MAINTENANCE

Introduction:

Maintenance know as fault detection and diagnosis then repair or replace faulty
parts and ensure that plant and equipment are available in a good condition to start
work.

The Condition of Machinery can be Judged by the Following Factors:

1- Performance of machinery.
2- Downtime of machinery.
3- Service life of machinery.
4- Efficiency of machinery.
5- Safety of machinery.
6- Environmental impact of machinery.
7- Cost of machinery.

Type of Maintenance:

1- Corrective Maintenance (CRM).

2- Preventive Maintenance (PM).
3- Predictive Maintenance (PDM).
4- Pro-active Maintenance.

Maintenance of
Mechanical Engineer
EQUIPMENT

PUMP

Introduction:
 A pump is a device that moves fluids by mechanical action.

Fig1. Types of Pumps

Application of Pumps:

1- Pumping water from wells.

2- pumping oil and natural gas in the energy industry .
3- Aquarium filtering.

Pump Arrangements :

1- Series arrangement ( can get greater discharge pressure).

2- Parallel arrangement ( can increase the flow rate).

COMPRESSORS

Introduction:

Compressor is a mechanical device used to increase the pressure of a gas

(compressible of fluid).
 Fig2. Compressor Types

Application of Compressors:

1- Air conditioners (car, home).

2- Air pumps.
3- Home and industrial refrigeration.
4- High pressure car washes.
5- Hydraulic compressors for industrial machines.
6- Air compressors for industrial manufacturing.

VALVES

Introduction:

Valve is a mechanical device used to controls and blockage the flow of liquid
and gas in pip.

Types of Valves:
 1- Gate valve.
2- Glob valve.
3- Butterfly valve.
4- Plug valve.
5- Ball valve.
6- Needle valve.
7- Diaphragm valve.
8- Check valve.
9- Pressure Relive valve.

Function of Valves:

1- On-off service.
2- Throttling (regulating) service.
3- Prevention of back flow.
4- Pressure control (control valve).

BLOWER

Blower: is a mechanical device used to pump the air or gases.

Types of Blower:

1- Centrifugal Blower.

2- Positive Displacement Blowers.

Application of Blower:

1- Transfer products in line.

2- Cleaning.
3-
 LEAK ARREST SOLUTION

Leak positions:

1- Flange leak.
2- Pinhole.
3- Gland sealing leak.
4- Clamp leak.

Pin Hole Leak

Solution On-line Off-line Standard

Replace flange to Cannot be done on – Depends on the cost B31.3

flange spool line

Cannot be done on – If the welding is B31.3

Replace portion (cut line allowed and must be
and weld) welded in thick part

Patch If the welding is allowed B31.3

and there is enough pipe
thickness
Sleek If the welding is allowed B31.3
and must be welded in
thick part
Clamp The most effecting B31.3
solution ,but costly

Belzona For low pressure and non- NON

hazard process-not
applicable for low temp
Table1. Pin Hole Leak

Flange Leak Gasket Damage

 Solution On-line Off-line

Replace gasket Cannot be done on - line Can be done on – line

Torque Can be done on – line but Can be done on – line

might help

Clamp (box clamp ,ring The most effecting solution Can be done on – line
clamp) ,but costly

Table2. Flange Leak Gasket Damage

Grove and Crack:

When you want to replace the gasket ,you must inspect the flange condition. If there
is a grove or crack ,you can do one of these solution

1- Apply build-up welding and facing.

2- Replace the flange.

But these solution based on time limitation and replacing the flange will be more
effective.

On-line solution:

1- Patch.
2- Sleeve.
3- Clamp.
4- Belzona.

*All these solution are temporary solution must be removed during turnaround or
shutdown
 Bearing

What is Benefit of Bearing:

Bearings provide either a sliding or a rolling contact whenever relative motion exists
between parts of a machine.

Types of Bearing:

Fig 3.type of bearing

 HEAT EXCHANGER

Heat exchanger is a device used to transfer heat between one or more fluids.

Types of Heat Exchangers:

1- U-tube heat exchanger

Fig 4. types of heat exchangers

2- Shell and tube heat exchanger

Fig 5. types of heat exchangers

 3- Plate heat exchangers

Fig 6. types of heat exchanger

Heat Exchangers Calculations:

The main basic Heat Exchanger equation is:

Q = U x A x ΔTm
Heat Exchangers Hydrostatic Test Procedure:

First - Prepare the Exchangers for hydro test by providing necessary blinds and
venting arrangements; Second - If it is shell side pressure test, open tube side channels
for inspection of tube sheet areas, tubes and welds shall be clean and dry; Third -
Minimum 2 calibrated pressure gauges shall be used for testing, the dial of the gauges
shall be positioned in such a way that are clearly visible to the operator controlling the
pressure during the test, one of the pressure gauges shall be located in the highest
point. Pressure gauges used for testing shall have dial graduated over range of the
intended test pressure; Fourth - Minimum of one PSV shall be installed in the test
loop to avoid accidental over pressurizing, PSV set pressure shall be 105% test
pressure; Fifth - Fill-up shell side with water and ensure water fills up fully by
opening the vents; Sixth - The metal temperature of the pressure parts shall not be
lower than 17°C and not higher than 50°C during pressure test; Seventh - The test
pressure shall not be applied until the vessel and the test fluid are at about the same
temperature; Eighth - Gradually increase the pressure in steps anh hold the pressure
for duration of 5 minutes at each step at 50%, 60%, 70%, 80% and 90% of test
pressure; Ninth - Pressurization rate shall not be more than 0,5kg/cm2 per minute;
Tenth - Pressure shall be further increased until the hydrostatic test pressure is
reached; Eleventh - Hold the test pressure until complete check of the tube, tube sheet,
joints and shell pressure parts and at least for minimum (1,0) one hour; Twelfth -
After complete inspection of all equipments, gradually depressure the system from the
highest vent point, complete gradual depressurization of the test pressure shall be
done in 1,5 hour; Thirteenth - Despressurization should not be more than 0,5kg/cm2
per minute; Fourteenth - After depressurization, completely drain the water, after this,
dry and carry out purging for thorough removal of water as per the requirement.

Finned tube heat exchanger:

Use of fin tube exchanger works especially well for an air heat exchanger. A finned
tube adds a lot of heat transfer surface area for the fluid outside the tube, which is
usually air or some other gas for a fin tube exchanger

Types of flow of heat exchanger:

1- cross flow
2- counter flow
3- concurrent flow
 Thermodynamics

Thermodynamics is the branch of science concerned with heat and temperature and
their relation to energy and work.

Zeroth law of thermodynamics: If two systems are each in thermal equilibrium with a
third, they are also in thermal equilibrium with each other.

First law of thermodynamics: The internal energy of an isolated system is constant.

Second law of thermodynamics: Heat cannot spontaneously flow from a colder

location to a hotter location.

Third law of thermodynamics: As a system approaches absolute zero, all processes

cease and the entropy of the system approaches a minimum value.

States and processes:

When a system is at equilibrium under a given set of conditions, it is said to be in a

definite thermodynamic state. The state of the system can be described by a number
of intensive variables and extensive variables. The properties of the system can be
described by an equation of state which specifies the relationship between these
variables. State may be thought of as the instantaneous quantitative description of a
system with a set number of variables held constant.

A thermodynamic process may be defined as the energetic evolution of a

thermodynamic system proceeding from an initial state to a final state. Typically, each
thermodynamic process is distinguished from other processes in energetic character
according to what parameters, such as temperature, pressure, or volume, etc., are held
fixed. Furthermore, it is useful to group these processes into pairs, in which each
variable held constant is one member of a conjugate pair.
Several commonly studied thermodynamic processes are:

 Isobaric process: occurs at constant pressure

 Isochoric process: occurs at constant volume (also called
isometric/isovolumetric)
 Isothermal process: occurs at a constant temperature
 Adiabatic process: occurs without loss or gain of energy by heat
 Isentropic process: a reversible adiabatic process, occurs at a constant entropy
 Isenthalpic process: occurs at a constant enthalpy
 Steady state process: occurs without a change in the internal energy

Applications of bernoulli equation:

The relationship between pressure and velocity in ideal fluids is described
quantitatively by Bernoulli's equation
 HVAC

H = Heating V = Ventilation A = Air C = Conditioning

The Psychrometric Chart

Some Basic Definitions

Dew Point Temperature (DP)

The temperature at which the water vapour in the air is saturated

Relative Humidity (RH)

Humidity Ratio (Moisture content)(W)

Sometimes called specific humidity, is the ratio of the mass of the water vapour mv to
the mass of dry air ma.

Saturation Ratio (Degree of saturation)

Is the ratio of the mass of water vapour in the air per unit mass of dry air to the mass
of water vapour required for saturation of the same air sample.

Dry Bulb Temperature (DB)

Is the normally measured temperature.

Sensible Heat

the sensible heat of air is taken as the enthalpy of dry air at that temperature as
calculated from 0 oC

Latent Heat

Since all the components of dry air are non-condensable at normal temperatures and
pressures

AIR CONDITIONING CYCLES

A/C equipment can be also classified according to its working mode:

Summer A/C system,
Winter A/C system,
All year A/C system.

All A/C systems work according to cycles having the following operations:
Mixing process between the return air and the outside air,
Treatment process: Cooling, Heating, Humidifying or Dehumidifying,
Removal (or add) heat from the conditioned space
 Figure (2.2): A simple summer A/C cycle

AIR CONDITIONING SYSTEMS

Figure (3.1): Relationship of the refrigeration and A/C

CLASSIFICATION OF AIR CONDITIONING SYSTEMS

o Unitary systems
1. Window, Split, Package, Roof-top units
2. Heat pumps, evaporative coolers.

o Central systems
1. All-air systems
2. Air-water systems
3. All-water systems.
 Refrigerants

Refrigerant Definition

Refrigerant is any substance which acts as a cooling agent by absorbing heat from
another substance.
What type of AC systems are available?

Cooling Only Split-System

A split system is a combination of an indoor air handling unit and an outdoor

condensing unit. The indoor air handling unit contains a supply air fan and an air-to-
refrigerant heat exchanger (or cooling coil), and the expansion device. The outdoor
condensing unit consists of a compressor and a condenser coil. Split-systems are
typically found in residential or small commercial buildings. These systems have the
highest energy efficiency rating (EER) of all the available AC systems. Manufacturers
are required to take the EER rating a step further and provide a seasonal energy
efficiency rating (SEER) for use by consumers. SEER ratings vary widely and range
from 10 to 20. The higher the SEER rating, the more efficient the AC system
operates. If heating is required, an alternate method of heating the interior of the
building must be used, usually in the form of electric or gas heating.

Cooling Only Packaged-System

A packaged system is a single unit combining all the components described in the
split system. Since the unit is a package, it must be placed outside the building and
indoor air is “ducted” from the building to the packaged system and back through an
air distribution system. These units typically have SEER rating from 10 to 18. If
heating is required, an alternate method of heating the interior of the building must be
used, usually in the form of electric or gas heating.

Heat Pump

Heat pumps are similar to cooling only systems with one exception. A special valve in
the refrigeration piping allow the refrigeration cycle to be operated in reverse. A
cooling only system cools the indoor air and rejects heat to the outdoors. A heat pump
can also cool the indoor air, but when the valve is reversed, the indoor air is heated. A
supplementary electric resistance heater may also be used to assist the heat pump at
lower outdoor temperatures. In colder climates, heat pumps require a defrost period.
During defrost times the electric heater is the only means of heating the interior of the
building. These units are manufactured as either split or packaged systems.

Chilled Water System

In a chilled water system, liquid water is pumped throughout the building to “chilled
water coils”. Since the liquid water needs to be at a cold temperature, a “cooling
plant” is required. The plant is typically referred to as a chiller plant. Vapor
compression equipment in the plant, similar to that described in “How does my AC
work”, cool water to a cold temperature and pump the cold water to air-to-water heat
exchangers where needed.

Window Air Conditioners

As the name implies, a window air conditioner is typically installed in a window or

custom opening in a wall. The Window AC can only cool small areas and are not
intended to provide cooling to multiple rooms or zones. These air conditioners are
manufactured as cool only or can provide both cooling and heating. An optional
damper in the unit can provide fresh outdoor air if necessary.

Packaged Terminal Heat Pump

Packaged terminal heat pumps (PTHP) are are similar to a window-mounted air
conditioner. These units are typically installed in a sleeve passing through the outdoor
wall of an apartment, hotel, school classroom, etc. PTHPs are completely self
contained and require only an electrical connection in addition to the opening in the
building shell. They use the outdoor air as the heat source in winter and as a heat sink
in summer. They also can provide ventilation air. Flexibility and lower installed cost
are the primary advantages of the PTHP. Disadvantages include in-room maintenance,
higher operating cost, relatively short life, imprecise "on-off" temperature control, and
they can be rather noisy.

Entropy Definition:

Entropy is defined as the quantitative measure of disorder in a system.

Calculating Entropy:

In an isothermal process, the change in entropy (delta-S) is the change in heat (Q)
divided by the absolute temperature (T):

delta-S = Q/T (J/K)

Enthalpy Definition:

is a measurement of energy in a thermodynamic system. It is the thermodynamic

quantity equivalent to the total heat content of a system. It is equal to the internal
energy of the system plus the product of pressure and volume

Formal definition

H=U+PV

where

H is the enthalpy of the system,

U is the internal energy of the system,

p is the pressure of the system,

V is the volume of the system.

NDT:

Nondestructive testing or Non-destructive testing (NDT) is a wide group of analysis

techniques used in science and industry to evaluate the properties of a material,
component or system without causing damage.

NPSH: net positive suction head

ASME: American Society of Mechanical Engineers.

API: American Petroleum Institute.

TEMA: Tubular Exchanger Manufacturers Association.

prepared by:
Eng. Mahmoud Mahallawi

Emai: [email protected]

Eng. Moutaz Masudi

Emai: [email protected]