Oil & Gas Maintenance Training Guide

g OIL & GAS CUSTOMER TRAINING CENTER
MAINTENANCE
MAINTENANCE MEANS THOSE
OPERATIONS WHICH GUARANTEE THE
SATISFACTORY FUNCTIONALITY AND
DURABILITY OF THE MACHINES IN TIME
IT IS AN ESSENTIAL NEED OF ANY

INDUSTRIAL PLANT IF IT IS TO
PRODUCE CONTINUOUSLY AND
EFFICIENTLY OVER A LONG LIFE
MAINTENANCE IS DIVIDED IN
TWO LARGE GROUPS
PRESERVATIVE MAINTENANCE
TO RIPARE OR TO PREVENT THE FAILURE
IMPROVING MAINTENANCE
REDUCE THE FAILURE RATE
INCIDENTAL PRESERVATIVE
MAINTENANCE
REPAIR AFTER A BREAKDOWN

RESTORING THE ORIGINAL
EFFICIENCY
PROGRAMMED PRESERVATIVE
MAINTENANCE
IT IS DIVIDED INTO THREE TYPES
1. CYCLICAL
MAINTENANCE IN PRE-ESTABLISHED
TIME CYCLES ACCORDING TO THE
DEGREE OF BREAKDOWN
2. STOP
IN A PREFIXED PERIOD ARE
CONCENTRADED ALL THE
NECESSARY MAINTENANCE
3. OPPORTUNITY
MAINTENANCE TO BE CARRIED
OUT ON THE FIRST OCCASION
OF A STOPPAGE FOR BREAKDOWN
OR OTHER REASONS
INSPECTORIAL PRESERVATIVE
MAINTENANCE
CAN BE CARRIED OUT IN

TWO SITUATIONS
1. WITH THE MACHINE STOPPED
2. WITH THE MACHINE RUNNING

WITH THE MACHINE STOPPED

WE MAKE USE OF
1. VISUAL INSPECTION
2. THE NON DESTRUCTIVE METHODS

ULTRASONIC
GAMMA AND X-RAYS
PENETRATING LIQUIDS
MAGNETISM
WITH THE MACHINE RUNNING

DEFINED PREDICTABLE MAINTENANCE
WE MAKE USE OF
1. VISUAL INSPECTION
2. THE NON DESTRUCTIVE METHODS

CHECKING VIBRATIONS
CHECKING NOISE
CHECKING THE EFFICIENCY OF THE
LUBRICATION
THERMOGRAPHY
RECORDING THE PARAMETERS OF
RUNNING AND OPERATION (Temperature,
Pressure, Delta P, Delta T, Absorption, Number
of Revolution, ecc.)
IMPROVING MAINTENANCE
IT CONSIST INTO IMPROVEMENTS OR

SUBSTITUTIONS OF SOME PARTS FOR
INCREASE THE EFFICIENTY AND
RELIABILITY OF MACHINE
IT IS NECESSARY TO COMPARE THE COST OF

MODIFICATION AND/OR SUBSTITUTION,
WITH THE RISPECTIVE ADVANTAGES,
AND THE GROW OF THE COST OF
MAINTENANCE
ASSEMBLY PROCEDURES
BCL
CLEARANCE MEASUREMENT
Labyrinth seal clearance
Journal bearings clearance
Thrust bearing clearance

LABYRINTH SEAL CLEARENCE
SIDE CLEARENCES
VERTICAL CLEARENCES
FOR A BARREL COMPRESSOR BEFORE TO CHECK

THE LABYRINTH SEAL CLEARANCES IT IS NEED:
1) ASSEMBLE TWO HALF RINGS

(CALLED FALSE LABYRINTH) ON
DIAPHRAGMS BUNDLE IN PLACE OF
LABYRINTHS AT BOTH ENDS OF THE HALF
BUNDLE
2) POSITION THE ROTOR ON HALF BUNDLE

AND LET THE ROTOR SUPPORTED BY THE
TWO HALF RINGS
3) POSITION AXIALLY THE ROTOR MAKING THE

IMPELLER OUTLET CHANNEL CENTER COINCIDE
WITH THE DIFFUSER INLET CENTER
Journal bearings clearance

MEASURE SHAFT JOURNAL DIAMETER

WITH A FOUR POINTS CHECK
TAKEN IN THE VERTICAL AND HORIZONTAL PLANES
AT BOTH THE FORWARD AND AFT EDGE OF THE
JOURNAL, AND CALCULATE THE AVERAGE VALUE
MEASURE BORE OF THE BEARING

SHELL AT FOUR POSITIONS
MEASURE EACH INDIVIDUAL PAD THICKNESS AT
THE PIVOT POINT AND CALCULATE THE
AVERAGE VALUE
DETERMINE THE CLEARENCE

WHICH EXISTS IN THE BEARING ASSEMBLY
SUBTRATTING THE DIMENSION
RESULTING FROM THE SUM OF
THE SHAFT JOURNAL DIAMETER
AND THE THICKNESS OF TWO PADS
FROM THE BORE OF THE BEARING SHELL
AN ALTERNATIVE WAY
MANUFACTURE A STEPPED MANDREL
WHOSE SMALLER DIAMETER IS
SHAFT DIAMETER PLUS
MINIMUM DESIRED CLEARANCE
AND THE LARGER DIAMETER
IS SHAFT DIAMETER PLUS
MAXIMUM DESIRED CLEARANCE
Dshaft + Max Clearence

Dshaft + Min Clearance
SLIP THE BEARING OVER THE SMALLER

DIAMETER OF THE MANDREL. ENSURE THAT
THE BEARING ROTATES
TRY TO SLIDE THE BEARING OVER

THE LARGER DIAMETER OF THE
MANDREL
Dshaft + Max Clearence

THE CORRECTION OF THE CLEARANCE

OF THE BEARING IS OBTAINED WITH
THE SUBSTITUTION OF THICKNESS
SHIMS UNDER THE PADS
THRUST BEARING AXIAL CLEARANCE

THE THRUST BEARING CLEARANCE
IS THE ACTUAL DISTANCE THAT THE ROTOR WILL
TRAVEL BETWEEN SHOES
IN AXIAL DIRECTION
THE CHECK IS TO BE CARRIED OUT AS FOLLOWS:
ATTACH A DIAL INDICATOR TO COMPRESSOR CASING

WITH THE PLUNGER, DEPRESSED ONE-HALF,
CONTACTING THE END OF THE ROTOR
APPLY FORCE ENOUGH TO THE OPPOSITE

END OF THE SHAFT TO MOVE IT TO THE END
OF ITS TRAVEL
SET DIAL INDICATOR TO ZERO
MOVE THE ROTOR AS FAR AS POSSIBLE
TOWARDS THE OTHER END
THE AMOUNT READ ON THE DIAL INDICATOR
IS THE THRUST BEARING CLEARANCE
DESCRIPTION OF
PROCEDURES
FOR CENTERING THE
COMPRESSOR ROTOR
POSITIONING OF AXIAL POSITION PROBE
THE AXIAL POSITION PROBE SHALL

BE SET SO THAT,
WHEN THE ROTOR IS IN THE
CENTER OF ITS THRUST FLOAT,
ZERO READING IS OBTAINED ON
THE MONITOR
USE THE FOLLOWING

PROCEDURE
1) AFTER THE CHECK OF THE THRUST BEARING

CLEARANCE FORCE THE ROTOR
AGAINST THE INBOARD SHOES ASSEMBLY,
ZERO THE DIAL INDICATOR AND ADJUST
THE PROBE GAP UNTIL AN INDICATION
OF ONE-HALF THRUST BEARING CLEARANCE
IS OBTAINED ON THE AXIAL POSITION
MONITOR IN (-) DIRECTION
2) MOVE THE ROTOR AS FAR AS POSSIBLE

TOWARDS THE OTHER END
3) THE AXIAL POSITION MONITOR SHOULD READ

ONE HALF OF THE THRUST BEARING
CLEARANCE IN (+) DIRECTION
ALIGNMENT
BY ALIGNMENT WE MEAN
THE COINCIDENCE
OF THE AXIS OF ONE MACHINE
WITH THE EXTENSION
OF THE AXIS OF THE OTHER
DURING NORMAL OPERATION
TO ACCOMPLISH THIS
YOU HAVE TO TAKE IN CONSIDERATION AN
INPORTANT PHENOMENON
THE THERMAL EXPANSION

AT WHICH ARE SUBJECT THE SUPPORT FEET
WHEN THE MACHINE IS IN OPERATION
THIS MEANS, IN PRACTICE, TO

REALIZE A FIT MISALIGNMENT WHEN
THE MACHINES ARE STOPPED, AND SO
ARE COLD, THAT WILL BE
COMPENSATE WHEN THE MACHINES
WILL BE IN OPERATION
GENERALLY WE CAN HAVE A SITUATION OF

THIS TYPE
DRIVE MACHINE
DRIVEN MACHINE
EVERY GENERAL CASE CAN BE

SCOMPOSED IN A
RADIAL MISALIGNMENT
AXIAL MISALIGNMENT
BOTH MAY BE SPLIT UP FURTHER IN A

MISALIGNMENT ON ORRIZONTAL AND
VERTICAL PLANES, SO WE CAN HAVE
RADIAL MISALIGNMENT ON
VERTICAL AND ORIZZONTAL PLANES
AXIAL MISALIGNMENT ON VERTICAL

AND ORIZZONTAL PLANES
FOR DETERMINE THE RELATIVE POSITION

OF TWO SHAFT WE UTILIZE THE SPECIAL
TOOL IN THE FIGURE
THE TOOL IS GENERALLY ASSEMBLED ON

THE SHAFT OF THE HEAVY MACHINE
THAT IS THE REFIREMENT FOR THE
OTHER SHAFT
NOTE: BECAUSE OF WEIGHT ALL THE SHAFTES

HAVE A BENDING, SO THE HUB OF HEAVY
MACHINE IS NEVER ON THE VERTICAL PLANE.
BUT THE BENDING THERE IS ALSO WITH THE
MACHINE IN OPERATION, SO WE CAN TAKE
THAT POSITION LIKE REFERENCE.
BEND SHAFT
IDEAL AXIS
THE MEASURAMENT OF MISALIGNMENT

IS MADE WITH SOME FORMULES THAT
UTILIZED THE READS OF DIAL GAGES
MADES WITH THE USE OF SOME
IMPORTANT CRITERIA
1) EVERY DIAL GAGE MUST BE ZERO

IN ITS START POSITION IN THE WAY
THAT IT IS POSSIBLE TO HAVE A
PLUNGER DISPLACEMENT BOTH IN
COMPRESSION THAT IN EXPANTION
DIRECTION
2) ROTATE BOTH SHAFTS IN THE

DIRECTION EXPECTED FOR
OPERATION
3) THE READS MUST BE TAKE EVERY

90 RUNNING THE TWO SHAFTS
TOGETHER. THIS IS NECESSARY
TO AVOID MISTAKE OF MEASURE
BECAUSE OF SUPERFICIAL
IRREGULARITIES OF THE DISC
4) TAKE READING OBSERVING THAT

THE INDICATOR READS MINUS WHEN
THE PLUNGER MOVES OUTWARD
AND PLUS WHEN THE PLUNGER
MOVES INWARD
A A
B B
RADIAL MISALIGNMENT
VERTICAL PLANE
HORIZONTAL PLANE
CHECK FORMULA
PAY ATTENTION !!
THE READS OF DIAL GAUGE

MUST BE UTILIZED IN THE
FORMULAS TAKING IN
CONSIDERATION THE SIGNS
0 RADIAL 0
MISALIGNMENT
-4 -4 +5 -5
0
0
-8
+1 -9
-8
THE READS ARE TAKEN ON GREEN FLANGE

AXIAL MISALIGNMENT
AXIAL MISALIGNMENT ON
VERTICAL PLANE
AXIAL MISALIGNMENT ON
HORIZONTAL PLANE
WITHOUT AXIAL DISPLACEMENT
A
B
5,0 -0,5
av = (A - B) / 2
B A
5,0 +0,5
WITH AXIAL DISPLACEMENT h = 1 mm

A B
5,0 -1,5
B A
5,0 -0,5
POSITION WITHOUT DISPLACEMANT

PAY ATTENTION !!
THE READS OF DIAL GAUGE

MUST BE UTILIZED IN THE
FORMULAS TAKING IN
CONSIDERATION THE SIGNS
A AXIAL
A
MISALIGNMENT
B B
V.P. -4 O.P.
0
+1 -5
+5 -1
0
+4
TO CORRECT ALIGNMENT
THE MEASURING MISALIGNMENT

MUST BE COMPARE WITH THE
MISALIGNMENT VALUES THAT THE
MACHINES WILL HAVE FOR TAKE IN
CONSIDERATION THE THERMAL
EXPANSION
FOR CORRECT POSITIONING OF THE
MACHINES PROCEED WITH THE
FOLLOW STEPS
1) CORRECT THE AXIAL MISALIGNMENT

ON THE VERTICAL PLANE
2) CORRECT THE RADIAL MISALIGNMENT
3) CORRECT THE RADIAL AND AXIAL
MISALIGNMENT ON THE HORIZONTAL PLANE
CORRECT THE AXIAL MISALIGNMENT

BY ADJUSTING THE HEIGHT OF THE
SHIMS PLACED UNDER THE BEARING
PLATE OF THE COMPRESSOR
av
S L

TO CORRECT RADIAL
MISALIGNMENT ON VERTICAL
PLANE THE COMPRESSOR MUST BE
EITHER RAISED OR LOWERED
( WITHOUT CHANGING ITS
ANGULAR POSITION ) BY INSERTING
OR REMOVING A SHIM BENEATH
EACH SUPPORT PLATE
TO CORRECT AXIAL AND RADIAL

MISALIGNMENT ON THE
HORIZONTAL PLANE JUST MOVE THE
COMPRESSOR HORIZONTALLY BY
MEANS OF THE ADJUSTMENT
SCREWS IN ITS FEET

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g OIL & GAS CUSTOMER TRAINING CENTER

IT IS AN ESSENTIAL NEED OF ANY

REPAIR AFTER A BREAKDOWN

IT IS DIVIDED INTO THREE TYPES

CAN BE CARRIED OUT IN

1. WITH THE MACHINE STOPPED

2. WITH THE MACHINE RUNNING

WITH THE MACHINE STOPPED

2. THE NON DESTRUCTIVE METHODS

WITH THE MACHINE RUNNING

2. THE NON DESTRUCTIVE METHODS

IT CONSIST INTO IMPROVEMENTS OR

IT IS NECESSARY TO COMPARE THE COST OF

Journal bearings clearance

Thrust bearing clearance

LABYRINTH SEAL CLEARENCE

FOR A BARREL COMPRESSOR BEFORE TO CHECK

1) ASSEMBLE TWO HALF RINGS

2) POSITION THE ROTOR ON HALF BUNDLE

3) POSITION AXIALLY THE ROTOR MAKING THE

Journal bearings clearance

MEASURE SHAFT JOURNAL DIAMETER

MEASURE BORE OF THE BEARING

DETERMINE THE CLEARENCE

Dshaft + Max Clearence

SLIP THE BEARING OVER THE SMALLER

TRY TO SLIDE THE BEARING OVER

Dshaft + Max Clearence

THE CORRECTION OF THE CLEARANCE

THRUST BEARING AXIAL CLEARANCE

ATTACH A DIAL INDICATOR TO COMPRESSOR CASING

APPLY FORCE ENOUGH TO THE OPPOSITE

POSITIONING OF AXIAL POSITION PROBE

THE AXIAL POSITION PROBE SHALL

USE THE FOLLOWING

1) AFTER THE CHECK OF THE THRUST BEARING

2) MOVE THE ROTOR AS FAR AS POSSIBLE

3) THE AXIAL POSITION MONITOR SHOULD READ

THE THERMAL EXPANSION

THIS MEANS, IN PRACTICE, TO

GENERALLY WE CAN HAVE A SITUATION OF

EVERY GENERAL CASE CAN BE

BOTH MAY BE SPLIT UP FURTHER IN A

AXIAL MISALIGNMENT ON VERTICAL

FOR DETERMINE THE RELATIVE POSITION

THE TOOL IS GENERALLY ASSEMBLED ON

NOTE: BECAUSE OF WEIGHT ALL THE SHAFTES

THE MEASURAMENT OF MISALIGNMENT

1) EVERY DIAL GAGE MUST BE ZERO

2) ROTATE BOTH SHAFTS IN THE

3) THE READS MUST BE TAKE EVERY

4) TAKE READING OBSERVING THAT

THE READS OF DIAL GAUGE

THE READS ARE TAKEN ON GREEN FLANGE

WITH AXIAL DISPLACEMENT h = 1 mm

POSITION WITHOUT DISPLACEMANT

THE READS OF DIAL GAUGE

THE MEASURING MISALIGNMENT

1) CORRECT THE AXIAL MISALIGNMENT

CORRECT THE AXIAL MISALIGNMENT

TO CORRECT AXIAL AND RADIAL

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