,
replacing worn parts and changing oil. Because of
these factors, lubricants formulated with synthetic
PAOs or diesters really are the best lubricant
options for rotary screw and reciprocating air compressors, respectively.
Q: Besides selecting the right lubricant, what else can
maintenance professionals do to enhance the life and
performance of their air compressors?
A: One of the best things a maintenance professional can do is implement a routine oil analysis
program. The key to the success of any oil analysis
program is to be able to trend the results. Quarterly
oil analysis is recommended for both reciprocating
and rotary screw compressors.
Trending oil samples on a quarterly basis
should provide valuable information on equipment
and lubricant conditionsand be the final verdict
on oil change intervals. Recommended testing criteria includes, TAN (ASTM D 664), Metals by
Inductively Coupled Plasma (ICP) (ASTM D
5185), water content by Karl Fisher (ASTM D
1744), and Particle Count (ISO 4406.2). P&S
For additional information, please log on to:
www.exxonmobil.com
PUMPS & SYSTEMS
SEPTEMBER 2004
43
ATTENDANCE &
EXHIBITING INFORMATION
www.minexpo.com
Sponsored by
THINK
BIG
Your job is big.
SEALING SENSE
Q. How do you determine the primary cause(s)
of mechanical seal failure?
46
SEPTEMBER 2004
www.pump-zone.com
vibration and wear are taken up internally in the bellows, and here the secondary seals are truly static.
The mechanical hardware supplied with and integral to the seal is used to:
Fluid contamination, which might be the presence of harmful solid particles in the seal cavity
fluid.
www.pump-zone.com
SEPTEMBER 2004
47
Conclusions
Recommendations
Supporting documentation
4. Feasibility Study
In the context of a fan or pump system, a feasibility study is a documented analysis that establishes the business case for modifications that improve
some aspect of the equipments operation. It is supported by test data and in-depth technical and economic analyses. Although potential system
improvements are sometimes driven by the need to
reduce energy costs, more frequently other objectives must first satisfy criteria for the operation. In
meeting those primary objectives, energy optimization should be thoroughly considered because of the
long-term operating cost implications. On the other
hand, options that reduce energy costs sometimes
carry some aspect that is detrimental to the operation. These also need to be addressed as necessary in
the study. The focus of the feasibility study has three
main components.
Evaluation of existing operation
Review background and overall design of the
system.
Establish relationship be-tween process, system
and fan or pump requirements.
Investigate the current control strategy.
Review maintenance history to gain understanding of past problems and remedial actions
taken.
Conduct sufficient performance tests so that
capacity/efficiency, process requirements and
system curve(s) are accurately established for
the complete range of operating points. Tests
should be conducted to a recognized field test
standard, i.e. Air Movement and Control
Association (AMCA) Stan-dard 203 or 803 for
fans and Hydraulic Institute test standards for
pumps.
Obtain sufficient electrical trend data to develop an annual load-duty cycle.
Conduct internal and external inspections as
possible.
Development of technical options
Review objectives for the retrofit.
Prepare list of possible options that address
optimization objectives in the context of the
current operation.
Analyze options on basis of technical suitability,
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SEPTEMBER 2004
Control refinements
Systems calling for precise fluid control and the
flexibility to meet various product requirements
may benefit from an upgrade. This could involve a
change in damper/valve design, modifications that
improve the stability of the operating point(s), system changes or conversion to variable speed.
Noise reduction
For fans, there are numerous techniques that
reduce noise levels. These include insulation/
cladding, low-noise impellers and silencers. The
addition of silencers frequently necessitates an
impeller upgrade to handle higher system pressure
losses. A valid alternative to retrofitting a fan is simply to replace it with a new one. There, however,
may be many reasons why retrofitting is better, i.e:
SEPTEMBER 2004
33
Safe To Use
Non-OEMs To Maintain
And Refurbish Crucial
Turbomachinery?
Heres the answer from California.
Having been awarded Edison Mission Energys 2004 Gas Turbine Maintenance contract for five facilities, Thomason
Mechanical Corporation is demonstrating how working with the right non-OEM contractor can save time and money.
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SEPTEMBER 2004
Starting Line-Up
Thomason brings wideranging experience to this project, having served the power
industry since 1975 in rotating
and reciprocating machinery
installation, maintenance and
overhaul. The company has been
working on industrial frame gas
turbines since the early 1990s. As
a non-OEM, Thomason focuses on lowering customers risks
during machinery maintenance
and setting high standards of
timeliness, quality, reliability,
safety and productivity.
The Thomason organization
is part of the Field Services unit of
Wood Group Gas Turbine Services, which has 2,000 employees
with in-depth knowledge in supporting operators of gas turbines,
steam turbines, generators and
other high-speed rotating equipment. Wood Group is recognized
worldwide as a leading independent gas turbine maintenance
provider.
PUMPS & SYSTEMS
Working with a
non-OEM for
field engineering, maintenance
and inspection
can be a lowrisk, high-gain
opportunity.
Bundling Outages
A leading independent power producer, EME has earned a
reputation as a responsible operator of environmentally sound
projects, and it takes its commitment to reliable energy production seriously.
When EME was evaluating
service contractors for the 2004
gas turbine maintenance programs at its California cogen
facilities, it set out some unusual
requirements. The proposal bundled the outages of five sites:
Kern River (300 MW), MidSet (38 MW), Salinas River
(38 MW), Sargent Canyon
(38 MW), and Sycamore (300
MW). EME is a 50% partner
Special Supplement: Rotating Equipment
SEPTEMBER 2004
35
1. Prescreening
Consultant collects data for performance and efficiency testing as part of a
comprehensive energy assessment.
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SEPTEMBER 2004
Prescreening is used to
describe the activities required to
evaluate whether there actually is
an energy-saving opportunity
worth pursuing at a specific site.
During prescreening, the site is
not actually visited (typically, this
is the case, but theres no reason
not to visit the site). Therefore,
this step primarily concentrates
on non-technical issues. The type
of required information is usually obtainable through a phone
call. Other sources are also used
depending on availability, type of
company, etc. Typical information gathered and issues investigated are:
Operating hours
Electrical rates
Utility program availability
Company financial viability
Future plans for plant
Payback criteria
Personnel technical knowledge and decisionmaking positions
2. Screening
For facilities that show promise after prescreening, a site visit is required. Screening refers to the
qualifying activities conducted during the visit to
the customers office and related inspection of the
equipment. In most cases, sufficient information
can be obtained to provide an initial approximation
of the energy-saving potential. The following functions and data gathering are required to obtain sufficient information to make a decision on whether
continued pursuitand further investigation and
study is warranted.
Technical information to define specific systems, ie. motor, sizes, driven equipment types,
other system componentry, equipment age and
condition, control, etc.
System classification, ie. fixed resistance, constant pressure, constant flow or fixed resistance
with constant static pressure requirement.
Operating information, ie. number of hours,
number of load points (as defined by the particular process parameters measured or production records), motor amperages, control parameters/set-points, etc.
Process and instrumentation diagrams, equipment specification sheets, performance curves,
etc.
Identification of system problems, ie. inadequate capacity, control, vibration, noise, excessive maintenance requirements, premature and
unscheduled equipment failures, etc.
Physical inspection of system from point where
fluid enters system to point where it is eventually dispelled. Note the following:
Damper/valve positions
Ductwork/piping and system design
System maintenance condition
Motor and driven quipment nameplate data
Leakage, blow-off, recir-culation modes or
other wasted flow opportunities
Prioritization of issues critical to the site, ie. reliability, payback criteria, longevity requirements
(future plans), control, flexibility, process capacity, etc.
3. Audit
The audit is a technical review of a particular
system to establish the existing conditions, determine the energy-reduction opportunities and establish the optional methods that will achieve the energy savings. Typically, the audit uses all the information gathered during the Prescreening and
Screening phases. Sufficient additional detail may
also be required to compile the data into a suitable
report format. To prepare an audit report requires the
following:
SEPTEMBER 2004
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