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This publication has been made available to the public on the occasion of the 50th anniversary of the United Nations Industrial Development Organisation.
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UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION Vienna International Centre, P.O. Box 300, 1400 Vienna, Austria Tel: (+43-1) 26026-0 · www.unido.org · [email protected]
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Report on A ctivities of 4 . UNIDO-Workshop ron Fertilizer Plant Maintenance
Place or training CHEMIE LINZ AG, Linz, Austria Period of training: May 11 to June 26, 1931 Participants: Mr. Md. Mansur Rahman/Eangladesh Mr. A.U. Mohammed Zubair/Bangladesh Mr. Yang Zhichao/People Rep. of China M;r. Dessoki R. Ramadan/Egypt Mr. Prem Kumar/India Mr. Johannes Pudjihar':o/lndonesia Mr. 'rtursidi Iaziioor«^noto/lndcriesi 3 Mr. J.A.M. Silva Costa/Portugal Mr. A.M. Ferreira/Portugal Mr. A. Hassib El-Asmar/Syria Mr. Murat Ercan/Turkey Mr. R ifa t Günebakan/Turkey
Training programme: 1st veek: May 11 - May 1 5 ,1 9 8 1 Opening of fourth workshop by Mr. C. Keleti , general inform ation on Chemie L in z , vorkshopprogranune, instructions on safety measures, fundamentals of maintenance, spare part?; system. 2nd veek: May 18 - May 23,1981 The training took place in the technical section rf the ammonia dept., central workshop, electrical-
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and instrument dept. The team was s p l it up into several groups. Study visit to peat pro ducing plant near Salzburg. 3rd week: May 25 - May 29,1981 Activities were set in the technical dept, for water supply, gas reforming, air separation, urea and melamine production, central workshop and m«iteirûi testing dept. I 4th week: June 1 - June 6 , 1 S81 During th is week le c tu re s and p r a c tic a l work took place in technical dept, for nitric acid, calcium ammonium nitrate, ammonium sulphate, sulphuric acid, compound fertilizer, cement, phosphoric acid, single super phosphate and central workshop, as well as water supply and gas reforming. Study visit to hydro electric power s ta tio n on the Danube. 5th week: June 9 - June 13,1 £»31 Training activities centred on lectures in measure ment and con troll d e p t., c e n tr a l vorkshcp, n i t r i c acid , ammonium sulphat, sulphuric acid and compound fertilizer plants, heavy duty bag production faci lities. Study visit to maintenance section of petro chemical plant in Vienna. Inspection of heavy equipment division of Voest Alpine. 6th week: June 15 - June 19,1S31 In the departmens for civil works, engineering and design, material testing, instrumentation, boiler inspection and safety valve repair, training institute, electrical maintenance, nitric acid, sulphuric acid . • and ammonia production.
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7th week: June 22 - June 26,1981 The final week was spent in vater supply, gas refer ming, cooling water plant, material testing dept., instrumentation, electrical workshop. Seminars vere provided on cost con troll, pollution controll and refractory lining. Study visit to maintenance section of acrylo r.itrile plant in Erins and to bearing manufacturing z^rks in Steyr. 5; U К Vх V* V ■ c t , r С В i Jv '• Со i i. \ o i Vi ! i ! ' ^ \. \ л> 3 ! ; 1 ' к N í $ - 4 \o í ti ¡ '■; : 4- 5[ 1 V к V i . * ii- к ^ i 4 ^ vi ! V4N1 С f>i » I * , ; ' ! Ч£' ÍJ с c. i < Ч" ! ч V« N c L ^ £ 1 ] * - Cs Ч t i V . U к к ; £ > ' vt - 4 ! V ï 1 1 * i ^ к Lí ■/. $ Ì с- Кл с i i N .>4 U’ ti ЧЧ S Í : У О- ^ :vv C * c 1 i k \л Ч '"Ь 1ч ! ? V V 1 ^ к * ' ‘•Л 'й 4» tt t — ! ^ ! 1 ^ \¿ 1 • [ ^ ' чг> > Í ч! t < 5? ! í - 5 IT I ! v j i fe t ______: ll) ( y H 1 к > ! í 1 s ♦ ! «У
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'/Z 1/ / /j A / 31 . >/r/ / £>Ay ______I I CHEMIE LINZ Afì u Month: June 19^1 •l V IV L 'xüi- Name;Mr. a .U.m. Zubai. r RECORD OF WORKING TIME N ationality:Bangladesh ^ P r o je c t: UNIDO-WorJcshop a te D e p t. A k t i v i t i e s Signature CL A T A le 1 ' • ' ./• 7V . •••_/•'*/ V. .'l VS 2 A Ta/ tr*, v 7 *9 /J. p. ’ v ' *f‘ A h rn-P'' t AA/\rr.\‘tX f / K ,■>, , a, /» T.J r S-Ai / a. *. i ' . / ■". • ’ . t A V v \V 3 A TN i iAC 4 T K r\ e.%< \j '( 'fin T /r *« N 7./Ì./V 5:1/7. //»fs 7/. /•;./< ■ t . m ih>T'»j, N: t.i L’//.ßi . <■'< > •' i .. 7/r-'. " "■ A i, •(. \ \< 5 A 7 a/ '"-v 7 7ff < A A . r A.\i, . '-.fi' 1-i 4/A/. 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A k tiv itie s Signature CL Cf Ï--V T H p ne 23 s e v f F c f- n u r . *->t 9 " t V -tA t t i ^ T 'A T , ¿ i ' i s . 24 ¿ i e - y j r t 2u L ^'S/7 70 Acèvio rev/ f'^^rjr /*,/■ **;/a/T, T t / ir l ■ > !'A c t iv’ f ^ 7 SVi y/’ , * 1 25 C-C'I CtrUTCPi • 7 / Aj />i_ / tt'T7 /AÌ7 i h i l T UfiJ/fifl PP ll 0 ' / 6 >0 <'\>ihjT>P£'/_ t . 26 f / t j - t r u cL-ss/erjS 1-Ì i A-e 7> / f ■ '* / mT c ^ 'S o 'd 27 . 0 / V -— 1 '1 1 L'i, , k \> ‘ ' C CHEMJ.E LINZ AG Month: May -1981 ) IVL 4 ) Name: )'M 15. /'£/><.?// i> rscfr'oï' o f c / j t f v f fo »/1.1 ! n /f f/Si :- 18 . >- J ft uY'*/fTji iC7~ /A, Cf/Z//.//? ¿iYîlY sI/ ¿Yf'Ste /f/t/jT., f h i { 19. -^ fh L-:T lZ/j/yr//»-e_/> f k Y/r•>, Y f t , f ----frt----=------1------20. J f s e f t \ 4 X ' / f f SiÉc7Yìft~>c I'YeY/cO/ / / c i \ x r f / ‘> Cl, f O •*,?/*• z-e_a_f f c + Y e /r y-teLy ' 21 . ^ft/Yv/n.^ . /{T sfr eff/ra f Yx¿¿Cl/ ff/sr//f 22. ~l>YcrYt//J/X n f x/xxfs-y oûJ o/~x±Z./- f f / s 7 f + ■ 23. f z C u Y k - o/îîa / s/(e.Z /tee* -w /rfa sa _____ , 24. # c / , S a * ' J " Y J 25. o f x x / * f 7 h t f •y*^-/z\Y^x'> 26. - 31 . Y Z c/ f Y C/______;______7 _ 1 CHEMIE LINZ AC "Ú . Ù Month: june 1 981 IVL Name: Mr. z. Yang RECORD OF WORKING TIME Nationality: China P r o je c t: UNIDO-Workshop ite Dept. A k tiv itie s Signature CL te 1 . Xitì^— -• 2 c p f rr/ 'T?s-ccf W*/ : s / n yJ /U< L— t 7 ^ / 3 /Ó u— ■ • -7 / . --»r - - 4 ■'i 5 t< J 1 CHEMIE LINZ AC u SJ Month: j une igf?1 IVL Name: Mr. z. Yang ' RECORD OF WORKING TIME Nationality: China 81 P r o je c t: UNIDO-Workshop ite Dept. A k tiv itie s Signature CL ne 23 " i ’ r** •< , / ‘ ^ — • . . 24 f * /' • • •• . 25 26 27 ‘ » h f ' \ .Tir / >. ' j Í CHEMiE LiNZ AG u VJ Month: May 1981 * 4 1' V. TVL W Name: Mr. D.R. Ramadan ' RECORD OF WORKING TIME Nationality: Egypt , 58! P ro je c t: UNIDO-Workshop O ite Dept. A k tiv itie s Signature CL IV 10 Yvi Vii'NKjrf. mTZ"wl7r^ Voy C .L I 11 M i I CIIEMIE LINZ AO u Month: June 19A 1 IVL & Name: Mr. D.R. Ramadan ' RECORD OP WORKING TIME Nationality: Egypt P r o je c t: UNIDO-Workshop ate Dept. A k tiv itie s Signature CI» 1e 1 ' I / 3 rft ¿ ( ' Ì Y é i \ lì.tè‘1 c < iffC / - C'/\ i- L 1/1\fJl 2 t i 1 v/ ; 3 /1 4 5 6 \C-tv 7 > SS ^ <*.»/ ■ ">1 8 y 9 -it f ( /VT’P^ V\? Coq j C a 1 P*'1^ * Y _L __ ^______10 11 f-L*.' ~ tY ? i î. : ' ¡'■Wl'ZÜ? v t l ' & --/ A i sjt ./ C ¿1 .“\” v 1 1 12 ~fT\ -i.1 4— \ 'f /t / f ^ x v~ 7 / 1 i\i ~j 13 \Jic\‘T~ 7 D/_ TT4 r t-4 Vr t-A V 1- / •./ . f 14 \ V— \ / . \"\ A \J 15 16 1/ Ï? M ♦jt ¿TT_a / T" ii. > s. . t 1 1 A JÙT r*-. A P /J vjV^LUV,- 18 K v Y\ *»/ *V ^ a v/ 19 . , » / J 20 X 21 V- 22 t CHEMIE LINZ AC! u Month: June 19A1 IVL it) Name: Mr. D.R. Ramadan RECORD OF WORKING TIME Nationality: Egypt 81 P r o je c t: UNIDO-Workshop »te Dept. A k tiv itie s Signature CL ne 23 : 24 \ 7 1" 1 " s V ,* ( ftzTAtfiw i'tct/Sl 25 26 27 ' ' (/ c/ / r r r i r Î CHEMIE LINZ AC Q Month: May ig8i IVL 4> Name: ft'cn K o m /ia RECORD OF WORKING TIME Nationaiity: ¡t i .m a i i " P r o je c t: UNIDO-Workshop ■lay Date Dept. Aktivities Signature CL 10. &£NL. fAfULlVAL- /N .. VifWN/l. ATTRHAen A T CHEMIE L f n _ 11 . Cf'FN/Md f /-' F-CuPTH W eCKiHc r . / N T P C A . / < T t C r* Tc Cl. f TA N /Î c /••/.' V 1 f 12. i 1 's* O P. P SLU c P Pf.CCP.AMME r £' C/-) 7*<’.'s <*J ~/f /-v £/" C L I \s V\\JQ1 13. tt In s rjZoc rtcMZ ùn s a f f t v m/fa S o /J F .1 hucusstct* s v* i r h <■' t u, l. nr Per 14. 1 » F un ¿A MC- J* TA LS OF MAIN TE N A MC.F. SPARE PAKTS LysrCTl OF CL 15. o P.EPA/A CPCtAN/JL AT/CN CF CtiEMLG. U I N «2. - Vt± ! T Té MA/t y", fifi P T T PTP .. 16 ; \ JV 0 L / A A V 17 . 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FC, 28 . x' JA 0 L 1 h F* NcPKilicP -frv Aalfnc/hc ni j_____ 29. &Th b IICULLIPNL Fee Up-Efl Sifipppp. - ViSt r To U Ce A &ICPAC,£ •* A fi Cf'F, ’i* F, u n . j 30. * HOLIOAV l-IOLlPPy 31 . ____ 1 .CHEMIE LINZ AC3 u u Month: j unG 19^1 r'\ IVI 4> Name: Mr. P. Kumar RECORD OF WORKINC TIME Nationality: In d ia 31 P r o je c t: UNIDO-Workshop ate Dept. A k tiv itie s Signature CL le i A r a M r ß f o j f riCM f <-* t>äP~T. \/ 1 1 T Tc b~*AT£/il K j, * Aiti-É r\ b t'f t> i-/'l7bJL 2 AT G ViC,T TC Sr£/)M A E Ccfi iH Q 4 GAS D/v,<>ib*(; Plamts Ai s < v Sc ! f /v<. Cr PAcA ì-E m. s ì m ù \ 3 /I t P INTÌÌCIÙC W fN VISIT ■ A f±t b 7if«. D/l 1 3 QSML. V i s i t t 0 Pe t P 0 C.H £M T£ S c. h w e c H A T 4-€*tc-uPS/oH Te> VIEMMA 1 4 < H 0 L IJ> A y 11 15 T M P TECH ÒISCOSS/0HS <£Q. ME c H. resrt/MG^ y nETAUoQfiAPHY OP S. Tf£Ls . j PwL v\ . IAZW,,!»«■*/*,/ b\ 16 T M P O fScc/SJ >0 MS £* 17 M s c u ssiohJ w it h OES/QHS + C/Vli. £HQ6. oepT-rs. ¡m ir ro *tft eqe> 4- oscHMge Pv m PJ 1 8 ' HOl-lJ>Ay 19 f i r n ùtScvsxtoH s w /t H E” 6AS. i E CAt* CL ¿v* Cpj mAsrp H£At &on-ep^ • jfU_____ 2 0 \ H ot-i x> P y 21 V H o a r>AV ■ 2 2 T rt E $ PM E P A L v is e t TC /NJT)A;vWA/r T>Gpr r CHEMIE LINZ ACI Month: j urlr> i 9fli IVL ' & Ñamo:Mr. P. Kumar RECORD OF WORKING TIME Nationality: India 81 P r o je c t: UNIDO-Workshop i t e D e p t. A k tiv itie s ( Signature CL fi T/V t>, s.c >.*is C ê A t c c 25 C c -i r C MTC L ^ / 1 - Ì I TBILNEHMER аш 11 4 . UNIDO - WORKSHOP ON FERTILIZER PLANT MAINTENANCE » 11 .5.1981 - 26.6.1481 'Nr. : Teilnehmer: Geb. Daturn, Geb. O rt: A n sch rift: Beruf 1 1 . Mr. Md. Mansur RAHMAN 1 3 .1 2 .1 9 5 2 No. F 130. Officers Mess. NGFF Mech.Engin. Bangladesh Dacca. Bangladesh Denchergang, Sythet 2. Mr. Abul Ula Mohammed ZUBAIR 3 . 3.1954 Bangladesh Chi ttagong.Banglad TSP Complex L td .*C h ittagon g Mech.Engin. 3. Mr. Zhichao YANG 12.1934 The Petrochemical Plant Elec.Engin. China Guangdong. China Guangzhou 4. Mr. Dessokl Ramadan RAMADAN 1 0 .1 2 .1 9 4 6 Semadco. Talkha Mech.Ihgln. » Egypt Kaluob. Egypt 5. Mr. Prem KUMAR 4 . 2.1936 National Fertilizers Ltd. Mech’. Engin. Nangal Unit. Naya Nangal 140126 India D istrict Roopnagar (Punjab) 6. Mr. Mursldi KASDIOPRANOTO 30. 8.1939 P.T. Petrokimia Greeik Mech.Engin. Indonesia Sala. Indoresia Jl. A. Yani. Gresik 7 . Mr. Johannes PUDJIHARTO 7 .Ю .1 9 3 8 (same as above) Mech.Engin. Indonesia Prembun, Indonesia 8 . M r.Jose Antonio Matos SILVA COSTA 19. 2 .1950 S. Sebartio. 3860 Avanca Mech.Engin. Portugal Aveiro, Portugal 9 . Mr. Antonio Mario FERREIRA 19. 5.1941 Direccao de Manutencao Mech.Engin. Portugal Figueira Da Foz, Quimigal, 2830 Barreiro Portugal 0 . Mr. Abdul Hasslb 3L-ASMAR Г" 1$. 3.1951 Homs, S y ria Mech.Engin. S y ria Homs. S y ria P.0, Box 280 1. Mr. Murat ERCAN 8 . 6.1954 Turkey Ie tanbul, Turkey Azot Sanayii TAS Gsmlik Meoh.Engin. Tesisleri, Gemlik/Bursa 2 . " Mr. R if a t GÜNEBAKAN 2 1 . 5.1940 Azot Sanayii Taa^Isl. Kontrol, Instr.Engin Turkey Gaziantep, Turkey Sef MUhv Gemlik ОС///П CHEMIE LINZ A(« £ > О Month: May i 98l (cT. IVL it) Ф Name: A/UPS, ¿7)/ л . RECORD OF WORKING TIME Nationality: /aj.õckc л/-\ * P r o je c t: UNIDO-Workshop а У )ate Dept. A k tiv itie s Signature CL A /\AL A '4~i_ /*.' l i W M A x i Y C L 10. •Л 11 . C'P l k / a)¿-> c/J//c ¿/ T- n с’л'д'^/г/' /Л, /~P¿'/11 С/ уaa¿< ГС Oc. A ¿/)*.<•>t'С 12. IVc/CKÜ/f С/’ P/¿ci'С Л 1С-/¿ ~ , C'äJl-Л A./)»/~/r*L Г Г 0 Г У Т .... 13. Гл,итл'ч вГ'СУС ¿'/L A/TMI . />/Л0 Г$Х/1'АС ty.C-tl'tt •ч V f4 14. Tl л , аАац к >'4 с * с г А/А/л.'гсллл,с-С' $ s» * .¿ *а Г ас з'улуг л / г a 0 L I 15. /<У t'AiSL ¿c Ал,/)А Г/о л; р г a L. / L¿J>r /г А /А/Л, TL-А, /)у сб " SY )*}/.',~У/ССА АС? 1 16 ; fToJL/ А А-у , 17. H o l / а * у 18 . А г H- / /ШГГФГТ fe АЛСьЛ'гл; /t/Ьъ-и-г A-tA-tjcrcbA-Kc с *с¿У) л; < ьУ)т} ¿ ч / tr>¿^ /0Г L '/¡/Г'} /<Г ¿i //, ' ^ 19. A r н óc/w¿^ г н и л ее ? L i-rey Coaja./ ч:с4с/v ч / o t h ., - J К / T A T С А 6 а /tv Î А Г,СЛ; ¿у,7Г 4К/> СГ4К/>*Ау / ГА /Р Ь + ^ а Г- л ъ ¡Т-ктОА ‘ /Ы ^ 2 0 . Т Н г/ГА Р S-LiC-tucr . ï te Air ÖA ^2-rc, C f / ' '' ÍC.CT¿ К ¡/¿л^чУ __ Агг<-'{Г,Г~>С' '4 ИАН г /Ъ а с ол/а/СГНС/ к 9С2-иПС~к /МАГА V ¿ i//s> f l ' Ь/Л) ¿í¿¿ 21 . A T b ¿ г .. - 22. A Г H- T ?sc L iS-/¿,v Cjnr~tíi~ /V’2vv ГССПЫС. y A¿V>áí-7~ С7Г- 1 f v 1 7 23. ^yCt/Aír/XT/L' 7~ 24. r P ri-C P A T . sASCCSJ/CA AAitf’T' ¿v Crt-~ £'r m / aí-aç /ГЛ/£> / У~С J A t '¿> H ¿¿г А АУЛ/- / ~ Т ( А •7С/Л*/' <г/=- 25. г м p . SAJL/Г' AÁ&C / V ¿M A%.j> AZ-é-AtuC t-^-rx-ek * / Í^í/C í./éV£K. А СС-К.А-/С- ¿/A.'L 7l 1 1 Ш * 1 - ÃAPiO /¿¿‘Г о У 1 < r ^ ^ r¿ T \'C /¿ < T t í A ^’C A A **- /УГА iL>*Ç¿ y f ¿ " K , K / / v r /С 4Js\. ¿''TC * ¿ t A - — 26. ТАР 5¿'A !£-/«/^ МГТЛсЛ'#/СЛА>иу /W V^W 7YÍX> . 3 ! л Й Г A^TM ivTXr'c^ t /L kjOZ l \ Ájt*u 20 z a p / / /y/t i' / -' W ^ ! 21 H p L/A/) A / S (A a .'A/[ y \ AsA~C~rr*ft ^f-z. y-1/7 yrM "<> / / ^ » X 7 > y1 / / » ,VV ' ' ’ V'y ^ , : ^ • l<' / ^ ^ 22 r e ~ L . I ly . - iV « . jr //¿" y- t . A / ^ y ; J ?~b A -y . o-r, y- \ T r 7 ^ 1 ^ ^ Z.-//A (V/)/ A y CHEMIE LINZ AG Month: ¿y/ l r>) IVL 4 > £■■ Name: ■ /. /’ ¿/ //// /j RECORD OF WORKING TIME Nationality: -igg-, P r o je c t : UNIDO-Workshop Date D e p t. A ktivitie s Signature CL Mav 10 (*f€NCRA-L ,f /? R / L’A- L / /V IT '(T V A- . A- T T € A' P r 0 A / C. C *7 l'' A or AT / ft & c p T M ’cT ■16 - , ' ^ L , d A y - - 17 — />6 C/ d 4 y ~ 18 A t m MSA*/*’ J СНЕИ1Е LINZ AG {J .1u г МолL h : Junc l 9Я1 IVL Vi) w Name: Mr. j. Pudji.harto^ ■ RECORD OF WORKING TIME Nationality: Indonesia P r o je c t: UNIDO-Workshop ite D e p t. A k tiv itie s Signature CL ie 1 Z fT é r Affrifa/A/cr / V / Ci/jv, v/T/f 4Г& /> '/> / fcb/s 2 4 т Ф '7lKA/ P lÀ ЛуСу/J/cv stT# СЫ/ AFT ù WCW f i f a г 7 * C/A . \ 3 4 r r /Ъ т Jc<*y ÌJJiìi-JHtx. V l i { /f-r~/’ Mj'r-, / Af'CAutr-', a AV.7 Cf/U- 4 CreveKt-L &r&A‘/AtS ^С7/*;Ч V/t'/f / Л/g* У tfl/ào ¿ 7 7 Ь/ЕГГ/Цс У*ГА t/fy/po & 4уфл' к'.Ар Сф /Ц’л' 5 / f TP ¿4\j<-1 ¿'Tf-Lt-x, b ì t y /f/7* Л » н /■/••» ^/>i. K.J l/'ì.£- 6 (rttV ìiW I /'■e ì/'/J tT ir p 7C v t к s'?4 ititi , l Ài' c \ U i fi to'/A, V t ?ti ) 7 — ÀOÌ/* t 8 — /J~&//(£ *-*, «t fu i" 7ti;*x /ГГ\Х .... 9 T f f k l /Ч с у Н ^ у Af-rtr-tutì, f t t u ' Ю T it t i *' À-z/^ty^C /*4W-,\ //.'Jr>*cl 7 / ‘V ^ > c / bKSwjtr a //. '‘y t i t " 'u'v ------I И 7 f f V " A 7/#47f ’ . - / ______:______,. / ,/ il CHEMIE LINZ AG ' J M Month:Mon t h: j unp t 9я i IVL & w Name Mr.j .a .M. Silva Cont * RECORD OF WORKING TIME Nationality:Portugal P r o je c t: UNIDO-Workshop ate Dept. A k tiv itie s Signature CL ie 1 T h w J t u f4 {- 1 }<. U i . 2 T h vJ jllv ._. .. ' 3 T h к/ ^ч+п ííuj',v^. 4 кл tz-o-il/^ kr,^,...... rU¿- -____ 4 Кл-í h Wl I h Uaa^cÖc) (X^jí-1 i J-i j-*Ui-4voL-k СЛл tVwtí. Cr ■ Í7.Ç í: l k¿ 1______5 T и лУ kl-l vj-CíAé a^O, ixJ^ 4- LjL tJLoilti-OX-í (*л 1C >v |~.л . 1 í ( a _ . ----- 6 7 — 8 — % 9 Ат P (j ...... * p ■ff]- /1 ...... C o _ v Ì ^ ¡ J <г < - ■4 н 3 1 u l 1~ * tí п 00 V ã <Т\ ш • • и- > * >ч • íO X •Н s : - И f l * •• С £ • • О л -> о •н с Е 4J о Ю X Z Z Э ф Cl x »-4 Е- СЭ J « о . о £ (Л -К ь 0 > 1 с о < о *-| N Z Z гэ и •J ы и ft о •<-> о “ > и о ^ а . CHEMIE LINZ AG S ri \J '»k .r w M0nlh:May 19»1 IVL VÌÌr w Name:Mr. A.M. Ferreir-i ■ RECORD OF WORKING TIME Nationality: Portugal 58-1 P roject: UNIDO-Workshop ate Dept. A ctiv ities Signature CL av 10 I ~ I'v n irk .' it- <■ H C H J r L.U' i '■"() a i.V 1 V /■» l Pm \ i w.' 11 9 1 . tljtL f> tHEhih L T i v V . Vf/A fc'T r T U . eCi W & r tc r 1 12 13 14 15 16 . , 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 J CHEMIE LINZ AC] u \J Mon L h: June f V ,r~. 1981 IV L lv*/ № Name: Mr. a . m. Ferreira RECORD OF WORKING TIME Nationality: Portugal P roject: UNIDO-Workshop a te D ep t. A c t i v i t i e s S ig n a tu re CL ie 1 4 t m v»-if 6A<«: J«U C W 0 T -A -T W V IS IT 'lO. (o i< « U ^<-1o A t P nvr 0. 1 M iu u i: (.ct„Tcii- >riTi L, VA. V 1 2 AT ^ uEfo*T t* .»Ol-T ^ f 0*\ ri> F ">V 1C rv**/ n "hr: l?r*'Vi7 VJlU*. . tfT 'llT T O I ti-fi 3 N / * w 4 f% pwF-c a l f- T I fti S- uu'TH T -k ?p TTsw A u t> .ol/ tI gS n f r.ft»C' P e r . .IIHtTlwjC- U TlH u 5 t T. y i\-i^rt 'Irf C A K' Va- 6 Excoitvrow ~io M y rto -PLECTurcft-L. Pe iWE«.s-T a H oM A R OCpr ft) S> P M 7 — HoL 4 * y _ ...... 8 - 9 f. C&&4VTiATTo*j r f ATP. . v js t t T o s.s . p 10 *v t T \j;i-»i4"~(t> T 'k o ^ \v : k L /1 i ■ ii. 1 tOvC'H '\^i\ 11 ft T ' p u W ^ V -Nii.^'4-'Vo •■ v. nA ’if- V) v\ r^Cv^'V'- 12 T^T T I 0 .vOtST A L PI ft / LIMA 13 VI^IT ~10 Ppltc [HPMiC 7 l/Iff/A 14 15 AT- >P 16 is T P tfv-fci 'It; tU* № f k ^ ‘ -‘V-\ixaV P ^ i P«-'! O-.xu/vutw ,-(m W ' '".I- 17 Wt.v { ■ ( } 1 ’r ‘ ■ ' ' * CHEMIE LINZ AC Month: May 1981 IVL Name: n / i . ¡\ ■ ,ltAK ‘ RECORD OF WORKING TIME Nationality: ,,, * P roject: UNIDO-Vorkshop May Date Dept. A ktiv ities Signature CL 10. rjrni 't*' vafTuui . ni4tnJéaü**Hfr r? v-Häm salma c f c i ■ /' V v - 13. Un '/cui iton i rh un a tursi > dncun/oh ui// (nfd dff'A/i ,.nu r 7 14. f*ndflto>unt\,U vi'/nein 1U /<•/>/ ri fl J 1 15 . / X !•/»«//- tfiri/Uitien Ctti. Yt}>f TC t ’/O-dd UfiilC t ult/ 'à i / A J P 16 . / ' tbl'Jj* 17. / ite Dept. Aktivities Signature CL le 1 A T N , /7/ „• 2 t\ n V />/it u n t e t i flu r-,L*l/ ..III fit rsf\, 3 A r / v ■ ' / 1 /1 /i, latiCii » / r/u /./// >r,irjftr ‘ Ic'ti'.'t 4 5 /1 T/V *■ 1 ' 1 f f'' 1 /"OV /V ! .1 1 < » t Il 1 1 i <-?! 7 >/,< / r < / 1 / 1 « 1 . Ll.t /lillà t ' i ^1/. ,H ■ __^ 6 •?,•)>*. l Ai iti'Lli: .1 ?L< filiujmtJ/ 11 fllllN ///PtÎL i lit T t\U f/.i.l' II'/.’.II 1 _ . 7 / J____ 8 / 3 /Pi /n/»f 9 ATT. i A , 10 lyV U C ^ N ATÌ' ^ L'rt'imn 1 it //'fun 1 i / h i d l’itnl/ m u / Alili l>fi u,, L /h iti l'fmi/ 1 1 1 ATI' i/'/OP-J if » a A t 1 - ^ .5 ‘'lK< / 1 ’ V ii// A' -i- n-' P ' V h / • 12 Jt »U. ¿4/ V//// A V W i/ JllriMf/l )Hl 1 3 lOU i 1 5 ATH 16 ATI] . A r ? »An11 ^Vu -L^ 17 V/U . .»< 18 / ! -, (r. i| . 19 AT *'i k ( / 1* //•//«»" H < /rf r f« n t a > -H-J ■ h ïwii >M t"-'f timi tMi.//’.i 1 li/i.;//. 1 /L '.i . i . u < ¿ ^ ,1 / 20 '/. i j ii 21 / iL: J 1 i'<“1 22 T r L \'D‘ t V'V fl L f ilCii./ ‘u-*i l<— ------CHEMIE LINZ AC, /J u Month: juno i9fli /4 IVL o .t ) 'xtf' Name: Mr. A.H. El-A^mar ' RECORD OF WORKING TIME Nationality: Syria •81 project: UNIDO-Workshop ate Dept. Aktivities Signature CL me 23 .7 / - 7 :,i- 24 V - ‘< v-'t'f ACKU , ,;„.J.v , S'Tt'Yrt ; 25 i. i '' • /Li i f. LVr'tV.- . A-br»/ •'¿•¿hhi'i < >■ >i /•$, / 26 27 * : i i !------CHEMIE LINZ AG Q 9 Month: May 19gi IVL & Name: ^¡kR i'T £•-*,/ ,»:v * RECORD OF WORKING TIME Nationality: y ' Project: UNIDO-Workshop May Date Dept. A ktiv ities Signature CL 10. k*-ne> ^(i /\ r n 'v ,T .A n \/i-üi'i'a.r ^ itr:f.w ieJ V:,y ' L - . 11 . -7 Oy>._',Wr.c|.. / li 47 j ip i.! '■'.•),]>_ t • >. r. / 0 7 rn ¿t r. n 12. h i d i 'i 13. lA 'tri, i tiLi-.i £>»'>. s o f ' i t y WÎV.!A,'11"Î. , ri i f „• . i.i.-ilA C.I.U-;/ .7-: f,-:ir .v i -iv/ l T f c n r / 14. L j> M a i l ' l? L \ ct i\c “ ! /p-n re ^ a r f . M u.j.' £ r rVt o f C L . . I . // 15 .) 16 ; - 17. — . 7 7 W £ . f- InA. öt pt j Vijit fo In.fit'. w ^ r k j / i c p 18 1 / / / V'-"V /c ih r > -ire jft.fy ' 7 rW £r ^ V“A 7‘ ¿At? ^ ivtruu-i > c. «..«>7 t, , c'«.! )*/u/t4s 19. r n a r / s < ^ ------yl 23. G e n r f o I IG A. C Cr j t ci7 ¿c P o r 7 c * 6 L n i- < : r -c->t j Iz i'i.i1 i.f . / V .. I f ,r 24. — 2_5 « 7 7 7 VV O r so h 'J 'u t-/ ( 1/11 ru 1 \ 26. T h w V /Jif 7o ihe Crrpi-nJi> rij p/c-jfic M(,lc-rml onci r l i f e t /Vi r 7 27. O r ne * - n i G en ero/ Aij'e^fcnK/î ivi ih /Ae B L T n c a l end t t * i c i £•/ tV c r i W u p an ca • — 29. THW 7c /A r fi v i ' J m, 31 . — CHEKIE LINZ AG {J Month : r •• June 1 9 3 1 IV.L &> Name: Mr. m . E reran RECORD OF WORKING TIME Nationality: Turkey 31 Project: UNIDO-Workshop a te D e p t. A k t i v i t i e s Signature CL ne 1 T m W ^ ^ T !f\/ c ► '«./ J) '£T t- 1 c ' J f'trvt ¿-/i u ! 1 /i. .'mr Ì i Ao 'j '■ ■( i. > Ì ( 1 1 U/\ t 2 t m W \ -,IVt 1 C | 1 ' i w » t • *U‘* |c* fM * : ^ t i H ) t * iXl t.» » ù*\ i *\ **•1 M t •> 1 f r t i-i n i (j l/i i /1 i *C ' r 1C j'c *i > i,i « 3 TH v\/ N *• I /c *Ikì ~Lhi in <•', .k Ih i /, / i i t J v m n -,/ .•ct' « -» ; < rj£ ¡i'ifh *hr in K-rAn c . 4 (3 C‘i It r>': I V ii"/ ^ Hk j / r>q . C r-Itvri/ vv/Wl (A/m (. < t n -1 "Jit V\,'l i I-; ¿i v ., / t f t J U o i i ». ■' /'Ì 7 , 5 ~T H VV / / P<.^ rA<.i\un^ 7 — ' 8 9 P T:\l ( IU < 11 /9 T Aj . X (. 11 r C /. ^ |\('./ 12 GV*I ir*.:/ V;i " f -fc \l c'.-j t f l p ’f'e / Linx. 13 (; r ilfrn l \ • ) "i -*c (hcii.n /'Ain't'/ V/C/’i/ k i 14 — /■’.;;ii'./ii.i --ii c o t "t r k ! • vtf tin r 1 i it-m ; vs (< vc ( i / 1 >•> :j r'iv ( a . ^ i/ '■ A / / m f| 15 T /VI r 16 T i ^ r J*/ Ur^i **c * c ^ \ »luA ■. ^tTti' l '( ^ vt f c v f i#»Cj e-'«/*, /* t- M t 17 & (VIer ci C e i r e . i l Airc/.h<> »• w- ^ O vi 1 <»»•«:' PcJiy/i tk - f i ' j . X‘-i i ic / ■ / ? & < ^ ------;------u ; ,-*n 1 »Vi. vi c l : 18 — 19 T M P 5Vi/f/'ec/ c/> i^i t»11 (Iv j 1 im/ i / ' V C ¿(. / ■/'io'/ e • f'.v; r t P 20 — 21 — 22 f i r e > . t- /y /t< J i rw.-.« . / • CHEMIE LINZ AO i f ...... u J u n o i9°'i /4 J'W Month: IVi № Name:Mr. M. Ercan ' RECORD OF WORKING TIME N ationality: Turkey >81 P roject: UNIDO-Workshop ite Dept. A k tiv ities Signature CL / ^ / Sv v _ij n.,| c / * i c (’ t w < i • ^ J > /t < •'A t **/'■•(p C| ‘•s«: -'fc,) /v m ' » | ' /’’* "f i '/ ' * ♦ ' * ' o v ij t p- ri o f", jie 23 •It e 24 * / t "/ C /’^Cf yli'M t / »Cl/7 T i a J' /» * «;n( / )» k-i . i * a «'y , /nTf / J V t y \ *. : f)i ; c t > / /c^ i t t O 1 1 m ! i • / M/\ci f«. c /. /» ^ / / /»11 r / /. ''iy n,. f ^ 25 C ~ t’ llt'I'il / 26 p~mul c ¡i-‘ <■ «- ■ •/,i u - « » ; c- y ■ i' <■ i ' o / J / v . ,i o r/i i ; > ( c' 27 ✓ / . ’ H I ¡ 1 ^ u * i I f _ ... w CHEMIE LINZ AH 9 9 Month: May 198n IVL Vf) # Name: P,/o/ (-u/\u /v; » ' RECORD OF WORKING TIME Nationality: \r c. " Project: UNIDO-Workshop C Le. •i ) May Date Dept. Aktivities Signature CL 10. (-I'.tt/'J-U f A t r 1 •< 1 / n Vi f lion , ri / / f n 7 f lV l> V ^ 11. ( 0 /5 f r? i n of //?£ Z W i't /: / r o <:/(.< f //1? n ( c C l r L 1 12. Wcrfslirp dnjfrif" r r f a n/sc/f /on S .1 r c \ ( ,-J i , m i i un W.N, ( i \; / / ,V f ^ 0 ,■ •/ ,M, 'f 1 14. /s f V.» v> Z o >vi r n 1 r\ 1 o of iv\0iitP C.i rtn( T J 'ipüi ( pciti^ «./<■» h of C i- 15. i? f pri,r 0 c ,f r' o ' sa i o r\ of C 1. \j i <> > i / c »'fl .nlcrtcoi Cc PP pa< }m< ,¡1 A i p —^ 16 ; / / cli 18 . Tfl vJ C e d r g ! \flj o r k f , k c p T t ^ T . - 19. v . // i l /lfc- 7T I 20. Z ! s/e. r> /’i./s n/o -f / if, n ca iTf/ A / g. ^ f r't a j 7 -f •> A / o ,/f . Zv.v | 21. t hvaJ C c. n/f r Li/ V/V) o r k i h & P ! 22. ¡■f " "iiit- i_l' I ■ _ f>, ^ i £ k c or Mu H t ^ p f a T plan/ of c i . vtor sf( |2 23. — f 24. .25, t a rp M "f 1? T l r« \ ]P ^ 1 1 V\ Ü5 f ^ & t Ì W\ K\rf • 26. T.MP /x 1/ p > 0 / £ } ' 27. Cc r ck \*J ^ f ^ I'l <' p >•*• vaJ ^ 1 ^ t "1 r i C ov / ) ^ «L jo f • 28 . / r g / /’ J a v/ i ■ M 29. F p f^\ r\ ^ (’ r 1 rj 1 T <*- S i l V, ^ p c ‘ 1 4M •' n f ■ " / , - 30. fl i cJ O 'j 31 . ______£______• i I CHEMIE HN¿ AC Month: j une -igfii IVL & Name: Mr. R. GUnobakan RECORD OF WORKING '"IME Nationality: Turkey , Project: UNIDO-Workshop te Dept. Aktivities Signature CL e 1 A T N N/Zr~ / C Zz. / cV C /-I 4V j A A l, A S o,,, „■/ /3 ex f /> r c J u c h 2 ff /t A o ■•f' -, ? * \\ , V ^ - : 3 .'t ' / n 't '' o JIG/ 4 j>lo o i ** X pfYy E h £ r Cl} AA Q. $ i~ ì ri f VJ f t A /.{(->! cJO Wjof ^ Coi'iiCil 5 f i T j i A j ,i f 1 C A c / oi , C A /A, A 'A A S o f) J J\a r pr 1.1 ol a ( '/ . / / / .. .. / J X 'S . / J ■ , _ ( t 15 t № f A <;fru i* i í ..tA /.'S *,/•> d } i / \ ... ,y¡ 16 1 K\T - 'V - 1 (' n \ f 1/- If' r T — - 17 Q r e, y\ <&-r o- \ ■ w\ e ■?- *\ \ (a £ , / - o . Gr >***4 w i Gì T T r c r r a c j - 18 : ’ . - / .... - 19 T KA £ ’ n \ f n > M f n “/ P (: p A - S />4 — -— vf 20 h i o / i d o-si 21 ' ' ...... , . - 22 T e L ______£ / ¿- • b *■ b o r'l ^ ^ ______CHEMIE LIN2 AG S J i j Mon t h: (* x June 1 9 ^ 1 IV L . 'M fei1 Name:Mr. r . Güri ebakan RECORD OF WORKING TIME Nationality: Turkey P roject: UNIDO-Workshop ate Dept. A ktiv ities Signature CL me 23 TU £ U . Ò -C h u r J iv » <■' n 24 •/ÌV.+ U r (fu< f i 25 C o C, - C o ^ ^ r °l T # h J-'f 1 1 v' /’ , ' / / b n IV ] , " V* / . 1 CHMEUNZA6 ] UnMrZWdwn T»9 General Information Em»ftno*r (DurdiM tiltg* an) 4. OMIDO-Workshop HISTORICAL EVOLUTION CF CHEMIE LINZ AG2 1* Start of erection in 1940, heaping up the area near the Danube for 2 - 4 meters withgravel from the port. Question of location: The new plant was situated as a neighbour of VOEST because there was a surplus of coke oven gas. The original name of our company was "Österreichische Stickstoffwerke AG" (translated: Austrian Nitrogen Plants Ltd.). Initially only nitrogen fertilizers have been produced. This old name was too corr.p2 icable and too long for inter national usage. So we chaeged it to "CHEMIE LINZ AG" some years ago. Original layout of our facilities: 1. extension step: 50.000 t N 2 . extension step: 100.000 t N Start of production - Primary N : October 1942 CAN : March 1943 In the year 1944 we had reached a production of 55.000 t primary N. During the second world wnr our plant was bombarded by SCO bombs. From Vay 1945 to July 1946 production partly sood still due to damage and power supply. Until 1948 the former production was reached again. It was boosted strongly _r. the following years. 1 9 5 7 1967 1977 Production of primary N: 164,000 t/a 275.CG0 t/a 466.CQ0 t/a The number of different products increased during the same time from 2CC to 130G. Th» most important results of our chemical - technical investigations ycu will find in the Know How brochure of our enterprise. The most significant erections: 1939 Foundation of the enterprise "Österreichische Stickstoffwerke AG" with a layout figure of 50,000 t N. 1943 Start up as an enterprise producing only nitrogenous fertilizers 1944/45 800 bomb-hits, closing of the plant 1945/46 Reconstruction, installation of the departments investigation, development, sale and training, 1948 Foundation of pharmaceutical division and continuous extension of all plants 1953 Foundation of the production line for plant protective agents 1954 Start of the plants "Gypsum Sulphuric Acid" and SSP 1960 Start of organic production facilities (prepla 3 tics and plastics) 1975 Erection of the plant at E\.\S (acrylonitril) TABLE OF DEPARTMENTS TOU CAN VISIT DURING THE COURSE ATM: Division A t technic, high pressure Single train plant for NH3-production, old ammonia synthesis plant, ammonia storage. ATG: Division A, technic, gas preparation Synthesis gas preparation from coke oven gas and natural gas, gas reforming plant, Mater supply for the whole company, boiler feed water treatment, oxygen plaot. ATN: Division A, technic, nitrogen fertilizers Nitric acid, CAN, ammonium nitrate, ammonium sulphate, storage, bagging and shipping, plastic bags. ATP: Division A, technic, phosphate fertilizers Sulphuric acid and cement from gypsum, sulphur burning plant, single super phosphate, NPK, phosphoric acid, storage for fertilizers and raw materials, bagging and shipping. BTH: Division B, technic, urea Urea and melamine plant, storage, bagging THW: Central technic, main workshop Manufacture and repair of vessels, heat exchangers, pipes,... Machining shop, repair of pumps, gears, ..... TEL: Central technic, electrical department Planning of electrical equipment of new Chemie Linz plants, electrical maintenance, balancing of rotors TME: Central technic, instrument department Planning of instrumentation systems, weighing systems, maintenance and rare TMP: Central technic, material testing Recommendation concerning material selection for new and existing slants, check of welding seams, corrosion tests,... You will have also the opportunity to visit the following departments for a short time: TEW: Central technic, civil department Planning of new buildings and maintenance of cuildings, streets, rails, sewerage. Insulation and painting group. US: Safety department Safety instructions, registration of accidents, fire origade, safety means (masks, filters, respirators,...) TK3: Central technic, design Coordination of all investments (new plants), improvements in existing plan together with production- and maintenance departments, working out of drawings and investment programmes. IVL: Central planning, li:ensîs Licenses and Know How fr GBR: Discussion with members of tna works council. MECHANICAL JUflà füfi CrênATCRS CHEMIE LINZ AG During start up of a new plant normally we have some maintenance personnel in shift ( 1 or 2 shift locksmith). If the plant is in continuous operation there is no maintenance personnel in shift, for the complete plant of Chemie Linz only in two departments (ATN and ATP) each one shift locksmith is working. For example the single train ammonia plant, water treatment and also urea plant don't have a shift locksmith. If there is a trouble the operating people (production) can call the stand-by-service (on call service). For every production department 1 chemical engineer or production foreman - for every maintenance department 1 mechanical engineer or maintenance foreman and 2 locksmith with good knowledge of the plant are on call for the time of one week after the normal working ti»«i and during weekend. Since some years in Austria the profession "CHEMIEWERKER" (operator for chemical plants) can be learned. After the normal education in school (normal age of the person 1- years) a young person can join e.g. Chemie Linz and can learn for 3 years this profession. During this education in school, workshops and different plants the person becomes familiar with small maintenance jobs. Therefor in Chemie Linz the operators are allowed to fulfill certain maintenance jobs under supervision of the production foreman and in responsibility of the production department. ¡n the following maintenance joos allowed for operators are pointed out: Mechanical jobs allowed far operators in department . . . After order and instruction by the shift foreman the following jobs are performea by production side after relevant guidance uy the maintenance side in the later mentioned units. Beside the general precautions the following particular safety instructions have to oe considered: Pipes resp. pumps are to depressurize and to drain, hand wheels of valves - if required - are to block, blinds have to be installed, switches for motors are to lock or fuses are to be removed by the electrical department. For jobs with aggressive mediums the common safety means (e.g. goggles, orotective suits, rubber boots, gloves etc) have to be used. Flight devices or masks are to keep ready, also water in form of a flexible water tube. In case ofescaping N0-, 502-, CC/C02- or other dangerous gases the working area has to be left immediately. In principle all jobs are to be fulfilled in such a way, that neither the worker nor its surrounding will become endangered. For all jobs up today a work permit was required also in future a work permit is necessary (look to safety instruction no . 6 - maintenance jobs in the plant). \ > General instructions for all jobs 1 1) Don't use wrench extensions for tightening sf screws 2 ) Tighten nuts on flanges and lids crosswise and uniform 3) Clean sealing surfaces before installation of new gaskets. Treat.-,sr.t of gaskets before use: For steam, cold water, hot water, air, sulphuric acid, lye mixture graphite + oil Nitric acid, NPK-slurry, ammonia silicon grease 4) Use only not damaged oolts of sufficient length in the required quality and use not damaged nuts. Grease them before use. 5) In the case of changing armatures pay attention to material pressure range and flow (arrow). 6 ) The general allowance to fulfill maintenance jobs is limited by nominal pressure 1C. T) Welding joos are not allowed 8 ) To erect scaffolds higher than 1,5m is not allowed (call scaffolders). Gasket material to be used: ) Stean, water, condensate, cold gases,compressed air, Phosphoric acid Ruober reinforced by faerie Nitric acid klingerit 4C0 or Klingerir Acicit Sulphuric acid 98 % Klingerit red or Teflon Sulphuric acid below 76 ji, h2SiF6 ^ingerit Acidit or klingent rsc Gils, coating agents \lingerir oilit or «.lingerit rsc Beside the already mentioned general joos for every --nit of the csoartment particular joos are listed up, which are also allowed to ce performed oy preauction oerscnnel: Some examples: Sagging and shipping (unit 62G): Greasing of vehicles (dumpers, fork lifts, wheel-leaders) w C w F Bag welding nachines: Turn or change of r izor olades Clean the filters of the vacuum pump ) Equalize felt-disk Clean preheater and pre-pressing device (grease with silicon oil) wuwP Reolace tubes Check and clean cooling water filters Adjust ammeter for heater Loading of accus «LwP Central raw material storage (unit 631): Change armour plates on conveyor chutes ¿WP Repair small defects on belts WWP Change shear-bolts on reclaimers wuwP Replace grease nipples and grease tubes *WP Clean and oil pneumatic hammers WCWP Replace rubber aprons and beltcleaners .iwP S i g n e d by S i g n e d by Head of production department head of maintenance department r Safety instruction 17 VC^cLE ELECTRIC чд\3 "CLS AYd v C l \ T I \G L.VHS To ^ix the required precautions ana Tor the interest of good cc-oceration outdoor companies and workers from outdoor conpanies uncer observance of u'VE - instructions E 1 and E f e following precautions are ordered: vo.aole electric "“and tools 1 ) for jobs in vessels, containers, t-oes and similar s-ail equipment z * ; conductive material and for jobs on such equipment with comparable narrow dace conditions. 2) Jobs on metallic conductive roints such as grids and steel-constructions 31 jobs cn good conductive Points (soil, concrete). 1 ) for joos on poor concuctive points Supn as -or* fees « i f try and ~ot - doers, offices, or tile-floors. Adcitional there is mentioned f a t oiscon-ecting oransdr-ers m,_£t oe loca outside of the dangerous rooms ana only connection of o-e electric hand to is aliened. Cn supplement you can see different kincs of electric nand tools and tne allowance of use. Safety instruction 6 •-'AINTENANCE IN THE FLA.NI All jobs m connection with maintenance, erep’ion, ;er>,::L"g, etc on or fcr scuio-ents of oiants are to he allowed cy a .erscn :*soor;;;l; *or mis olant before start of worl-ans'uc. ’ -¿ 3 is done 3 w r i t t e n "i,_'_C«A\CE - S-'ccT-’ for repair works (see sheet A 79 o), signed by the res crsidle leacer of the pertain area or m charge cf the leader by a cerson who is ’•ace responsioie oy m e manager of the department. “he allowance sheet is valid only fcr one certain .crk, Due to insignificance or littleness ano if tnere is no risx rerfor—a-oe of ;r< is allcwed without allowance oaoer. 'o ?i< such 3 1 = me re500ns1 0 1 . 1 t. of ordering- (production foreman) and oerfor-mg-o'-'ice [-jircsnarc* 'ore-an.'. The issuer of the allowance sheet and the performer of m e wcr* are resconsids for using the oreventation-xeans befoy and during f a service ..or«. Cn principle t’’is allowance sheet shail ce for all oeoole ccncerned witn ere service job: - 9 1) a m e m o r y aid 2) avoiding misunderstanding oetween ordering and performing =ioe 2) exact determination of precautions •1) clear limited rescosioility The allowance oarer has to oe signed cefor .cr< -:e :‘ :~ar':e oy me tsc- - ioa. : i ‘ Tne original (yellow) cf the allowance snaet is The observance o f the ordered safety-instructions by the executing people is c o n - troled by the competent supervisor. Allowance sheets for entering pf sewages and Purification ruts must be signed also o y the c-a'ety ter: ar me n t . Safety instruction 13 SCAFFCLDI\3S, LADDERS For erection of scaffoldings during execution of civil-works the § 1/ - 33 of t~e order about "prevention of '«orders ara e-rloyees” 13 valid, further the otanoard "G\CRM В 4C07 - scaffoldings." § 35 - 37 and C'.uRM F 51ГС concern ladders. Revision of iadders according safety instruction 2C. During erection and «orbing of scaffoldings the following procedure is coiicatery: Erection j f various scaffold is cerfcr-ea by civil derart-ent due to order— sneets ( f ::n A 19). The original of this s~eet 15 sent to t-s civil cect. from the troere ore copy together with the order '";r dismantling z f t-e scaffold regain о t~e •orcerer and one cooy goes to the safety ergineer. ''•e safety engineer has ~.~a possibility to oreceive safety interests cn time. In all the cases that civii dept, has a oermanent «сок order fcr ouiidmg of scaffolds, the number of the permanent work order rust ce written on tne order for builcing a scaffold. Tnerfcre no separate work order is required. Is there ~o permanent work order by civil debt. beside the order fcr cuilding a scaffold a.st a work order is required for accounting t"e work-ansnio The sheets are so srra~oed that ootn carts can oe written as copies, work orcer and scaffold order ~u = t is handed over to civil dept. 'he cetermination of wur<_anship in saoh 033s is to oiv.de in: с-act .lace, ri_ z f t*“? -C3rf*Cij 3rw ГЭС-1Г tii lC2C 2 rl.. i. ^ . 1 “ '• Z . rrderer take o,ar to» scaffold o-. signature o n one concerning scaffold oroei (scaffold taxen ever). Csre for the scaffold arc to -airtain it in a rsoular stete till now is the duty of the orderer. -e nas to cnec< continuously, ne is “dt rssooncipls for tna faulolsss ano reg_lar erection itn is tne e«clusi.e ti'.j of the scaffolders. rut taking over osrt. is resoonsiole for tne faultless state of tne scaffolaings. To avoid tne improper use of not read, scaffolds or seen scaffolds not ta For the case that a scaffold is not used longer, disassembling of the^scaffold must be ordered with the sheets Э - 5 of form A 99. Immediately after beginning disassembly the civil dept, fix the plate "Don't step to scaffold" on the scaffold. Than the scaffold must be removed promptly. Concerning wooden double-ladders according CNCRM F 5120 instead of chins there must ba used steel-ropes with 4 mm diameter to avoid moving of the two beams (look to safety instruction 20). Zur Beachtung! $Ji£A/T/e>A/ p / £ t s & Ein- und Auslahrt an den Werkstoren nur nach Einweisung P A $ $ T f> e s a u t OAMy A fT e-ß . __ /A firet/c/'M Die zulässige Höchstgeschwindigkeit beträgt 15 km/h. THE MAX. S>ff£j> / S A m / 6 Rauchen ist im ge samten Werksgelände, mit Ausnahme besonders bezeichneier Bereiche verboten Jo vT snek* /v TH£ AßEA o r CL, E Jftep r /M TA* SFSC-/AL MAHM£J> Das Hantieren mit olfenem Feuer ist verboten (Explosionsgefahr1) ioV'T MAMif Win, f/r e ( £K?LOS*0*Sy J e V T TA VA P liT U lb /V TH*’ P lA A 'i o Fotogralieren im C'J Werk ist verboten § LU WCRKI rjj TI"E : In Austria the general workirg tine is 40 hours per week. General shj*~t: Flexible working time: Start at morning 6.30 t i l l 6.15 h 3/4 hour interrution for lunch Close at afternoon, Mo - Thursd. 15.30 t ill 17.30 h Friday 12.30 t i l l 14.00 h Recording of actual walking time on "time registration cards". ! I T O TA L « A u t x c t WE--- MASHiNâ, -TIH£ + Gesamt- Zeiterfassungskarte CHEMIE UKZ AG : — Saldo: BÉ ---hfiTHlNÜ, T|M£ Zeitraum: ' I BA LÄ ü c i~ ö r I * Saldo- roftndt j - Vortrag : CAW N a m e : v. [ i RAi-AHCe «Pt f Saldo 1: Kurzzeichen :______b. - SAt-AMCetiDCl Personalnummer : tie, uAruee — * Saldo 2: * Saldo 1 : j Unterschrift 1 _ Summen der plus- bzw. Summen der plus- bzw. i 1 « 1 1 r minus-Abweichungen : minus-Abweichungen : 1 i I : kommt Fixzcit geht WZ/BZi kommt Fixzeit geht WZ/BZ + ! -*■ r + ; _ . - .Mo : Mol 1 j ___|______Di j Di ! i ! i 1 1 Mi ; Mi j ! j i 1 Doj Doj __• } Fr | Fr j i ; f i 1 A 41 b The maximum plus- or minus-balance of one complete registration card is allowed with 10 hours. The employees of Chemie linz can take two free noons or after noons cr one free day per month if they do not go across t^e 10 hours limit and if the superior give his consent. Shift systems: Most of cur plants are on stream 24 hours per day. For this production lines in the different departments tnere are 4 shift groups working 8 hours cer day according to a shift table. These groups meet also the 4G-hours-week with temporally fixed free-shifts. Examples for different shift systems: A 3 c D 2 shift groucs A,£ Monday till Frid-iy 6-<4 14-12 p;-tgir.g, loading 3 shift groups A,c,C Monday till Frid-.-y <-44 t o - l l tl~b superoncsphats 4 shift grouts A , 3, C , D the whole week fe- AH n - b f i f e most productions S-cCESTIOfi SYSTEM Ee clever, make suggestions In i?53 Chemie Linz AS has introduced £ suggestion system. -ow to make a suggestion: 1) The idea: Everybody can suggest. The office "Suggestion System" and the members of the works council will help composing a suggestion. 2 ) r’resertaticr: Possible over the sucerior, tne office of suggestion system or the w o r e council. Cns car also o_t the proposal into ISI the "suggestion-letter-box". 3) Registration and examination: The office check the suggestion formally and ask for the opinion o f ore or mere expert«. ¿) The decision; Acceptance or rejection o * suggestions is the duty of a "suggesticn-ccmnission". 5) R e«ard: The experts calculate the annual sawings end the sucgestior-cc-mission has to fi* m e reward. 6 ) Payme n t : If the suggestion i= positive the employee will get the reward together with the monthly salary. We distinguish estimable and ccrp_table suggestions. Concerning an estimable proposal ere can re-arc the suggestion with 2CC,- up to 3CCC,- shillings, deperdent on tne result of the valuation system. . Criterions in the valuation system: Importance err o r to o t ...... n e g l i g i b l e Kind of solution o r i g i n a l ...... a l r e a d y u s e d Effect of the proposal conplete change . . . .insignificant change Frequency of application o f t e n ...... s i n g l e Site of suggestion o wn business ...... foreign business Elaboration p ractically cestPd . .net tested Realization costs up to 5 3313,- .... more than S 5G00,- 1 ORGAN/SАТ/ON OF CHEMIE L/NZ A G . Г l j \ 4 k i SALARY SYSTEM LEAVE In Austria there is a collective agreement between the Federation of Trade Union» (labor unions) and the industry. In a distance of 1 to 2 years the two ccrties fix the wage ;->crease for a certain p-riod. In Chemie Linz AG there is a special system called "Salary regulation”. Our salary ir calculated as a sun of four grouos: 2) Basic salary (B5) It depends on the cositicn of the employee. The scale cf basic salary is diviced into 23 steps. 2 ) Seniority-value in cercent of the basic salary (EV) ^ 67 ■ years of service in Oenio Linz 90 - srtry years (age) 3) Experience value (EV) in percent of the basic salary. This value is 1 % per CL-service-year up to a maximum of 18 fj. 4) Personality-value (?V) It d'ipsrids on the opinion of the superior and increases from 3 to ^ ‘-'onthly salary: PS +- SV EV +• PV Holiday (leave credit) U p to 2~ service years : 2 A- week-days ( 4 veaks ) fc - 5a T'ore than 20 csrvice years: 30 week-days ( 5 weeks ) f\0 - S The study-years are arcounted in the sorvice-yrers in the *cllowing amount: Charge for Technical dirh Schcol : 3 years (duration of schorl 5 years C h a r g e for "'ec'-nical U n i v e r s i t y : 5 y e a r s (duration 5 - 8 years) More than 25 CL-service years: 30 actual working days ( £ weeks) Additional freetime for marriage, birth cf a child, removal, death of relations in the amount of 1 to 3 days. Recreaction leave in comoany own hostels Every 21 months: Production and maintenance personnel in very dusty and durty areas 27 months: Foremen and workers, laboratories 37 months: Employees in production cf'ices 96 months: Employees in administration offices Beside the legal rules end directions there exist some other SAFETY INSTRUCTIONS in the company of Chemie Linz AG: 1) General instructions: Competence, foundation^ smoking prohibition, alcohol prohibition, maximum speed inside the area cf CL, first aid performance, safety advise, ... . 2) Information procedure on fire brigade actions and accidents 3) Operation of fire brigade 4) Alarm ways for the fire brigade 5) Safeguard services 6 ) Maintenance business 7) Local extinguishers 8) Use of protective hoods 9) E n t e r i n g o f vessels 10) Foreign company workers in the plant 11) Protective equipment and protection clothing 12) Safety instruction N < 13) Scaffoldings, ladders 14) Storage of burnable materiels 15) Use of solvents . 16) Radiation protection 17) Portable electric hand tools (power tools) 18) Directions a^d marks for safety work 19) Responsibility for repairs on pipe!ine-briages 20) Bolt shooting devices 21) Directions for chemical labs 22) Apparatus , devices and equipments obligatory to revision 23) Loading wcrxs on waggons 24) Tr.mcoorticn tanks 25) Glass carboys (balloons) 26) Steel bottles 27) Pressure vessels 28) 5afety in the field of railway 29) Showings round the plant 30) Vehicles without rails (fork lift trucks,..) 31) Alarmplan for special departments 32) Fire protection in glue-plant 13) Report of industrial accidents 34) Transport of prussic acid Yearly control of all continual conveyors (belt-, chain-conveyors, . . ) and notice of the inspection in a check-bock. Yearly earthing control on tanks for burnable materials Control of the lightning-rods in a distance of 2 ¿ears. The ite'-’s unde dined we will discuss in detail. UNFALLANZEIGE S (Gern** I 363 da* Allgemeinen Sozialversicherung^ *»*!»« (ASVG). 6GBL. Nr. 188/19S9 .) * Meldepflicht beaeM bei Tod oö e mehr al* drei Tagen Krankenstand. De Meldnfrist betragt fünf Tage! a c c u m x r r - N o t 'c f S Bitte *et laaeuhra «insendonl Der eeila Durchschlag in tyr Ihre Firma bestimmt. t. Firma. Anachnlt (Batnabaortl. Poattaitnhf. Art da* Betrieb*« 2. Zahl der im Setneb CoHFAmJV AOOF&S b«chifigt. Personen OF G'UP aJ3Y & T 7\ 3. Familien- und Vorname des Versehrten (m Blockschrift) 4. VerKfcarwngmwfMT 5. geboren am CoMFLmTar M M f OF ffff <3fSAGC-lD pf& S0*J f A j S y ß A H c y - ¿ 4 P * M o HS cHC fZAnrjT UcruTr ¿3 6. Anschrift 7. Staatsangehorgkeit 8. Gastarbeiter A i t p ß e & S fr AMCrtOOAt-'ry i Q ~ . D ü I 9. baschäftigt ah / im Betrieb seit / Abteilung 10. Farn. Stand 11. Anz. d. Kinder \*JCßV/Aj<$ A s unter 18 Jahre f A H / u y S t a t u s F u M A e J A c F *SP#gvT/Cnt~> SFK-i>*0 I— ] «33» 1— 1 UUSHUL-t-wp i-- i C r^ O D d H 'S 12. Leteling f | ausgelernt | | angelernt | | Hilfsarbeiter 1 | ftii S u rarlJ__ u/tfime <8 yeM iS 13. Name und Dienststellung des Zustandqen Vorgesetzten 14. Vorgeseheneris) Arbeite— VPHcf Art# ?cs,7?cM c f c& iparrerur SQ FaF/cP, -,t,iPiac*iS<& sB&T^nF UCiT __ i£yf o r k . tA r '___ 15. Ziatandige Krankenkasse / Kootonummcr p “ C& H Perrtf^r ¿Xc/C-Fu*!# 16. Vorbeschadsgung (Aibeitsunfail. Berufskrankheit. Wchrdienstbetchadigung. Invalidität. Opferfursorge) mit Rentenbezug «n PFmV/euS t*JUL/£fa$ 17. UnfaHstalh im Set'iab Iz.B. Standerbohrmaschine, Kran; Aufstellungsort und Fabrikanonsnr.) . 18. Wochentag / Datum / Uhr zeit des Untalles FLACtf oF ¿fec/JatsT {» T *9 TLA k T ’T U / g f k -3AV/stkTf- ¡T /k* cr/yxißen J7 19. Wenn nicht ident mit Bctricbtanschrift: Genau* Anschrift der Unfallstelle (Ort. StraSe. Hausnr . 20. Arbeit eingestellt am / Uhrzeit Bundesland) l F a jo T f U>e?uTtC4t. IMiTH CCMPAVy APOßB s\f t'Voeji T^/Ar/SHirO ßFACY" A pP tJ S~S CM ACC/Z?gKfT~'t3‘-Ac^3' CPAT 21. Verletzter Körperteil und Verietzungsan 22 tot D B -JL T tf tA!Ju£.e2> P *e.r O FT*** C F I F Z t U g y r * . U 23. In welches Krankenhaus eingeliefert7 An welchem Tag’ 24. Erste Hilf* im Betrieb? To usH'Crt -ftosf, t a c f ■.'•Ma t z > 4 y n n Ä - n 25. Erst behänd« Inder Arzt / derzeit behandelnder Arzt (Name und Adresse) P'r4& T' /V v F(p£.T / Joj>A Y Mm ¿Jy ¿4 L TP»MT/ f F - J > o <=t o F. 26. Schilderung des Unfallherganges, so dafi sich jedermann cm klares Bild machen kann. (Arbeits^rrichtung und Unfallursache, eventuell Art der beteiligten Fahrzeuge) 3>e£C/d/PF/OA) OF THF /$CSl£>tpjr - /*) S/H PLf LOtP&S UMD&K- STA AU>/F 6 rcF ev&kx'#oj>y 27. Bei WegunfaMen: Von wo ist der Versehrte weggegangen’ Wohin sollte er sich begeben’ ACC/PerMTZ 0/0 W r « r h / A - y 0 F JMS DrSftBc&J) p&rßSQrf F£cH - 7T> 28. Unfall zeugen (Name. Anschrift) 29. Arbeit wieder aufgenommen am ( y / r v g c r THf Aerc/J> 30 Erhabung durch Polizei oder Gendarmen*7 Dienststelle7 /MSuißy' OF TDLfCcf l 31. Weich* MaSnahmen werden getroffen, um künftig ähnlich* Unfall* zu »rmeiden? 32 Crt, Oafum ¡/\M iA tr Mf4£L//2mr U/ic 6 V TV PptrO ervF B&/IIEL1NZA6 S u c h 4ce/CZ>ertY(. (M Thtr F L i T u P f FiffTtfosicmpei. firmenmaQige Zeichnung LLA ■ 1-017* U - Nr. PROCEDURES FOR ORD£f?/N Exanole for Inventory record 610/021 Sulphur melting pit, 21.000 x 4.300 x 1500 mm with coils and agitator Three phase current motor, 5.5 kW, 1400 RPM, gear transmission to 84 RPM, motor-number 693970 6Ю/С22 Sulphur pump, vertical type, size 1 1/4, . VSO - 861 - 1/4, temperature of molten sulphur 135 °C Fa. Lewis & Co ; TPC-motor, 4 .8 k'.V, 2870 RPM, motor-num'a/er 694200 610/023 Sulphur pump, equal with 610/022 TPC-motor 4 ,8 kW, 2870 RPM, motor-number 694201 610/024 Sulphur furnace, vertical construction, 3130 0 x 7750 high, steel shell, brick lined manufacturer Reisner & Wolf 610/025 Waste heat b o ile r 1800 0 x 7600 long, 225 n2 sur face, 16 kp/cm2 steam pressure, insulated, registration number 2236, boilerfeedwater-drum 1500 0 x 5000 long, 10 m3 volume 610/026 Hot gas filte r ...... « » £/*£*■ O SlSAr At IHVEETORY SYSTEM Each building in the company has an own number. Por admini stration buildings the numbers 1-99 are reserved. For the different buildings in the plants the numbers 100 - 999 are in U3€• Each machine and apparatus has an apparatus-number (e.g. 610/024 - sulphur furnace of Hon3anto plant). The first ( u u /r ) three figures mark the building in which the machine is in action. The second three figures determine different machines (U H ir] in a certain building. Electrical motors are separately num bered and inventoried by the electrical department. All machines and motors in the field and the replacements in tb.* stock are marked with the apparatus number. 1 1 LECTURE FUNDAMENTALS OF MAINTENANCE 1) Production and maintenance Position of maintenance in a production process 2) The maintenance cycle 3) Some technical terms Administration Precentive maintenance Corrective maintenance ‘■'od if ication Replacement Direct preventive maintenance Indirect preventive maintenance 2 Subjactiva inspection Objectiva inspection Surveillance Bath tub affect 4) The economic effects of preventive maintenance 4age costs Material costs Administration costs Purchased services Conversion costs Direct maintenance costs Indirect maintenance costs: 6) Maintenance in a production process a) Operation Duties of proouclion department b) C o n t r o l c) C a r e d) Maintain e) C n - c k f) P e r a i r Duties of maintenance Ceoart-ent 7) Maintenance and company—intern organization 8) The man in the maintenance process 9) Wear — reason for maintenance W e a r C o r r o s i o n F a t i g u e A g e i n g Kinds of wear: 1C) Wear- and corrosion—phenomenons a) E v e n a nd s c a r r e d c o r r o s i o n b) Hole corrosion c) Ir.tercrystallins corrosion d) Transcrystalline corrosion e) L a y e r - c o r r o s i o n f) Bacterium corrosion g) C r e v i c e c o r r o s i o n h) F a t i g u e i) A g e i n g k) T h e r m a l i n f l u e n c e s 11) Types of faults 4 12) Registration of wear-processes 14} a)Activs and b) passive protection against corrosion .a) Avoidance of destruction b) Building of a protective layer 15) Technologie and methods of maintenance ) - d u t i e s Operating people '■"aintenance ceoola knpwl gflii / acau t \ technical behaviour, «ay of operation, trouble behaviour, «par behaviour, n a terprce 3 I Methods of maintenance | i ; saint.after trouble maintenance due to pre- the plant______dstsrîîi-îd u n p l a n e d pl a n e d maintenance I standardised repair of periodical check periodical rspsir daaapes __ I plant shutdown J plant shutdown plant shutdown 1 :■•:i ■■— .. i------I search for trouble [ check operation j 1 check operation I check operation 1 determine^trouble [ plant shutdown 1------"T”------j [dismantle^partly 1 dismantle partly | 1 dismantle partly | dismantle partly ______1______check for sub— c heck determined m Parts.. ------.a rn n a n t fyulta __ \ VéK 1 c heck, touch up or determine (subsequ. replacement or replacement of de— replace determined secondary faults t o u c h u p r e q u i r e d ? 1 t s r m x n e d p a r t s n r carts or qrcuos « . j g r o u p s repair primary and carry out replace- secondary faults m e n t o r touch u p t - -- — 1 .a * - - - 1 [ a s s e m b l y j a s s e m b l y j a s s e m b l y ______1 ¡ a s s e m b l y l 1 ______t t e s t r u n ( t e s t r u n 1 [ t e s t r u n 1 [ t e s tr u n ------1 1 f start operation [ start operation | [ start operation | ( start operation 16) Repairs 17) Maintenance schedule 18) Preparation of maintenance 19) Maintenance Management - Planning - Realization 20) Demand far repairs 21) Investigation of repair material 22) Planning and account control of maintenance 23) Specialization according to used machines E u i i d i n g s Civil facilities (streets, sewage,...) V e h i c l e s Hoists and conveyors i-'achine to o l s T u b e s Pumps, conoressors, turbines,... I 2 4 ) Surveillance and maintenance in cnemical riants 25) Maintenance and pollution control CHEMIE LINZ AG u w r Z e w w i u s 4. UNIDO-Vorkshop LEAFLET ABOUT HA!IDLI?.'G OF AMMONIA 1 . Properties 1.1 At normal c o n d itio n s Ammonia (NH.j) i s a c o lo u r le s s gas with a characteristic pungent odour. It is readly liguefied by cooling or compression. The liquefied Ammonia evaporates readly and fastly at atmospheric pressure. This gives rise to a strong refrigeration to 40 degrees C below zero. Ammonia is very soluble in water, the saturated solution containing 35 % Synonyms f o r aqueous s o lu tio n : Aqua ammonium; W ater o f ammonia; Aqua ammonia; Ammonium h y d ra te . 1 .2 L iq u id Ammonia, aqueous s o lu tio n o f high c o n c e n tr a tio n , likwise gaseous Ammonia of higher percentage have an irritating effect on the skin, mainly the genitals the respiratory tract and mucous membranes of the nose, due to an alkaline caustic action. Liquid Ammonia can also cause frostbites. The pungent odour is waring in due tim e. Maximum allowable Concentration in air (* M.A.C.) 50 parts per m illio n (= TLV: tre s h o ld lim it v alu e) 1 . 3 Fire and explosion hazard are present but are considered sm a ll. ./2 A 2J n b T *) M.A.C. = that concentration in a working atmosphere, of a dust, fume or vapor such that if it is exceeded, for appreciable periods, damage can be caused to the health of exposed individuals. 2. Handling 2 .1 Ammonia, gas o r liq u id , i s b e s t removed by sp ray in g w ith much water into it. 2.2 Explosive limits: 16 to 25 % by volume in air. At certain lim itations (15,5 - 27 Volji NH^) an ammonia-air-mixture is explosive, therefore in rooms, where such mixtures might occure, the use of open fire or light, also smoking, are prohibited. In case weldings or jobs with open flames really have to be done during erection or repairing work, this is only permitted with the special approval of the management of the company under adequate supervision and observing special precautions. 2.3 Poisonousness and danger of explosion need utmost care at all jobs at containers, apparatuses, linings and fittings for ammonia (depressurizing, careful evacuation, blowing out with N2, repeated rinsing with water, detaching and closing of the pipings) Mines and canals are only allowed to be entered with utmost care and using the suitable breathing equipment. The precautions for ar . ant prevention of the "Beruf sgenossenschaft”, end. 4, Section A are carefully to be observed. 3. S torage: 3.1 Cylinders should be stored away from heat and sunlight. • /3 3.2 They should never be dropped. 3.3 Connections to these cylinders should be tight. Caution should be observed when opening containers, and gas masks should be worn. 3 .4 Recommended sto ra g e in f i r e - r e s i s t a n t s t r u c t u r e s , away from Chlorine , Bromine, Iodine and Mineral acids. 3.5 Water is an effective fire-extinguishing agent. 4. Treatment and Antidotes If liquid ammonia is spilled upon the clothing, all clothing should be removed immediately and the body thoroughly drenched with water. If the eye is injured by ammonia, it should be washed immediately and copiously with water and this may be followed by the introduction of a saturated solution or boric acid. If pain is severe, use local anesthetic, such as 0,5 % solutions of pontocaine hydrochloride. Thereafter, the application of olive oil or some similar oil is desirable. Continuous warm boric compresses to the eyes may be of value. The usual treatment of corneal ulcers should be instituted and an ophthalmologis should be called at once. Respiratory and circulatory measures should be taken if the concentration of fumes has been severe and the respiration affected. Inhalations of from 5 to 7 % carbon dioxide in oxygen should be given and if pulmonary edema ensues, the use of oxygen by means of a tent or intranasal apparatus is advised. 5. Precautions 5,1 Ammonia vapours are lighter than air . / 4 US - 4 - (d e n s ity =0,6 referring to air) therefore they escape overhead. Good aeration overhead has to be cared for because of this. At sudden ammonia escapes, for instance at breakages of turbines, fittings or containers, leave rooms as quickly as possible, pro tect mouth and nose by holding moistt ied rags in front of them. Even a dry handkerchief or the sleef of a jacket will do at an energancy at fire. 5.2 Leakages can be found by searching with a wooden or glass^tick, which was dipped into HC1 solution of about 15 % (be careful, corrosive!) or with moistened red litmus paper; at a presence of ammonia, white mists occure resp. the litmus paper changes to blue. 5.3 Absolute necessary jobs in ammonia poisoned rooms (for instance handling of valves, turing out of m achines, sa v in g of hurt people) only using suitable precautions, for instance: Fresh-air-, compressed air or oxygen breathing apparatuses and use of an impervious special suit for the protection of the body (picture 1 and 2) 5.4 At the use of the oxygen breathing apparatus the filter K, identification colour green, is to be used. At the storage in rooms 'with normal humidity, temperature and atmosphere, the filte r is durable for 3 years in an unused condition when ./ 5 US - 5 - closed by the manufacturers. After expiration of the time of storage, also unused filters are not allowed to be used any more. 5.5 At the work stronger ammoniacal water (ammonia solution) w ell-fitting safety-glasses have to be used, so that no thing can sprinkle into the eyes. p ic tu r e l p ic tu r e 2 / 6 6 L ite r a tu r e A Nev Dictionary of Chemistry ed. by Stephen M iall, LL.D.B.Sc. Longmans, Grenn and Co., London Römpps Chem ie-Lexikon Franckh'sche Verlagshar.dlungt Stuttgart Bd. 1 Ullmanns Encyklopädie der techn. Chemie Verlag Chemie, Veinheim, Bergstr. Bd. 7 Handbook of Dangerous M aterials by N. Ir v in g Sax assisted by M.J. O'Merin and W.V. Schultz Verlag: Reinhold Publishing Corporation 330 Vest Forty-Second S t., Nev York 13, U.3.A. M erk b latt über den Umgang m it Ammoniak Berufsgenossenschaft der Chemischen Industrie Verlag Chemie, Weinheim, Bergstr. CHEMIE UNZ AG U n w U A M M a u a n il Tag •*»* u u EmpfAngtr (DurdtatftlAga an) 4. UN'IDO VorkshoD Pecvcling Increasing density of population, the formation of over crowded regions, Trowing industries with expanding nroductions and finally, welfare of each people lead to an enormous burden on environment. The disposal of growing wastes of industrv, traffic and homes had become a world wide Droblem, which concerns each of us. Wastes coming from industry, business and house-hc-.cs are distinguished belonging to their use in cooling waters, Drocess waters or fecal waters. All these waters burden in various m.anrers the waters in whies, tnev are drained off, there are rivers, the lakes, th^ seas and so on. In this way, the natural force of self purification is not suffi cient as it is chown bv many examples. Hence, industries and public administration spend a lot of money for purifying waste waters. So the industrv of Austria spent 9 billion Austrian shillings on purifvina water in the years 1970 to 1970. 'ihat is 41 percent of the whole environmental expenses. To keep the quality of water in good condition or to improve the qualitv of it, many project- ct canal i^ation, r i”:r i cat i on niar.-" ¡r i control system^ ire realised. Che-’; •? Air./, now cpo*" d1' "’TO million shillings on environmer.ta 1 purposes. iV million -hill inns are related to purifying water. . / 2 A » /1 b uu 2 Cooling water The water supolv of the industrial plants of Chemie Linz ir. Linz and nnr.c ir resulting total Iv from Danube water and not from underground water. In this connection we have to emphasize that "lost waters in our plants are cooling waters. I think there are about 95°i cooling waters. This predominating part of our water input is given back to the river as clean water which is a little warmed up bv the coolers of our plants. Out the warmim ut> of our coolinc water is ir.sicr.if leant, because waste heat is used with priority in our olar.t. Ihe warmina up of the Danube by our cooling water i- on.lv 0,05 to 0,1 C. The warminc uo defends on the water bear!no of the Danube which is various in certain limits. I he leaiclative 1 i ”"i t in Austria for war-nine uo th° Z an."-1e Anoraanic process waters Only a small part of our industrial water given back ro the Danube ic oolluted. Where it is oo From the view of energy where it ic possible process- and washing waters are recycled. In doir.a so, two profits are obtained : f i r^r , far rami ns purification of warn® wa rprf and eerondl v, the production of val u able r^w material «*. ./i uu In t ^ i c Fide, ^riPTi.0 Lin?, d ° v ^ ;r'Oci 't r ^ -n o > v\ t^rriri *“ i or.*i 1 I V well-krown recycling processes, fer example, rhe production of AIF^ from fluoride containing waste 'voters of the Phosphate fertilizer produceicr. . The Alt,, is a decir“d raw material for aluminium electrclysir . The know how of this process was giver. to many foreior. countries and now there are such plants in DDB, Romania, "apan, Sweden and *ugoslavi a. Fecal waters and Industrial organic process-waste waters It is known that oraanic substances from industry and house holds are discharged into rivers end lakes. Ir. thi° waters the organic cubstances are eaten hv bacteria , exictir.g ir. the water. By this process CC„ and d„C are formed. Inis s . A reaction is a basic reaction for natural self puri flea tier, processes in our waters. This reaction car. only run in tne presence of a sufficient amount of oxvger.. In. absence of oxygen the micro-organism cannot exist. According!v, purification of waste waters is increasing in cases of decreasing of oxvaen. Such reactions caused by micror ersa- r.ism are used to ourifv waste waters by biological puri fication plants. These purification. Plants are installed before the waste water is running down to the rivers and laker, so that only purified water i s coring into the riverc and lakec, in the purification plant an additional effect is obtained bv bringing in much mere oxygen bv means of mechanical treatment. qe<'ider, with this mecha nical treatment of waste waters, the arising sludge in ./* uu 4 the biological step is recvcled. In this wav a purifi cation of waste water is auarar.teed and only clean water is drained into the rivers and lakes. xeaior.al purification Plant Linz In comparison -ith many other river? ir. densely populated reaions, the water quality of the Danube is not bad. In Austria we have water quality standards . The Danube in Upper Austria is of the class IT and III of a basis of a valuation of four classes . 3y damming up the Danube in 1979 for erecting a water power station near Linz, now better water quality standards are required. House hold wastes toaether with industrial wastes should be purified -in the reaional purification plant Linz. This Diant can purifv all waste waters of the region of Linz includina industries. So the waste waters of the '■'hemie Linz, the VCPST-AlDine 'steel works'* and of the rnnser sugar inductries are Durified in this biolocical ourification plant, too. Outside of waters resulting from house-hold and business orcranic waste waters are coming from industry. In our plants also organic waste waters are existina. But now we are making creat efforts ir. minimizing waste waters, '"'enerallv, people believe that onlv poisons are danseroK in waste waters. Admittina, poisons are very dangerous to natural self purification processes that all organic substances like unooiseness solvents, articles of food and detergents reduce the oxvaen contained in. the rivers ar.d lakes. /5 u u 1 This information should make von underctand that pouring out of liquids in drain pioes in laboratories is surely not the right wav of waste disposal. In principle, all wastes should be separated from water. Furtheron, all mother liquors should be recycled and solvents should be recovered, because , as you know, the purification of waste waters in mixed and in diluted state is much more expensive and technically more difficult. Clean water is nowadays too valuable to be used as means of transportât’on for waste disposal. Activities in our works situated in rnns (near Linz> In our new plants, situated in ^r.r.s, acrylonitrile is produced. Most of the waste water i«* incinerated. Cr.lv a small Dart of waste water whose burning ic not eeoro-ical, has to be Durified bv a biological treatment. To realize these processes it is necessary to combine re cycling steps and enrichment stages by adequate energv consumption. In the past , diluting of waste waters bv coolina waters was desired in order to reach lower concen trations of emission in the waters.fuch a dilution of waste waters is disturbing , if a biological treatment of waste water is intended. In our plant in rnrs, a special «■ewage system is erected to separate cooling waters from biological treatment plants. uu A Recycling methods Tn various point? of my essay you heard of recyclings or recycle methods. A? a matte’" of this principle, raw materials are recovered from wastes and can be used -o further reaction?. Nowadays, recycling is of great imDortance in waste economy. Tn chemical industries the recycle methods have been applied long before environment protection was born. The reason for such application was to improve yields of chemical reactions. An example is the synthesis of ammonia by reacting nitroqen and hydrogen. Once, passing of the reactants leads to yields of 33%. By means of recycling yields can be increased u p ’to 93°i. Another example is our gvpsum. sulphuric acid process. 3v Droduction of niah quality phosphate fertilizers, a great quantity of sulphuric acid is u^ed to separate an unde sired surplus of calcium from raw phosphate. Sy this reaction Ca S O ^ is formed, the so-called gypsum. This waste material is utilized to a simultaneous production of Portlandcement and of high quality sulphuric acid. Sulphuric acid is recycled to fertilizer production. This recycling of gypsum prevents the formation of giant waste gvpsum heaps. On the other hand, more than 1 10 000 tons per year of calcium sulphate can be saved from natural sources. A further example from Chemie Linz is the recycling of lubricating oil*- and the work-off of fibre wastes and polyethylene wastes. / - 7 uu 7 Thece recvclinar bv Chemie Linz are the r°ason that not tore than 1 % wastes are produced in comparison to the total production of chemicals. 1 % waste is a very low value in comDarison to 10 % in the great chemical slants of western Germany's industry cr other industrial sDheres. Removal of wastes Removal of wastes is a great problem. Not all wastes can be carried to refuse pits. In Austria there are only a few possibilities for removal of difficult wastes. Therefore it is necessary to remove these wastes in foreicn countries where thev are burned in special furnaces. In our Plants an oraanisaticn for wastes has been installed, it is the organisation-Dlan for wastes. This oraanisatior.-plar. fixes each waste from production process and determines its removal or its recyclina. If the way of removal is cone, there exists a waste book which determines what has to be done with the wastes . In this manner all wastes are registered and their further wav is determined. It is not possible in my time to speak about all this en vironmental problems. It is the aim of my report to show that chemical industries are able to colve th-^i - problems of environment within a sociable limit. New techr.oloaies make it possible to realize more extensive laws for the protection of environment. The proceeded development lets us see the future with optimism. This optimism seems to be very necessary, thinking of the great problems of the future , first the growth of the world population and secu ring of sufficient food for people and secondly, to make a natural environment possible in the future. CHOM E UN Z AG Unatr Ztfdwn Bwrtwitar H a u a ru f T*0 * mi t /tin Emfrfirg«r (DurcftscMig« ar) 4 . UNIDO—Workshop RESPOSIBILlTY OP DEPT. ATH Maintenance of the existing ammonia single-train unit and old HP-plant in the best way (good performance, low costs, short time). Improvement and rationalisation of the different facilities and processes. Preventing of accidents Controll of mainténancecosts > Working out of shutdown programmes Co-operation with different departments concerning expansion of existing and installation of new plants Good contact with production people and some central departments (central work-shop, electrical dept., instrument dept., civil dept., design, safety, ...) Stand - by service from frida.y to monday: 1 engineer or foreman 2 locksmiths organisation d s p t . ATH A . .. DIVISION A (AGRICULTURE CHEMICALS) Г ... TECHNIC H ___ NISH PRESSURE PLANT 7MS FOREMEN ARE ALLOCATED TO THE CERTAIN JOQS THE W AFERS - IF NECESSARY - ONE CAN SHIFT BETWEEN THE H FOREHAH-GROUPS Singl^-Train-Unit H»iwtow»wra Lay out of the unit: 240 000 t/year NH^ reap. 850 to/day NH^ Peb. 197:: Start up of ammonia»production. Productions figures: 1975 200 000 t/year NH, 1976 262 ООО " IV 1977 290 ООО " m 1978 294 ООО " m 1979 334 ООО " m 1980 291 ООО " daily production nov: 1 000 t/day <5 For maintenance ve needed: hours material 1975 117.000 11* 2 1976 84.000 5,0 1977 60.000 7,1 1978 108.000 * 10 ,0 * 1979 40.000 • 1 ,6 1980 90.500 ** 4,8 ** *) 1978 vis the 1st general revision **) 1980 a revision for changing cathalyst in primary reformer For this revisions ve needed: . *) 67 000 7*0 **) 50 000 3 , 0 The investment coats for the single»trai-unit vas about 500 Mio S in 1974. On stream days: Syn, gas production MH^-production 1975 280 days 217 days 1976 317 " 294 " 1977 335 " 321 ■ 1978 326 • 313 " 1979 - 362 • 355 ■ 1980 328 310 «. -, A ATH/Pa/Wl HISTORY OF AMMONIA PRODUCTION-PLANT (ATH) 19^2: Starting of ammonia-Produktion 75-000 Jato N ! with 4 units, each with 60 to N/day. ' i I I l H 1966: Expansion to 300.000 to/year 1975: STARTING of ammonia single-train unit Lay out: 200.000 to N/year I 1978: 242.000 to N/year, also we had a 5 3 » general-revision for 6 weeks Due to good operation and good maintenance the percental running time of all our facilities is very high. (100 % » 365 days per year) p.e.: Reciprocating compressors 9 9 , 5 % General revision every 45.000 hours \ \ ...... » • — - p y j, - - - • - - - — , M ain - m ise ria te used in S/riâte -tra in - C /nit CODE coMPOs'moti [% ,] APPLIKATION Hal. Hr. internai • coda Si Nn Cr h a Nt TÏ C r a m p itern r,Sm** water-^as- and steam • 4. 0ÌDS < q i f i 0 , ì s iW ° o,os pipelines up to 9 № 'c Uj St, 35.8 Tô t C £ 0 i 0, i s .1 to iüH2S HI ro,so Shell for Desotbefj éibsœàcr CJ 0,*t> 0,454- V *4 P,5 ¥*•» r* 4.54/4$ 4SHo3 ^0,tO 4** I f f 0,5T 0,0* shell foe secondary refortne, 5 0,404 0,4 CK 0.70Ì P.(r04 pipes in w uii*-h*at- e\utetn 4.73SS 4 3 C r H o t/H p,1t X» t o o />,(0 r up lo SSOK J i d o su lphu r - r e a c to r s £ AW -i/0\ 0,*>ì i i m o 4QcrMo 3-IO (0, In the first Single-tr&in-plantsf designed by Kellog there were used syngas-centrifugal compressors which were developed ✓ by Clark. The pressure in ammonia reactor was fixed with ca. 160 bars. To reach such a pressure Clark has designed compressors with two cases. The speed was approx. 10.000 Bpm. Improving the efficiency of ammonia synthesis made it necessary to increase the pressure in the ammonia synthesis. Nuovo Pignone, BBC, Cooper-Bessemer and Clark designed sompressors which reached a pressure of 320 bars. I One of the problems of high speed centrifugal compressors is their low weight, compared for example with receprocating compressors. The pipelines to and from the compressor have large diameters, there exist high pressure. Therefore it is very important to prevent forces of reaction delivering to the compressor. This is also a very important point for steam-turbines. The reaction force of steam pipelines is - caused by the high temperature of steam ($00°C) - very large. In our plant we did not make good experiences with pipeline carrier with springs, because the reaction force of the spring depends on the spring-constant. # • 3b we concepted carriers holded by weights. This kind of carriing pipelines needs more place, the advantage.is to have constant forces delivered to the pipelines. th Experiences in Sealing the 4 Stage of the Syngas-Compressor After having operated our syngas-compressor half a year ve had to svitch off the compressor because the oil-consumption increased. Removing the seals ve noticed, that the seals on recycle-side vere o.k., but on syngas-suction-side the high-pressure sealring vas demaged. The vhite metal vas melted and the 0-ring vas brittled. Enclosion 1 shcvs hov the seal-consumption increases. In enclosion 2 the operation conditions of the seals are shovn. A draving of the seals vith dimensions shovn in enclosion 3. In enclosion 2 it is obvious that on 7.9., 9*9. and 12.9. the seal-oil-temperature TI 6025 had increased. Except of this temperature could not be noticed any other disturbance. The result of the analysis of the residuals found on the seal ring in the case of the comprsssor and in the automatic oil-separator vas, that the residuals vere no coke-products of the oil. The residuals (zincdithiophosphate) are caused by connection of oil vith ammonia at the existing high pressure. After having repaired the compressor ve had a seal consumption betveen 1 and 5 litres per day. The brittled 0-ring material vas viton. But viton is not resistant against ammonia and ve changed it to Silikon vith success• To avoid a arise of zincdithiophosphate Nuovo Piguone had made folloving arrangement: ./2 1. To install a connection betveen syngas-discharge and balance-gas. 2. The pressure in the balance-gas should be holded about 0*5-1 bar higher than the syngas suction pressure. Through this improvement the pressure of ammonia in Reference- pipe is reduced. After having installed this connection-pipe we did not have any difficulties with the seals of the 4**1 case. It is to take care that the Quenchgas in the connection- pipe has a temperature lieing higher than the dewing point of the gas. If the temperature is below dewing point the labyrinths could be demaged by erosions. The arrangement of the Quenchgas-pipe can be seen in enclosion 4. ч 1 Si gZT/¿>} ,3 STOPP >ÚC*/¿£T Hl/.Cr ££ftJ£i.S-UM A ■££T T i n a c h *ерлл4Гч*) y* ac''i>cL~ te к $£*L-’5i-Rt\sm A+* 2S- &• ?£/£ NACtf .O ta b*74’C7>*cr:j/4ZZhJ e a ¿ r e , a ¿ Г¿Tl l T •' 1j -• ■ r ГА-LL y'Ohf <.*Ai-Ci.QI*J<3 ( T£lL ti) ib ¿ß ASIA : rti J M £ iVfJ ói КС*. i'AHHí;c*tr.*J ... V ' •' / • ££AL¿LR.'i:7, C£M K¿>J?/ Т н ТГЙЪ CNÀUSff iur.'J У r A/i.t и ч ь /,v f ^rALc¿-*ec>c*/¿z-'z.ea . 3ß О -я V}'S * s ) a n s r r ^ . i j - 4 C ' - V ? (/Hit A tt " c^As^tT/ T f '/е-клгко&аТ. ' P R o n k í j“ ^ ( W í » í S •’ 1 V«, е - м п т а г ' i . 4 ! 4. ъ I V н л н т Mt-AAT-SCtf !*■ ' л M a s * : 9 « *- . / -T' . с ■' 1 У ê ’4rfi«# tua л-ч U • ,-*1 #’х*вл • * И Л ft* 1__ . „ ------1 «i tî e ^ V ÖU1 4. G e h a u s S a n g dru ele - S^eVion Ù * ç/* Technical Experiences in the Benfield System 1 . Lov-Pressure-Pumps P 401/402 for Benfield Solution Starting our plant we noticed that the low-pressure-pumps developed a noise. We suspected the reason for this noise to be cavitation. Although ve checked the pump in presence of an expert of Worthington, ve could not find any indication of i cavi tation. We insisted on the warranty to be prolonged for one more year by Worthington. Worthington's expert agreed to it and explained the noticed noise with circulation. Before the prolongered time of warranty was elapsed, we checked the impeller once again very exactly but there was not found any indication of cavilation. When ve had to change the sealrings three months later we noticed the first indications of cavitation - the back of the blades were bitten. Steps for solving this problem a) Welding the bitten surface with electrodes consisting of hardfacing alloy. b) Introduction of 3 - 4 m^/Vi Nitrogen into the suction pi pe of the pumps. — We have two low p r e s s u r e pumps f o r B e n f ie ld s o l u t i o n . • / 2 2 In the suction pipe of one of these pumps there are two ellow pipes. At this pump we found cavitation only on one side of the double flooted impeller. The suction side of the second pump is connected with a T-part fo the main suction pipeline. At this pump we indicated cavitation on both sides of the impeller after only 4 200 working hour«. Our engineering firm, Fa. Uhde, found -out, that the noise of the pump disappeared by operating the pump with 115 % of the normal flow capacity. 3y reducing the flow capacity the ^oise increased. This syrpfcm was also an indication that the eois3 was caused by circulation. 2 . High P ressu re Pumps P 403/4Q4 3y washing and cleaning of our plant curing the start up the seals were contaminated with d irt. So we had to change this part from time to tine. Having started the plant it was not necessary to change the packings for about one year. But after this time we had a lot of problems with the Pacific-seals. Sometimes we had to change the rings already after one "'esk. We found out that we got spare rings from Pacific, that were not flat and fall of cracks. Till this time the sealrings were greased with Benfield solution. Having such a lot of problems with seals we changed the medium for greasing the sealrings and used condensate with a temperature of 65 ° - 70 °C. • / 3 Ill 10 1 2 8 Ш II = ^ = = — j 9 Q 1 1 1.8 j 1 .2 5 1.4 1A 3 - Condensate of such a temperature is more qualified for greasing seals than Benfield solution. The pressure of the condensate has to be a little bit higher than the suction pressure of the pump. To make this improvement it vas necessary to install a condensate cooler and a controlling system. Since we operate with this modification the seals have to be changed approximately once a year. 3. Efficiency of the CO^-Removal-System After having started our plant we did not obtain the efficiency of gas purification guaranted by Uhde. After a lot of difficult examinations we found out that the bad distribution of potossium carbonate solution was the reason for our problems. By installing leading plates we improved the distribution of Benfield solution to the ceramic intalox. The efficiency of purification increased after this modification. Finaly we installed two redistributers in our absorber and reached the design efficiency. IVL/ Operating Instruction V 103 for a vertical» double working reciprocating compressor, with two cranks, compressing gas in two single stages. The operator must be well instructed about the function of the compressor. t A Design Dates Media: natural gas Flow r a t e : 37 000 Nm3/h Suction pressure: 20,9 barii, can be variated Discharge pressure: 46 barii Speed: 495 U/iain Controlling system: automatic reverse flow regulation to 50 % of design gas flow. B Starting up of the Compressor 1 . Inform th e c e n tr a l comando s ta tio n o f our company about the start up of the compressor. Between two starts it*s necessary to wait 20 minutes after the first start, because during start of the motor coils are heated. 2. Open the cooling water main valve and also valves for the cooling system of the different parts of the compressor. (Soal packings, cylinders, oil-cooler). 3. Check level of oiltank. If oil temperature is below 10 °C, it is necessary to heat up with steam. /2 4. Start auxiliary oil pump and check oil pressure. (minimum 2 barii) 5. Open valves in suction pipeline and ir. bypass pipeline. Check the suction pressure. With regard to the rate of suction pressure see point C 1. 6. Drain the condensate separators F 103 and F 10^ (separator in front of the compressor anf after bypass-cooler). •v 7. Open valves in discharge pipeline. 8. Start the motor and observe the oil-pressure. 9. Switch off the auxiliary oil pump and check the oil pressure once again. 10.If everything is o.k., the compressor is charged by slowly closing the bypass-valve and by means cf the reverse flow controlling system. C Operation of the Machine 1. It is very important to take care that the difference in pressure between discharge ans suction is not higher than 2 7 ,4 b a r s . Therefore it is necessary to adjust the discharge pressure in dépendance of the suction pressure. For example: if the discharge pressure is 44 barii the suction pressure may be 1 6 ,6 barii as minimum. The suction pressure should not be less than 9,8 barii, in this case the maximal discharge pressure is 36,2 barii. The suction pressure should not be higher that 27 barii, it is important that this maximum pressure is not reached. •/ 3 Following points have to be checked periodically and must be written in a operating book for instance every hour: a) Suction pressure (Safety valve is set at 30 barii) Discharge pressure (" " " " at 46 barii) b) Oil pressure after cleaner c) Oil temperature after oil cooler d) Temperature of discharge e) compressor bearings n motor " g) motor c o i l h) cooling air to the motor i ) cooling air from the motor j) current consumption of the motor. 3- During the inspection round every two hours following points are to be checked: a) Seal packings for tightness b) D raining o f se p a ra to r F 103 and F 104 c) Compressor for knocking.grumbling and unusual noise of the valves. d) Level of the oil tank. 4. Cooling water flow rate is to be adjusted not to pass a maximum temperature of 45 °C outlet. 5. The compressor is to be switched off immediately if a) a bearing or a seal packing is overheating or if a seal packing is leaky. b) pressure of lube-oil is less than 1,5 barii c) suddenly a knocking noise is heared or if the valves operate not properly d) a safety valve does not close after bloving up. •/ 4 D Switching off the Compressor 1. Svitch off the motor 2. Close valves in discharge pipeline 3. Close valves in suction pipeline 4. Close cooling vater main valve 5. If necessary, purge compressor vith nitrogen. E General Maintenance Crankcase is filled vith oil, type Mobil oil extra heavy vith a viscosity of 60 - 83 c St at 50 °C temperature. Oil leakages have to be compensated vith the s ame oil type. If the compressor does not operate for a longer periode, the com pressor must be turned by hand once a day. Before doing that the auxiliary oilpump has to be switched on. * A" DATS»« V 103 I mportant: The difference in pressure between suction and discharge may not higher than 27,4 bars. P os. Nr. [Operate range' Alarm/shut down Suction pressure PIALLHSL 120 see point C 1 h ig h : 18/10 barU low: 28/- barU Discharge pressure P1AHHSH 119 max. 44 barU 45/52 barU o TIAH 110 o Temperature of discharge o X «0 E TlAH 116 • 130/- °C Oil pressure after cleaner PIALISL 113 2 - ( 3)- 4,2 barU 2/1 ,5 barU Instrument air pressure PIALSL 221 7-7,5 barU 4/4 barU Oil temperature after TIALH 113 25 - 40 °C low: 18/- °C c o o le r high: 50/- °C Temperature of compressor bearing east TIAHHSH 107 45 - 65 °C 70/80 °C Temperature of compressor O 1 0 O 0 bearing west t I ah 111 >o 75/80 °C Temperature of cooling air to the motor TIAH 101 5 - 35 °C 40/- °C Temperature of cooling air from the motor TIAH 102 25 - 60 ° c 65/- ° c Temperature of mctor b earin g TIAH 106 40 - 65 °C 70/- °C Temperature of motor coils TRAH 104 60 - 90 °C 105/-°C A ^ l O A 'SSr E l U/ta G Y\ i j vk»\ I Draving up a Programme of a General-Revis ion of a Single-Train 1. Operating our plant( all technical defects and leakings are régisted in a booklet. These defects do not make it necessary to turn off our plant, but during the next standing all these defects must be repaired. 2. The technical department puts up the programme for the revisions of tanks, boilers, coolers, etc. which have to be done. In a discussion vith the TÜV (technical inspection department) and the material testing department there is fixed the class of inspection. The technical department is also responsible for the inspection of the machines. Generally there is to say that a machine which operates normaly should not be opened. Before deciding to open a machine or not two considerations should be done: a) By measuring the efficiency it is possible to recognize a defect or a wear for example on the labyrinths or on the balance drum. b) Comparing the operate dates with the dates after first starting up the machine there also can be drawn conclusions about condition of the machine. Therefore it is very important to regist all dates that are taken after first start up very exactly. The particular works which have to be done are ordered in groups (from 100 to 700, see enclosure). ./2 2 Every work must be v alu ated in regard to lenght and to the number of required workers by a foreman. Afterwards must be made a time-table which shows the number of the necessary and dis posable workers. X X GROUP 1 0 0 0-101 Heater for heating naphtha or natural gas. Open and c lo s e manhole cover. Inspection of the protect iron-bars of the burners. W-101 Nitrogen preheater Open lid for official inspection GROUP 2 0 0 V-202 II. W-208 III. W-210 Superheater for high pressure steam Pressure check. W-207 Superhecfer for medium pressure steam Pressure check. V-2C9 , W-211 Heater for prozess air Pressure check V-202 , V-203 Combustion air blower, flue gas blower Cut out the shaft-cover-sheet for oil level inspection glass and for grease nipples. Inspection of the guide blade-bearings 0-201 Primary reformer % Open two of the collector pipe-covers, check and c lo s e . Open manholes , inspect chamotte cover . Clean flue-gas-channel 0-204 Additional heating for waste-gas Open manholes, inspect chamotte cover . / 2 J 0-202 Additional vessel Inspection and cleaning of inside. Repair combustion air heat-exchanger ( No. 4 is blocking) Inspect vail at inspection hole. Clear lubrication pipes. Combustion air and waste gas duct Inspection and cleaning B—210 Mixing station for steam and natural gas Inside inspection and check natural gas baffle V-215 Water preheater Remove heat-change pipelines for inside inspection. t ï B-208 R e lie fta n k Open handholes, blind off, official inspection B—203 Degasifier tank Widen passage for L-206 (Level controller) Check shover (System Stork ) and change T -p a rts. B-209 Instrument air tank In sp ection and clea n in g o f tank and le v e l c o n tro lle r / 3 » . 3 P -207, P-208 BFW-Pumps Clean f i l t e r . P-208 : Change fla n g e o f valve for minimum load pipeline T-203 Turbine for P-207 Repair oil-leakage of clutch-cover Change in s u la tio n . B—212 Natural gas mixing station Remove and in sid e in sp ectio n . K—201 Secundary reformer Open for changing air nozzle. W—201 Process gas heat exchanger Open both manhole covers. (Gasket of the hot manhole is not tight ) Cleaning and inside inspection. V—203 BFV-preheater | Change pipe bundle, in sid e in sp e ctio n Cb?nge drain valve. Installing test-blades. B—201 Steam boiler Open and in sid e in sp ectio n . P ressu re check (Pressure check also for No. 4083 and 4162 ■ support system ) T-201 Turbine for process air compressor • / 4 4 Inspection of the rotor . Repair oil leakage of the compressor-side clutch cover. Repair seal packing of control-valve and the leakage of the pipeline for the pressure- indicator of the injector ; the idling-device does not function properly i V-204 Condenser for T-201 Open flan g e and in sid e in sp ectio n . Repair cooling-vater pipe to the condenser V-201 Process air compressor Check lo v -p ressu re and h igh -p ressu re r o to r . Gearbox-side high-pressure rotor bearing is leaking. Clean air-cooling of lov-pressure compressor. Change cooling-vater valve for 4. stage. Check ..on return-valve. V-214 Process-ad r-cool er Inside inspection, al.;o for condensed vater tank and level controller. T-202 Turbine for generator Repair seal box of steam entrance valve T—204 Back-pressure-turbine for generator. Repair seal box of steam valve GROUP 3 0 0 w-301 Gas heat-exchanger Pressure check. Repair leaky head-gasket. 1-301 NT- CO- Converter Official inspection, manholes to be opened in CD service. Change nozzle for condensate V-302 t V-303 BFW-preheater Official inspection . Repair baffle T-310 1-302 Low temperature-converter Open man holes to change catalyst. Official inspection. s / GROUP 4 0 0 K—401 Absorber Open manholes, remove ceramic intalox and inspect inside. Install redistributers. Revision of the level controller. F-403 Lye separator Open for official inspection . ^Revision of the level controller. W—401 Steam generator Open for official inspection (inside revision and pressure check ) W-402 BFW-preheater Remove heat-exchanger. Pressure check ( 2x) V-403 R eb o iler Open for official inspection (inside and pressure check ) V-404 Benfield solution air cooler Remove distribution pipe, pressure test. V-408 BFW -cooler Remove bundle (inside inspection) ./2 2 B—404 R e lie fta n k Open manholes for cleaning and inspection. F-401 Condensate separator . Open manholes for cleaning and inside inspection. Official inspection for level controller. F—402 Condensate separator Open manholes for cleaning and inside inspection. Change draining valve. O fficial inspection of level controller. F-406 Lye double filter Inside inspection. Grinding 4-vay valves. Change valve in the p ip e lin e to the f i l t e r (valve case is corroded) K-402 Desorber Open manholes for inside inspection and cleaning. Repair corroded pipeline to P-405. I n s t a l l PV/H- 411 and PV/H- 412 in pipeline-system . * S F—407 In je k to r : Control injektor nozzles and valves. V—406 BFW-preheater Change p ip e lin e s of BFW-system. • / 3 3 T—401 Benfield solution turbine Seal bearings of guide-blades • Change p ip e lin e s fo r greasin g s e a ls v ith conden sate of T-401 and high-pressure lye-pump P-403- GROUP 5 0 0 1—501 Methane generator Open manholes for inside revision F—501 Condensate separator Open manholes for inside revision and also revision for level controller. • W -501 Gas - Gas heat exchanger Remove heat-exchanger for official inspection and pressure check. W—502 B o ile r Open fo r clean in g and in sid e re v isio n 2=5031 504 final gas cooler Open for cleaning and official inspection. I Welde in a valve in cooling-vater-pipeline. \ \ ' I % GROUP 600 T-601 Syngas-turb: ie Inspection of condensation-turbine-rotor and of the condenser. ) Repair decreased cooling vater pipe. Check sta rt-u p equipment and ad ju st i t . S) Change prepared o i l p ip elin es . V-601 Syngas-compressor Inspection of bearings, seal-system and rotors o f case 1-4. Install capacity flov measuring nozzles in. balance-drum-pipes of stage 2 and 3 (F-6006 and F—6007) Change g a s-co o le r Official inspection of separator F-606 (also level controller) , F-601 , F-602, F-603» F-605, seal oil tanks No. 4054 - 4057 • level controllers 4156 and 4157 , and separators © 4208 , 4058 and 4059. Install valves in seal-oil pressure pipes of s e a l- o il pumps. Change o i l - f i l t e r s and clean in g o il- h e a t e r s . Change one o f the o il- c o o le r bundle and clean m the other one . 4 0-701 Start-up-heater Inspect supports, pressure check ft • 2 i W—701 Vaste-heat-boiler Open "Brettschneider" gasket. O fficial inspection pressure check. W—708 BFW-preheater Open "Brettschneider" gasket (seal ring is leak) Official inspection, pressure check. i B-701 NHj-expansion-tank. Open tank for cleaning and official inspection. B-706 Mixing-station Remove for inside inspection. F-701 NH^-separator Open lids and remove pipelines to the separator. Clean and in sid e in sp ectio n . F—702 NH^-separator Open lids and remove pipelines. i Clean and in sid e in sp e ctio n . W-703 G as-cooler Remove elbovs of tvo of the five coolers. Pressure check on this coolers. Gas / gas-heat-exchanger 4; W-704 Open flanges and remove bundle. Cleaning and inside inspection. W-705 Freezer Remove flanges for inside inspection. CHEMIEUNZAG IteMrZalcfMn Baarbattar Hauanif Tafl ATG Empting«, (Ourctwdiitg* an) 4« UNIDO-Workshop P la n ts, A ffa irs and Competences of Dept. ATG 107, 146 Old and new waterworks (river water, cooling water supply) 140 Chlorination station for well vater (0,7 r 0,8 mg ClA H20) 144 Shallow well (horizontal filter tubes, well s h a ft, pumps) 204 Air dividing plant (2 units, each 1 700 Nm'Vh °2)» compressed air supply 204 a,b B o ttlin g of oxygen and compressed a ir 206, 209 N2-gasometers (2 000 m^, 500 m^) gas- 207 02-gasometer (10 000 m^) holder 208 Cracked gas (M2 + H2) - holder (25 000 ra^) R .-B r. Pipe bridges RN Network of pipes, piping of: K0G, natural gas, heating gas, cracked gas, steam 25, 20, 7, 2 bar, compressed air, river-, well-, hot (90°C)-, warm (40°C)-, drinking-water, boiler feed water, condensate, oxygen Machines, compressors and pumps in dept.-area (except standard pumps) ./2 A 23 /1 b 2 201 Desulphurution of I0G 212 Battery (block) of bottles for high-pressure N2 202 Old gas dividing plant (reforming plant) 220 Naphtha and Orthoxylol storages and pump sta tio n s Pipelines for naphtha and orthoxylol 101, 211 Natural gas pressure reducing stations 110 Old boiler house (2 units, each 12 t/h steam 25 bar) 110 a Contact mud circulation reactors (flocculators) 203 Boiler fee vater treatment 21 3 Naphtha feed v ater storages 214 Naphtha - steam - reform ing plant (iC I-p la n t) /w-у-? TT ríñ JhL Ltll¿y, К ? U R fr ли fc. ( $cLlu. 1 *Uu U£l MÁ- Tei a l hardness 4 2 ,1 ' 4 4 4 4 ,0 " d * f t ' 4 И ^íruÁ^lL^^Á-iA^ÒL Ltríonab barjnest AQt V" Ct Tf 1 ,l * 4 H г г е н l¿f4¿i¿4t U&tf¿, i*í- J t f 0 ( ¿ n M ) lí.tw jfi (4UÌ 2%t ÇKM ■Щ,Ч- :*{/((H ,V toe 0 (C¡S* ) П,} ? a ( w ) Sf,i Auf/{ (tytl Kí LlÍCsiCAc íU.* № vC' IM,1 ХЧ -luf/t (e Ç c ï *U л *у (2 M , r ■ i; ■:.,< i КМкС<, - 1 ^ 4 si ■ 1*3 AtLj/f 1 4 ,0 ■H ¡ t I L i e b e m / - f¿ Toiai ~ F e с, :г 4u¡(l 0 , n C ,H luf/f i ¡ 0 ¿ 3, С tiff/ 3// 1^/f ¿V с 0 c WCÒ - ■; ■Zolf % i,OÕ 'lU'l/t 0 , i r (■'.ci :u ¡/( . %о /ц ,0 AU tuf / / !? # ~ АТ a *¡¡{ 4 1 ,1 c) ^ / S64 ~ 3 $ A u f¡( ) o( \ H ■•«//<' е,чь 'luffe 0,24 LAV',// Pí>y‘ ” № ч * с, (г ш { ! ^ 0,41 c-12 '.t f f a * Aot *> A U jj/ ЪГ C ,c ^ ¡ ¡ f í» 0 C on d ac Luity '•34 к 4 b U S f t ,*, TUAo~C IL b 4^c CSjcu. C0% COl free A,Í :.c гЧ/{ 'ftiLU.i'ÍÍrf опупел t , r <■:J ,u ,f( i 4.Sp¿n d \ r u n S.1 fauAfátifa. ■ A ,S J 4H íuc^ü ИмЛ СЯ*0+и4/&&} 1 1 - 4 И \ 0 ( J t f " ) Al ft Aufj( [JO,*) 11,í t n , t ¡ 1 0 (& ” 1 Й,У iu¡/( (Щи) A1,\ (■'K.t? d b t á ¿ ¿ 4 /úS’C' A ■. C AtUtuCutif (?Sú'£ ¡%l stuft Ac 4, V ^aéj¿ \ c '~ i l ( ¿ ,r -fÁJUÍ “ b ¿ C, 0 7 SM\ft CfOb u Ox 2f t ^ \ ft '*S ■ o » - Я ’ ^ \ ft 4c\ J C°\ ~ :t.4 -^f/y ■;? uot ~ C,c1 Su^f/ ;; roo vo>~ Ai, o 'tu^ft 2Ç, o A4 ft Ъ , г > V ' 3 %b '-¡/< 4 - 0 e,* > t « , + 0f 02 AUfft 0,o C US 1,0 A0t в к * %'<'*■> n 4 t f é u ftíiij 2cf- 4 o 'L Ht- to '*'s/съ Cob / b - \ ■ sh ь. l& u iu G ft 7/2 ^ f t О Ь Ь + Ь Щ 0 0 ATG/Mi/t '.iék- m f l n r \ A n I 7 W V -T I t / HISTORY OF Np - PRODUCTION (ATG) Np ____ parts Of N in NHj (14 Mol N + 3 Mol H = 17 Mol NH7 ) Spring 1940: Beginn of raising the terrain about 2 - 4 m. Antumn 1942: Starting of production on basic KOG. (1 unit for desulphuration, 3 units for gas dividing and 3 for CO-conversion). 1944: Output 55 COO t Np/a \ \ , < vA o 1944/45: " 800 bombs from allied airforces exploded ! in CL-area *nd plants. May 45 - July 46: No production as neither XOG nor energy isre a v a ila b le . 1948:, Output from 1944 vas reached again. ‘t Production increase V 1965: to 237.000 t Np/a or 718 t/d max. (3 units for desulphuration, 6 for gas dividing » and 7 for CO-conversion) * 0 I ♦ 1966: Start up Naphtha-Steam-Reforming plant. In c r e a s e >/ 1974: to about 320 000 t Np/a. "H ~ £lt> ooo (- * 0/; m ; ' /<■>/, > Naphtha - Steam - Reforming - Plant (ICJ-Process) Generals: Engineered by Humphreys Sc Glasgow, London, 1964 - 1966; erected by ourselves. Laying out: 300 t Np/d (365 t NHy'd) at a pressure of 28 (max. 31 bar). 3eyond of ICI licence (our risk) we increased the working pressure (inlet prim, reformer) to 38 bar and the daily output to ¿20 t Np (510 t/d NH^). Ve had bought machines, apparatuses and pipes qualified for the heigher pressure. Feedstock: 1966 (start up) - 1976 Naphtha (strait run benzines) since 1976 Natural-gas. Maintenance: hours material costs (Mio S) o 1974 21 o o ' ,3 75 general overhaul 56 o o o 7,4 76 24 000 1.6 o o 77 general overhaul 46 o 4,2 o 73 16 o o 1 ,6 79 21 000 o 30 (3 months) 3 o o 0,1 On stream days: 1 974 363 75 general overhaul 324 76 366 77 general overhaul 325 73 intended 3 days-shut down during Oir.gie-train-shut down for welding piping - connectiens between both plants. 362 79 365 30 till now - 2 - I S P - R • * o t o r T~( o C C u ) The "Contaot-liud-Circulation-Reactor" la especially used for eondittoning of aurfaeo vater vhtoh Bust be oleared of suspended setter« colouring sustanoes, organic dirts and carbon* Furthermore good results are attained in other fields of water treatment, especially at delronlng, deaanganitlon, deacidifying, deoiling, sterilizing (d«germinating), removing of disagrreable odour- or flavour substances, but also algas and float slime* In the water treating process many of these effects are to be attained ainultanously• -4- 1• In let 12* Desludgor motor 2. Inlet eontrol valve 13* Shaft of desludger 5* Cone 14* Desludger 1 4* Top ascending pipe 13* Sludge bottom with mixer •5* Lower asoending pip# 16 . Clear water collecting 6. Lengthening pipe channel 7* Mixer 17. Outlet of olear water 8* Rotation orusher 18* Catwalk and rail 9* Untreated water distributer . 19* Bridge t lO.Mainshaft of mixer 20. Overflow 11* Variable speed motor 21. Sampling pipes (for the mixer) ! KONÑIPUKMON 2- Zule ubrege hr епЫ Г 1 Копи» 4. Oberes Steigrohr 5. Unfern Steigrohr 4 St^igrolinnfMitgtnMf 7. lib ra m i 8. Webeibrecher 9. Rohwasserverteilung 10. Rùhrweri-Anfnebswelle 11. Regelborer Antnebsmofor für lü h m tfk 12. Schlammräumeronfrieb 13. Srhlammräumer-AnthebsweUe 14. Schlammräumer 15. Schlammsumpf mñ lib ra m i / 16. Remwosseriammelnane 17. Reínwasserobloui 16. Steg und G elin d e r 19. logerbrücke 20. Oberlauf 21. Probeentnahme Леве* BAUWFÌSEN SioftlbeSdher mit Bef on sohle Gonjttohlbehdlfer ohne Sddommrdvmer Die obigen |auwe»en kennen beliebig kombiniert werden - 4 e I I» C e n e r a lf taohnloal data Capacityt 5 - 3 000 n^/h (per unit) Turn-around tlnat about 60-90 ninutea (dwell tin«) Internal circulation: 3 - 5 x Quantity of flow (Capaoity) Saving of ehealcalai 30 - 40^ compared to conventional plants Speed of ollmb-up: c a . 3 - 5 m/h Transparence in oleaneA often 1,5 - 2,0 a ' water: Turbidity content in 10 ag/l, often 3 - 5 a g /l discharged water: Hat* of blow down* 0,5 - 1 . 0* of capacity •Hud oontenti 15 - 25 g solid nattar/l (9 7 ,5 - 98,59* wateif) F u n o tlon I Firet the untreated water flows into the eylindrio middle-part and 1« there aired with recycled deposite products and chemicals.. The rising streao is produced by a speed regulated mixer which vorks like a circulation pump. This mixer makes a good mixture of all components: raw water, chemicals and chemically activ mud. By help of the contaot effect of mud the formation of flakes begins immediately, inoreasing then quickly. After having passed I the mixing zone water oomes into the reaction zone and changes its streaming direotion. In this zone all ohemical reaotions happen whereby the flakes grow and grow. j la a i I I i ; - « - i \ quantity of 3 - 5 times of the capacity flow \ ' \ ' Jfer'- Jfer'- ' I a a ration on on the sharp separating zone between water muddy and rising clear pater, further on the quick sinking process of old lot of activ ismud carried along, so that each particle of raw settle directly* down This principleconditioning of e f fe so c t. called Good working of "contact the reacto mud r dereaoted can be mud. seen O p e work work as cry sta l centers on circulation*? which products of is precipitation the real reason f-or the surprisingly good water often touches and mud chemicals* The particles of slim The The characteristic foature of the KSU-reactor is the internal circulation} circu lated in the mixing and floccu len t zone* In th is cy cle the bottoa edge of the lower cylindrio part of the big oone a surface* In the outern a^rea of the big cone the climbing speed sharp separating zone is formed between and mud olear water* The The clear, oonditioned water flows into a top collecting the other par^streams to the outem parts of the reactor* On goes slower and therefore even small mud-particles cannot rise* channel (grouve)* ismud 3y a transported slowly turningin into autpmatio desludger the Yalve siia^ the pit removes sunken the and from mud then the further reaotor thickened, in in tervale* Then Then a part of-tfie water coaea into the aacending pipe, while Hud Hud peptide? sink to the bottom*' olear water rises to the % >v. Sine« long time it is Vnow, that salts dissolved in water dissociat« more or less into their components, that means into ions* Common salt, (kitchen salt) for example, dissociates to the positive sodium ion and the negative chlorine ion. By this dissociation water is electrically conductive and so it is possible to separate cations and anions by direct current* Nearly all salts dissolved in water dissociate so in cations and anions and the most important of them can be put in order as to be seen in the following schemet cations ar.ions Ca ( kco3) 2 ( hco5) 2 y Ca Ug S°4 Ca C12 i-g Cl„ r Na Cl | Na2 SO^ > neutral salts ”a2 S l0 3 J K - carbonate hardness N ■ not-carbonate hardness K + N - H « to ta l hardness | L Mot all Iona are equally good absorbed or delivered by ion exchanger«• A very good exchanging is given between oationa and hydrogen ions and between anions and hydroxyl ions* Polyvalent ions of heavy metals, like iron and aaganese are first taken up by cations, followed by alkaline earths, like calolum and magnesium, and a t la s t potassium and sodium. A cation exchanger, which is loaded with these ions is regenerated by acid. In this process the cations are pushed away by the hydrogen ion of the aeid. According to the law of mass action (Culdberg and range's law) a surplus of aold is necessary (opposite to the theoretical quantity) for finishing the regeneration. The same is current for the regeneration of anion exchangers by sodium hydroxide solution. If ion exchange substance is exhausted, the ion most difficult to be exchanged will break through first. It is sodium at the cation exohanger and it is silloio acid at the anion exchanger. The ions whioh are able to be exchanged are not only on the surface of the grains of the exchange resin but also Inside (interior). That means that exchanging reactions need a certain minimum time, to obtain relations between quantity of water, speed of f i l t e r process and quantity of exohange re sin . Variations are possible, like strongly acidic and slightly acidic cation exchanger, or strongly basic and slightly baslo anion exchanger. Slightly aoldic cation exchangers can be regenerated without a surplus of acid and slightly basic anion exohangers without a surplus of sodium hydroxide (caustio soda). In a combined employment of "slig h t"- and "strong"-exchangers i t is possible to further use the surplus of chemicals which is absolutely necessaxy for the ”strong."-exchangers for the regenerations of the ”slight”-exohangers. By this a lot of chemicals can be saved. So It is more economic. The combination of a contact mud circulation reactor with sand filters and a total desalization (deminerallzatio) enlarges the eoonomioal possibilities of application of total demineralization plants, sspsoially of plants with large hourly oapaoitiss. i / % Total demineralization / Procesa Such a plant consists of cation and anion exchangers vhioh ! Bust be regenerated when the substance (resin) is exhausted. i The regeneration process lasts 4 - 6 hours. In this tine the plant is working with another row. So i t is necessary to have at least two rows of apparates. Further it¡is a great * advantage to have clear water reservoirs (vessile) at the end of the plant for short time requirements o f - 4 hours« e.g. for snail repairs or short troubles. llixed bed filters are situated only in the last stage; they are considered to be safety devices. The water treatment should be finished before nixed bed filters. They have only the function to eatoh, or to kill irregularities or natural "slippage". By this, working safety (reliability) of the plant is increased, and for pre-inserted filter groups oosts in dimensioning of all apparatus (filters) and operating I expenses can be saved, beeause these apparatue can be fully loaded without risk. ì I! + I l I L i ; Wert/C s-tojjfb I a f r . 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Oâ-TCCL 0"f A AU* ¿Uiih •* iitUmittt f(*cJ \¿\4 - tKcLoLM.fe.ft Í AÍS i HA'C-Ó W v c b * < M * Ъ Ь ) bcu^^jf” L"fg. /ír/чл. > T^vv (Н /í)" cíeflllj pu.ti!pi ?vc V« ^A 4LhслЯ fil'fì&C . {Т*££^\ 94^ h/дои [S°/,yJ 1»«л—«wyi<ал ЛЛ b¡Mf. k’Tf^ iUWufets eie*/ *■ bwv^t /VrVUtAXkL/L k/&~ 0 $ ~ dein'nj рии/р; Al Si ttfrT i Mills f". OM.JL p , Td - fycfai ?YC (U-Ce L Durchsicht des Triebwerke» bei der 2. u. 5. Stufe-Kompressor Ost Reparaturrorgang r X i • Füarungaringäasäiuie bei allöü /.-».pf rtUff + f *-ff c f 4 Zylindern VAe ^ «- 2* Kühlräume bei allen 4 Zylin OeiMiKf * f * f *d dern reinigen. 3« Prüfen der Kolbenstangen &<**«. « f p * ' * J * * r*J. lage mit Rahmenwasserwaage, btt'4-lt ^гли.« (ia oberen und unterem Tot ) ~Th t punkt) Der Kreuzkopf вив an Ь* Ov». 4kt K« - — '~ j p*irfiLCe . der Lauffläche angedrückt worden. 4« Kolben mit Kolbenstange aus- Hev*\»r*. * * * d - fsiri-ь*. »W . Ti bauen und b ei TEW prüfen bzw. e g a lisie re n lassen . f&cg. /и li'C »**. f ky 714 7 5« Laufbüchse ausbauen, durch TLP prüfen und wieder ein *w«{ b ~ .,'ld |‘ч е/ам’и . ‘ bauen. 7/eiterselireuzweise i Vt-Л C*rtS-i 0,4 Ia f f - * * *-** d la unteren und' oberen Tot CA**d*A , lHff-e*b4t'e+*. *V»’Ä -fr *-+*"*- l***■( • ? punkt vermessen, sowie mit с r 4 b*. d*»* w4k Raucenvra33erw.oage überprü fen. Die Überprüfung der \/f-S -f'• Laufbüchse шив bei einge bauten Ventilen durohge- führt werden. 6» Kreuzkopfspiele messen. ofcfc&riMc*. c f c~ronl>t*-4' ?• Xrouzkopfbolzen ausbaucn. 'Pfiutf/e boli of c-y^# n i e A d • Zustand der Passung übor- tfifaU«. ü f prufon und festhaiten в. Kreuzkopf ausbauen und bei ^ e **^ *re c~ ro & k t^ d & +*di Tr prüfen und ev. egali tdi^ßyp. £ sieren lassen. (Stangenloch und Kreuzkopfbund) 9 . Gegengewicht ausbauen. AiX**C PO. Pleuelstange ausbauen. ose p, Уе ra L 11* Messung der Atmung bei Ы еж ib+rCM4Ü+\fr 0 " f lh r< *- J L.11^ ^ 0° - 90° - 180° - 270° - (j+stMiHf) o f CriLU.Ushc.'ff Kurbelstellung. 12. Feststellung des Pleuel 0"£ C*fC*4. CC. f ^ lag ersp ieles (Messung des '*-0 H и t C /f 14. у rfi-d~ Лс-*~г~> Kurbelzapfendurchmessers ra xL s-i'^ p ) Mtp t-t, r-c*** tM<{- und des p von Pleuellager- bohrung) "if 2 ^5 (сг€л< (( ir>'* Сгамк e * y t ) 13* Bei ev. Korr, des Pleuel c >‘C lagerspieles müssen die £.cet bdft »44jf b t Pleuellagerschrauben ge ( c*-rX*'u~g «/# xai4(t~*L mäß angegebener Dehnung angezogen werden. •«■/¿n/liic H . Bei Pleuellag«rzusammenbau £ jßi'UßUs) achten, daß bald« Lager*» * * * t4 (ft «H ! sch alten im Gehäuse f e s t s itz e n . 15. Pulet 3-13 g i l t fü r beide Stufen. (►WA 1 1 6 . Hach der Messung der *VtiCX *t+n.'^p Atmung bei beiden Stufen o f k-»4U , rn+Lcrc. Hauptlager 2, 3« 4t u» 5 MkUi'k //V. u .r ausbauen. ^CH»e^«’ny (m €+‘h (f 1 7 . Ausbau der Hauptlager a ) Zuerst Messung des Ö-) H&<£ tu* 1+4*6«1 / 0 £ c{t*t^4**X£. Lagerspieles b) Schraubenlänge im tfo-b'ct. U*~fU4- 0-f •'•* angezogenen Zustand fe sth a lte n c) Schraubenlänge im C’j (fmb'tt lt ~ « g L 4 ~ ( n i h »*» entspannten Zustand l ( <+*X PC r t « s ) festhalten.^ d) Lagerschal^an aus- d-J 7?eu*«re. 0i~ss • (&e c * +***(* - ; . bauen. Die Kurbel- v e ile muß zum Zwecke s/Catf- ¿e by Aw/ra*.- um c a . 1/2-Iagerspiel U t 4 + * { >4Ce LcJ-f o-f dU hydraulisch ange hoben werden. e) InCgerscha^fen durch ¿Avwj* TU? prüfen lassen. f) ffellenlagerzapfen durch TMP prüfen las •£•) ln eyecfi'ts-f sen. ( j o*+vn jl (j ) (?y fc t 18. Hauptlager einbaue». 19« Atmung messen - Kontrolle A 4 - (ftlL I * t t / W n f ( f j (siehe Pkt. beide Stujiti 20. Ausdkessetfn der Kreuzkopf- M tseLi^rc*i*e~i4 vf /u.c'«^tv*y ©f bahnen (Durchmesser und ^~rossbt^u4. . £ fl$ a++^C j i ) * f i+44 Parallelität)-beider Stufen 21. Ausscritvlren der beiden Stufen uniiev. Zylinder- Korrektur. 22. Pleuelstange einbauen. ~£.&f4i,ct r * J . • 23. Kreuzkopf einpassen und einbauen. 24. Stppfbüchsenpackungen, fcc.ft C~'r ^ + 4 / Ölabstreifung und Kolben« (ohne Bespannung) ein a.u d. f^'sU+y. (w '44n+i*.4 bauen. Messung der Kolben « *t*+ 4 o f p U l U. o f p * r l lage im angedrüokten Zu stand. ( C(bin/***-* Ctv, Der Kolben s o ll an der b n .fi, ) Mcc Ostseite (Laufseite des Kreuzkopfes) mindestens '*vkkily i4 u e> c*r*flfZ/tUl einen Abstand 1 ,7 - 1 ,0 010 bei der 2. Stufe und 1,4 - 1,3 na bei der 3» Stufe ron der I/iufbuch3e haben« Da« heiß t, la be spannten Zustand darf kein« Zwannlara d«a Kolbens entstehen« 25« Kolbenstangenlage mit Rahaenwasserwaage prüfen« 26« F e rtig - Zusammenbau TV m ’r4 f Schadräume messen« 27« Luftfilter, ölfilter, Öl- «anne, Rifox, Impulsleit ungen reinigen« Ölfüllung +*( (+u*k) , * t c a + * . , f/a4 Dichtheitsprobe der Luft TZykJ-**rt U i i f c f kühler« c ^ o U 28« Probelauf 29« Prüfung durch TMP a) Gewindekontrolle Kreuzkopf Lagerscheinen Lagerzapfen •) Dehnschrauben (Haupt A U «Lu-h'-fK&fto-e fe r e w j lager, Pleuellager, Gegengewichte, Stangenkupplung) J%c~fJ^r c { (n*si*tt Zylinderlaufbuchse (Bund) Zylinderdeckel (Rippen) Ht%f of cyt>'uU^r tevtrs C -L+f* Zy1inde r-Innenrippen- 'Z i 'b f c f CAf U ’m ./ .t + f verstärkungen. Zy 1 ind ergehn, u sebund Sl1C**M*Y~ o f Cy ¿ ' w V t r / (Verbindung zwischen 2 Zylinder und Maschinen- gehäuse)« c-y 1,'M-Ze-r C V c A 1 2 t m p PAPER 4- BUCK D C -O F F RKFOBMBR TUBES DURING PLANT OPERATION B . csxK u o a 1* Introduction Vhen * reformer tub« bursts during service the loss of gas through the leak is not necessarily intolerable, but the leaking gas ignites inside the furnace and oeuaea overheating of tin surroundings. To prevent damage to the refractory and to the neighbouring tubes, it is necessary to isolata ths failed tube. To achieve this.- either the design must make provision for shutting off any individual tube or, if simple welded up connections are used, the whole unit oust be abut down and cooled b o that the failed tube can be cut out and replaced, or the connections plugged by welding. Because the outlet p ig tails usually operate in the region 700-800°C, and no valves are known that could be fitted in each pigtail, and because at any rate, the expense and complication of fitting them in the design would be considerable, an all welded design 1= normally adopted. Initially, when an overheated tube leaked, tho fumaoe had to be taken off line losing some 3$ hours production. This represented a serious loss of output. Apart from that, ii. reformer plants built for the production of town gas, the manufacturing authority is under legal compulsion to maintain a Minimum gas pressure and i t could hardly afford tp shut down a fUrnace even for only JQ hours, should a tube f a il during a period of peak demand. Consideration was, therefore, given to methods of blankingroff leaking tubes, which would not necessitate shutting the plant down. 2« Background I t has been standard practice fo r many years to squeeze mild steel pipes on gas and water service when it had become necessary to isolate a line, and a number of devices are ccnmercially available for this purpose. However, the application of gross plastic deformation to pressure equipment containing hot inflamzable gases had not been considered. The comercially available apparatus for low temperature service are hydraulically operated, which is an advantage, but their frame has to be dismantled and then reassembled on to the pipe to be squeezed. This would have been perhaps acceptable for in let p igtails where the temperature is around 400°C, but the manipulation involved would not be acceptable in the proxioity of the hot outlet pigtails (?00-5CO°C) . For that reason a & clamp squeezer was designed so that the vait could be placed onto the p ig tail where i t runs horizontally iajicen t to the reformer tube (Clark and 511 me a Paper 2, Fig. 2) and all that was required in the way of preparation was to remove the legging on this section. 3« C Ciarp Scueezer IV tails of the ac^tazar are given in the drawing in F ig. 1 and the photograph of Fig. 2. I t is driven by a short 6 ton hydraulic ram, a anufaoturec by Bpco Flexi-Force. The main advantages of th is design are: (l) The G> chape of the frame reduces manipulation near the pipes 'before squeezing to hanging the device onto a horizontal part of • the pigtail. * . (2) I t i s oonneoted to the pump by means of a pressure hose of convenient length so that the operator is at a aafe distance while th^ tube la being squeezed. It is relevant to mention - 2 - bore that in the ereat of a pigtail cracking «fail« being iquaezad. Dillingham experience has ahem that ths fir« that resu lt« from a p ig tail failu r* do«« not causo significant damage. (3) Should ary aooidant happen to the hydraulic ran, to the hose, pr to the pusp, the quantity of .o il involved is very small (1 -2 p in ts). (4) After squeezing, the Java can he fastened together fay means of perewa to form a permanent clasp to prevent the internal pressure Opening up the squeezed pipe. The G olaap and hydraulic ram oan then he removed fay simply lettin g the Jaws slide o ff along the guides ffaom In the drawing. (5) The jaws are lept in position fay naans of fa all catches vfall* the plasp is being hung and while pressure is being applied. (6) Two lateral sheet natal pieces locate the clamp jaws an the pipe, pnd are crushed away as the squeezing operation is in progress. 4. Laboratory Tests Although from the above considerations i t appeared th at blanking- off reformer tubes by flattening the inlet anl outlet pigtails could be achieved with reasonable safety, it was decided to carry out seme preliminary tests on a laboratory scale. In order to sisul&te plant conditions, a test rig was arranged in which a length of pipe could be e le ctrica lly heated by nakirg i t an integral part of % circuit connected to a low voltage high current source. One of the ends of the tube was blanked-off and the ether oonnseted to a 273 p .s .i .g . steam lin e.- Provision for measuring the steam pressure iod for measuring and controlling the tesperature during the tests was made. Samp las of both Znoolcy and Cr-lio pipe were tested . The clasp it s e lf was tested under a 7 tom logd withouf i t showing any permanent s e t. 4.1 Incolov Pigtails Two samples of extruded Incoloy DS tubing, 1.12/32 in. o.d. x 8 s.w.g. es used for the fabrication of the outlet pigtails were used for the trials. One sample was ex-stores, but was aged for 72 hours at QOO°C in order to bring it into a condition nearer to that of ths pipes a fte r service. The second sample was cut from an actual p ig tail whioh had failed due to the presence of manufacturing defects a fte r a few months in service. These samples were heated to 600°C before squeezing. During the f ir s t te s t as ths jaws touched the tube, the temperature dropped quife considerably, but by insulating the ends of the pige, ths temperature drop was eventually re&iced to about only 20 C. In all, eight trials were performed. The results were completely satisfactory, except in one case, when a number of nrrnll cracks developed on the outside of the pipe, but no leak occurred. This cracking was not thought to be significant because the tr ia l was dcr.e on a part of the pipe which had been overheated to nearly melting point during the initial atteepte to adjust the temperature. Figure 3 ahowa ths general appearance of the tufas and Figure I* * orosa seotiea through one of the flattened parte. 4 .2 Cr-Uo PU tall^ The tests were done at 400°C on a length of US Cz^Lo steel pipe lVl6 in. o.d. x 5/32 in- wall as used for the inlet pigtails. At th is temperature the tube was too strong fo r the squeezer and a perfect flattening could not he achieved. - la- order to increase the stress on the pipe, the width of the Jaw faces of the clamp was reduced from y in. to y in.- but then the ductility of the material was Insufficient and the tube wall sheared. It was found possible to araid this bjr carrying out the operation in two stages. In the first, a set of Jaws with j in. wide and slightly curved faces was used. This spread the deformation over a large area, but s t i l l le f t a gap between the two well faces. A second pair of Jaws with faces y in . wide, snl seai-circulax cross section was used to close the gap. To achieve this the load had to be increased to 8.5 tons. The clamp withstood this overload well. Figures 5 and 6 show the results of the tests. V ' During the tests it was found that the original Jaws in 18/Q/Ti. were too soft and yielded appreciably during operation. This was prevented by protecting the Jaw faces with welded inserts of heat treated FY520 (B) steel whose yield strength is shout three times higher then that of a te a l. 5* Plant Experience The pigtail squeezer has been used successfully on several occasions to isolate leaking reformer tubes. Squeezing the in let p ig tails has proved to be ss easy in the plant as it was in the preliminary trials. On the other hand, with outlet pigtails trouble has been experienced on three or four occasions owing to cracks forming during the operation. It appears that the difficulties are due to a combination of the following factors (1) Efabrlttleoent during service. It is known that the ductility of Incolcy DS decreases with time due to an ags hardening process. The use of Incolcy 600 which is now readily available and reputed to be less prone to embrittlement during service will probably Isprova matters. 4 (2) Decrease in temperature. As soon as the flow of hot gas through the pigtail is restricted the metal temperature begins to fall and 90 does i t s d u ctility . The more quickly the operation i s completed the less likely it is for trouble to occur. The possibility of increasing locally the temperature of the outlet pigtail prior to fqueezing is also being considered. ; ( 3) The occasional presence of score marks on the surface and ptringers of inclusions inside the pipe wall which facilitate the initiation and propagation of cracks. In spite of these occasional difficulties it has always been possible to blank-.off the failed reformer tube. Even after cracks have appeared in the pigtail i t s flattening has been achieved a t a second attempt. 4 The use of screwed on Jaws to maintain the pigtail gas ti^it has proved necessary. Whenever the Jaws have been removed, the leakage of gas from the reformer tube has been seen to inoresse gradually becoming excessive after sc^e time. A second application of the squeezer and permanent damping 4 - o t th e p ig ta il h a a been sufficient t o roduae tha lai^isi to % VI « •aoaa.% , ~ Conclusion Blanking-off failed reforoer tubes without having to shut the plant down, by a^ieezing the inlot and outlet pigtails at teaperatura and under prws«^xw, has bean a ooaplete success« So far no untoward incidents have occurred and provided adequate qare i s taken« the isolation of the failed tube can be schists^ without danger to the operating personnel or to the plant« i f c ' L г 1 i ! Т О . 2 о CLAU? XX OFSRASXOr ♦ » I г i» ц а » 3 GUTLST PIGTAIL PIPO» (XHOOLOI Ш ) ади вдои aoo°o i QBD39 ааспсм Д О В Д Я ИР В IK W * 5 » à Г • 1 tfr t l • I ; 710*5 INLET PIGT1IL PIFS (ljt CS-UO) ' 0QOSSZSD AS 400°0 ï i i i 710» f раззз МУТИВ 07 p n s JN 1X0* 5 AdaorptIon-Safety-Loop In Linde*a air separation plant Froa main condenser liquid oxygen comes to a pump which d eliv er* it alternatively to one of two adsorption vessfts filled with g e l. Then liquid oxygen flows back to the main condenser. By this the liquid Og is perma|fent in circulation through an ad sorption apparatus. It holds back (adsorbs) of acethylene and propylene (propene). All hydrocarbons not adsorbed, like ethene, propane and so on somewhat enrich in the flu id . By permanent taking out of the adsorption safety loop 1^ of 02-production and by evaporation of this rate the remaining hydrocarbons are removed fro a the separation column (main condenser) fo r the most p a rt. The adsorption vessel has a service life of 8 deys. After this time filling must be regenerated and the circulation happens through the other vessel. Thq oontent of acethylene in the main condenser is limited with 0t1 ppm. Analysis are made daily* By reasons of safety hot nitrogen (with a pressure of .5 bar) Is used as regeneration medium. SOME FIGURES OF THIS DOCUMENT RRE TOO Ж Е TOR niCROFICHING fìND U/LL NOT BE PH0T06RRPHED. CHEMIEUNZAG EtapMngar (DurdWdiMg« ■") 4» UNIDO-Vorkshop Responsibility of ATW 1. Improve 8c ensure safety of operators 8c eq uip m ent; 2. Maintenance of plant to assure high productivity 3. Improvement of existing equipment 8c process ( together with APN) toward higher productivity, lower production & maintenance costs. 4. Costcontrol of maintenance activités. 5. Liaison with other departments of Chemie Linz to coordinate interdepartmental work (main workshop, instrumentation, etc.) 6. Assist public organisations to aope with disasters, (chemical spills on roads etc.) On-Call service from friday 14,00 to monday 6,00 1 engineer or foreman 1 mechanic - (only in areas without shift-m echanics!) 1 OPGAWSAT/OAS DEPT. АТЛ/ A ...... G/V/S/ОЛГ A (AGP/CULTUPAL CHEAf/CALS) T. . . . T E C H K / C M ... A//TP ATE PL A M TS ) т и в р о д н е н A f t e a l l o c a t e û t o t h e с е д т а /л/ h i a h t s . THE И/ОДДЕДЕ - / Т HECEHSSAHT- AfAY BE SH//-TEQ QETVTEEA/ THE 3 РО Д Е Af A H - G ДОС/HS. Shut down of plants Caused by lim ited manpower generally only one plant may be shut-down for overhaul. p.e: 1) AC plant Enns shut-down 23. April 1979 duration: 1 week 2) Nitric Acid plant shut-down 2. May 1979 duration: 1 week 3) Urea plant 12. May - 23. May 1979 4) Single train: unscheduled shut-down for one day o n ly Manpower normally allocated to individual plants is sufficient only for normal maintenance. For shut-downs the group must be increased in size. p.e: N itric Acid plant shut-down normal maintenance crew (group Servi) 13 men plus from ATN (group Hennerbichler) 8 H m " " (group Pointinger) 8 " m " THW (central workshop) 20 n Additional hands are used to increase individual work groups or are given complete tasks! o O MATERIALS USED BY ATM CODE COMPOSITION APPLICATION mat-numbei* internat, code C Si Mn • c r Mo Ni ALU 9 9 ,9 % for pipelines tanks (100% HNO, 1 - 4450 10CrNiNbl 89 ‘ 0 ,1 2 0 ,4 0 0 ,3 0 18 - 9 ,5 0 for pipelines, tanks,, heater (60 % HN03 ) 1 .4 0 1 6 8Cr1/ (expired) 0 ,1 0 0 ,4 0 0 ,3 0 1 7 ,5 for pipelines, tanks, heater (45 % HN03 ) 1.4561 *) "Nictrothal 40" 0 ,1 2 20 34 for supportnet for catalyst Lead for lining of tanks, pipelines, pumps Ferrosilicium 15 for dehydration column of HN03 1 .3 4 0 1 l20Mn50 1 ,2 0 0 ,3 0 1 2 ,0 rollers in CaC03 m ills 1 .7 3 3 5 1 3CrMo44 (or 0,13 0 ,3 0 0 ,6 0 0 ,9 0 0 ,5 0 for lye pipelines and drums A lca l )>) *) DUR 600 for velding and to armour to 1 .4 8 2 8 15CrNiSi2012 0 ,2 0 O 0 ,6 0 12,0 baskets in NH3~burners Teflon*) PTFE for linincs (special applicatio: & g a s k e ts ) *) Registred Tradenames 4 j u v e t и т г у ~ Photpkortcaod- Production ot O y p tu frt- Cot a njm tui fat/i/trotion Ca - Sufto t-propO'ahon Amonco' 6onaia prmduc tion Trantformotion t CHEMIE UNZA6 UnMrZwtfwn В м /twlw Teg ATP Empfänger (Ourd»*l*fl« in) 4. UNIDO-Vorkshop HISTORY Of PHOSPHATE - FERTILIZER - PLANTS (APP - ATP) 1954: Start of gypsum-sulphuric acid plant (production of sulphuric acid and cement from anhydrite). Single superphosphate (now low demand) Storages, bagging and shipping stations. 1958: Mixed fertilizers (closed after start of NPK-plant) 1958: Sulphur burning plant (Monsanto). Continuous improvements and expansions to increase capacity 1964: NPK - plant (1 granulator, 12 reactors, 1 cooler) - PEC process 1966: Phosphoric acid plant, prayon process. 1967: First expansion of NPK - pl*nt (plus 1 granulator ana 6 reactors) 1969: New NPK-storage with conveyor bridges, bagging and shipping in the south area of the company. 1970: Second expansion of NPK-plant (plus 1 cooler and some improvements). 1972: Heat exchanger for raw meal in gypsum sulphuric acid plant. 1973: Third expansion of NPK-plant Cl granulator, 14 reactors, 1 cooler). 1978: Second belt conveyor from NPK-plant to storage. Equipment to use valve-Dags 1979: Second economicer for Monsanto plant. From start-up of the plants up to now have increased the capacity of the cifferent facilities by removing bottlenecks, for example: Monsanto plant Layout 75 t/day H25C4 Actual 100 t/dey H2SQ4 Phosphoric acid Layout 60 t/day P205 Actual 130 t/day P2Q5 Due to good operation and good maintenance the percentual operating time of all our facilities is very high ( 100 it » 364 days per year) : E x a m p l e s : __ 1977 1978 1979 1900 Gypsum sulphuric acid plant 96 % 95 * 9 6 , 1 % 97,6 it Monsanto plant 98 it 97,3 % 94,0 * Phosphoric acid plant 94 * 93 * 9 3 , 9 it 93,9 it NPK - plant I 96 * 94 * 96,1 it 95,1 it NPK - plant II 93 % 95 * 96,7 it 95,1 * 4 waw waw srop T k VJ § k ,4C/£ M R . f f e / M O i FotZfhtAM 7¥fOSF¥roR/c MPR, ■PCTRU/VM STo*t/ ■PCTRU/VM ______cefiTArM PzAMK . o MR GRAc/SAMt ATP -(4BUR FO* YCWCLRS. FO* -(4BUR M R. FRAZM RS i C h ifF FOPEhfAM Arp -MAMAEEA T E J T S < S R e A - c a U SA/RR/MG po q z m a m M R. M /rCRHAYR 3ARG/MG AMO "PHOiRM ATR, FK R TIt-IX rh 3 *0 } S H A t - K l l i VrR tSTY fcG o**h (A4R/CULURAL. CHey~HCA^S) ? LOUC3M/TMS 2. G RO uRLtRO REi 4 R / K lD t U ( A A t - ' > T*HO&r>HATfc. FA RT/uzem s T'ECHU 1C. T'ECHU P /V /S /O M FO R£ h rA M n * r * l- T A T c * s r * R Ac r , 4 e t M e u r MR BARTOSCtf S U Lht/un/C . AC/O, 4 DRRUTy FeRtHAM 3 G R oi/R iAAO tR S 2 t M R L P R P S fO IO CR3M /THS RGANISATION VFPT. O ^ k tx Ô FoZ EH fM -OL/RC R ài TH£ TPAfMEU AAE Tne - krORMARt {A HKC.AS3AAV - °HE CAM £H/pr '.btriSACH THE Respu^ibilitt and tasks of department ATP Surveillance, check, maintenance, repair of different production units, stores raw material and final products, bagging and shipping, laooratory. Spare parts oarticulary used only for a special ourpose in one, two or three departments — order, record, store, use. Common spares like screws, bolts, . . . are in the central store. Drawings: Draughtsman for sparepart-drawings, modifications in the plant, sketches. Small projects are made oy the department, larger projects are made by the design—department. Drawings of design—department must be signed by the concerned maintenance and croductian departments. Record of drawings. Contacts with outdoor companies, agents and reoresentatives, suppliers of spares, m a c h i n e s , ... Jisit to suppliers. Correspondence with different companies, filing of correspondence. Prospects, leaflets about special machines, parts, technics, materials used in the department Contacts with other departments of Chemie Linz concerning repair, investment, oroduction, design, finance,.... ouoervision of delivery dates concerning spares, outdoor repairs, .... Elaboration of shutdown-programmes in co-operation with prooucticn ana centrai- ceoartments. safety in m e workshop and for all field reoairs. ~~e whaie equipment has to ooerate in a safe condition. 5afety instructions according to t^e Austrian law (one time per year),accident-.nctic Information of foremen and staff, other decartments, suoeriors,... Daily, wtexly, monthly, quaterly,... Investment programmes of small volume, repair programmes, estimation of costs. Cost control for maintenance, monthly computer prints, quaterly reports to division (comparison precast - aqtual). Collecting of literature and papers concerning used operations, machinery and p r o cesses. Training of foremen and workers in the field of technical knowledge, safety, efficient performance of repairs,.... Experiments and tests of new parts and products. Co-ordir.ation and co-operation with production aepartment (daily morning discussion) Calculations concerning machines, parts and the process. Energy conservation (e.g, screw compressor - new or repair ?) Engineering, orocess variables, physical chemistry i Accomplishment of authority-ordera like pressure tests, yearly check of conveyors, earthing measurement of tanks for burnable liquids. Obligations concerning pollution control (oil, waste gas treatmert, . . ) Mutual control between maintenance and production departments resp. central depts. Participation on seminars, courses, study of literature, visit of industrial fairs (e.g. AC h EMA,...) to improve technical knowledge. Expert for suggestion system Personnel problems - salary, transfer to other deoartments, overtime, . . . Jobs as adviser or start-up personnel in Austria or a foreign country. Training of oeople from other companies. Showing of plants to our customers and other intrested grouos (schools,...) Collection and filing of experience, repair cards,... Stand-oy or on-call service from friday to monday 1 engineer or foreman 2 locksmiths .ACTUAL PROGRAMMES, PROJECTS and PROBLEMS T o r d e p a rtm e n t ATP Wheal loader with 1 m shovel Loading conveyers for very long wagons Palettizer for open air storage, unit 63A Replacement of fork lift truck Replacement of dumpers by a wheel loader - 3 m shovel Replacement heat exchanger VI - sulphuric acid plant Replacement hot gas filter - monsanto plant Replacement phosphate scale - phosphoric acid plant Improvements on bulk loading systems - 620a and 633a Speed-controllers for belt conveyors Belt conveyors for coke Unloading and loading of ships Asphalt for ooen sulphur storage Dose of trace elements Imorovement conversion in Vonsanto plant New sulphuric acid plant - douole absorption Sound protection — unit 601 Oose of coating agents (siliceous earth) Lacerating machine for paper bags Dedusting units far phosphate and potassium ¿econd palettizer for unit 634 (ooen air storage) Scales for bulk product Replacement cement Gagging machine Tank for AS - lye utilization cf sulphur concentrated iron oxide Preparation pf hot water for division C 3ul< loading into vessels Reclacement KSB — comoressars Extension silo, bagging and shipping - unit 633 Coal dust combustion for cement kiln Utilization of acid-oil in the kiln Dedusting of waste gases of spheràdizer I and II Sale of caterpillar (tracked vehicle) Removal of fertilizer-rests from boxes - nearly empty - unit 633 Utilization of excess steam Pipeline for sulphuric acid between the units 608 - 626 - 627 Covers of eternit on conveyor bridges Cleaning of cement silos Investigations about use of palettizers in unit 620 a Investigations about corrosions on spherodizers Reduction of P205- and F-content in by product gypsum Repair painting of conveyor bridges Roof repair of clinker storage Repair of chimney sulphuric acid plant Repair painting - unit 631 Repair or replacement of electrostatic wet gas precioitator PQSSf3/L/7?£S TO REDUCÁ SHUT-DQHN ' T/ME ч A r v о 03 / *» i ft „ I ? i t ! ! Í <1 ¿ v. з ÇÇ S«= 11 v: > 'S * Й < *. 4j .. H $ i ? 11 ? ° Л e и X и c v co'J £ * £ £ * * * * <*- & > u i M VI § ^ 4 4 ^ V ) 9 4 T V) á 'о к о к ч à V) £* Vj г ч Г/г>Ь ¿ * rp /'fy ы 1 COMPARISON of maintenance costa r 1. quotar 1961, departr>wit ATP 1201 - Sulphuric .add - vonsanto alant -C I | General s h u t d o w n planned for June 1981 1"’C2 - G .-p s u i " sulphuric acid olant -11,1:4 General shutdown planned for September 1931 1203 - Cement >29,0:4 Routine check and overhaul in winter time. General overhaul of clinker crane. 12C4 - Supercnosphate >i4,3,o Wooden front sices of tne buildings 621 and 622 are in repair (programme roof— repair cy civil ceot.). Change of granulation from granulator 1 and 2 to granulator 3 and 4. 1205 Phosphoric acid - 4,C;ii 1 2 0 6 \PK production > 1 1 , 7 4 Repair and painting of NH3-, natural gas- and water pipelines, preparation repair of spherodizer III (ring, lifters), installation of n.ew metering device for H3PC4. 1221 - Area silo west - 3 9 , 6 4 Repair programme of roof-top not yet realized. 122222 - Area silo south - 1 2 , 5 * 1224 Cement silos >I4,2,o Overhaul in winter time 1227 — Eacoing and snipping + p ,u ;« Training cn and start of calettizing unit - -ig-er c r s t s ry oepartxents ATP, TEL, TVE. Repair of reclaimer chain by Th w . Vore breakdowns on loaaing vehicles. 1220 — Cement bagging ->139,£i Overhaul of complete bagging and loading station in winter tine. Gauge pf cement Dagging machine. 1229 — Central raw material storage - t , o * 1230 - Department laboratory -5,£:* 1916 - ATP-’WorKshcp -5,-.* SAFETY MEASURES FOR THE COMPLEX FERTILIZER STORAGE AT CHEMIE LINZ PLANT SITE______ A. PRODUCT ' • - complex fe rtiliz e r (NPK) or occasionally CAN (28 %) with max. 0,4 % C. - storage feed temperature max. 50° C. Continuous measurement by means of two independent thermocouples. Temperature is indicated and recorded with max. alarm in the control room of complex fe rtiliz e r plant. B. DESIGN MEASURES 1« Belt conveyors - belts within the silo in flame-adverse material speed controler (shut off) straight running control (alarm) emergency switch with pull lines (shut off) - lower belt temperature-control by pyrometers for the storage feed conveyors (alarm in the control room of the silo) - division of the belt bridge into fire fighting sections - . t by means of waterspray-curtains - emergency exits (ladders) marked by arrows (always two exits for each belt bridge in addition to the stairs in the corner stations) metal detector before the entrance of the silo (shut off of conveyors) and additional magnetic metal-pick-up at the way out of the complex fe rtiliz e r plant / 2 - 2 - swivel chute located in the last delivery station before the silo for discharge of the belt conveyor to the open a i r . - arrangement of the belt conveyors so that they cannot be an in itia l heat source for the fe rtiliz e r - fire extinguishers (C02) within a distance of 35 m along the belt system - telefcn system with connections in a distance of 100 — 15 0 m - interlocking of a ll belt conveyors to ensure shut down of preceding conveyors in case of fa ilure. 2 . S ilo . - partition to 12 boxes, each with a max. capacity of 5 000 t . - thickness of partition walls designed that in case of a decomposition in one box ignition in a neighbour box due to heat transfer is not possible. - a ll c iv il engineering material used is flame resistant - feed product is screened by gratings to remove lumps - heat sources like steam supply lines and electrical cables are not in contact with the fe rtiliz e r - electrical equipments are mounted sidewards and designed in wet-room-standard. Main switches are outside of the silo . - lightning rods protect the silo - emergency orientation lights in the roof top of the silo, along the reclaimer path and in the lateral belt-channels (automatically switched on in case of power fa ilu re ). No bulbs but only fluorescent tubes are used. Handlamps are not permitted. / 3 3 - windows for opening and closing along the roof top (5 i of the ground flo o r a r e a ). A ll windows are remote-controlled from outside the silo by a separate supply of compressed a ir and daily operating te s ts . - emergency exits from the roof top, the reclaimer pathes and the conveyor bridges marked by arrows - extinguishing line (dry) for fire water in the head building of the silo - flooding line for each belt channel with a capacity of 2,5 m3/min. - hydrants outside the silo connected with a ring system of 600 - 400 mm diameter - 12 mobile water canons each for 1,5 m3/min adjustable for spray or jet application - free outlet of product slurry after opening of the doors cn the end of the belt channels - emergency exits from the lif t - separate repair box for repairs on the reclaimer and jo£s w ith f i r e . C* MEASURES BY ORGANISATION - general s t r i c t p ro h ib itio n of smoking exception: dayrooms, o f f ic e of supervisors, workshop and control-room in the head building of the silo - repair jobs are only allowed in accordance to the written. "job permit" - welding within the storage silo only under special supervision and not near the product. Control of the spot for 6 hours after finishing of the job by means of an infrared-instrument. / 4 — * t — i - operating manuals for a ll working places, safety instructions every half a year - control of the storage silo every half an hour recorded by means of a printing-watch and control book wireless contact of the control person to fire-brigarde - sufficient respirators for compressed a ir and gas masks, most of the operating personnel is trained in heavy gas p r o te c tio n - free access for tha trucks of the fire brigade - warning plan (sequence) in the case of danger - shovels and buckets are available 1 FACTS ABOUT STORAGE SILO FOR NPK UNIT 633 l e n g t h 1S 6 a w i d t h S3 m volume of the building: 125.COO m h e i g h t 22 m 12 boxes, each 50CO tons * 60.000 tons storage capacity repair box for reclaimer possible extension: 4 boxes each 5.000 tons = 20.000 tons ■"ax. st o r a g e h e i g h t 14 m wall thickness between the boxes: 1 m max storage width 43 m number of gates to the storage : 24 max storage length 14 m wechanical equipment: Z reclaimers delivered by SCHADE (Western Germany), each for a capacity of 130 t/h. weight of one reclaimer: 40 t capacity of feed conveyors : 2 x 60 t/h capacity of reclaimers : 2 x 180 t/h r . e a d building with control -room, screens and crushers l e n g t h 46 m w i d t h 1 5 m neight 27 m ragging and shipping length 106 m •rcth 19.5m width of the leading came 9.6 m -eight of towers 24 m vecbanical equipment: 2 bagging and shipping stations, each for cu t/h bagged croduct and 60 t/h bulk product 5elt conveyors - feed conveyors to storage silo 2336 m ------conveyors between silo and bagging station 700 m conveyors for wagon loading 56 m conveyors for ship loading 777 m conveyors to open air storage 35 m total 3904 m Energy supply electrical energy 800 kW installed power drinking water separate station for compressed air steam supply fire water supply over 14 hydrants supervision and control from 2 control rooms the whole plant is equipped with dedusting filters of high efficiency additional railway lines 4 5 G 0 m additional streets 650 m 2 dayrooms for operating personnel, rooms for supervisors, modern sanitary facilities 9 CHEMIEUNZAG ûeneral guidelines for fertilizer storages jnder normal transport- and storage-conditions mineral fertilizers are wetner explosive nor self-flammable. In general it is sufficient to hte fertilizer dry and clean to avoid contact of different products and in consequence chemical reaction of the mixtures. Fertilizers with ammonium-nitrate (e.g. CAN,.\PK) can decompose under influence of extern fire or heat at temperatures above 130 C. Decomposition will proceed slowly without extern heat supoly through the total fertilizer mass. A yellcw- :rawn, pungent smelling, poisonous smoke will be developed (nitrouses gases - dangerous breathing-poison). Preventive safety measures If the following recommendations are onserved the cancer of thermal decomcosition ran oe excluded certainly. In case of fire in a storage decomposition can oa avoided with high propaoility. Please observe: 1) Clean storage rooms before storing of fertilizer containing ammonium-nitrate. In particular follow this instruction for bulk-stores. 2) Eurnable products e.g. coal, sulphur, corn, oil and fuels also acids, u~slaked lime, CAN and thomas-phosphate are not allowed to mix with fertilizers and are to store separately. 3) Smoking and use of fire or open light is prohibited in the storage room (also welding, soldering,...) 4) Take provisions that ammonium-nitrate-containing fertilizers can not be heated from outside. Steam lines (even if insulated), electrical cables, electrical motors and heat producing lighting fixtures also hot exhaust gases of vehicles may not coma in contact with fertilizer. Also thrre must be a guarantee that conveyors for fertilizer transport can not run hot, 5) Should occur a fire in the area of the warehouse immediately the fire origade must be informed in which buildings fertilizer containing arpmonium-nitrate is stored to protect such fertilizer stores against fire in the best way. / \ CHEMIE LINZ AG guidelines for successful fight against thermal decamoosition of NPK-fertilizer The necessity of the use of laoour-saving proaucts in the field of agriculture isads to fast increase of the demand for mineral fertilizers in general and ’.FK-orccucts in oerticularn These fertilizers are not explosive or self-flammable under normal transport- ana storage—conditions. Complications are not to expect. \PK-fertilizers containing ammonium-nitrate can decompose slowly at temperatures above 130 C oarticulary due to influence of fire. At some fertilizers decomposition will stop if heat transfer from outside is stopped. Other formulars can decompose completely over the whole mass of stored fertilizer and can develope a large volume of hot nitrouses gases (350 C) and water vapour. rhe gases are poisonous, the fight against hot spots can only be performed by use of creathing devices (in the open with B/5t- or F/5t-filter3, in closed silos as well as in areas of nigh concentrations with heavy Dreathing devices). \PK-fertilizers mostly are stored in oaper- or plastic-oags. An interruption of the reaction oy w ater- irrigation of the bag-piles will not be exoected. The most secure method to avoid extension of the hot spot is to divide concerned mass of fertilizer *rom the rest, to transoort it to the open air and to make full use of water spraying to stop reaction. In case of decomposition of bulk fertilizer it can be brought to open air at an early stage of reaction (e.g. by shovels). Another way is to spoil out the en dangered amount of fertilizer by means of a strong water jet. ATTENTION; Ths fight against decomposition by other measures (e.g. foam, carbon dioxide, steam, cover with sand or fertilizer) is useless. Decomposition even can be accelerated oy such measures. In case of decomoosition of palletized material fork lifts can be used to remove the concsrned piles to the open air. Under certain circumstances wetting of the store house can be avoided. There is no danger for explosion for the fork-lift-driver. But he has to wear breathing devices. After some time of reaction the bags will fall to pieces. The decomposing fertilizer then can be spoiled by a strong water jet. Poisoned persons are to lay with the face to the ground, body in half-side-position, keep the person warm and calm and provide a doctor immediately. Wash eyes and mouth with neutralizing products (e.g. bicarbonate of 3 % concentration, but no boron- water) , eventually start breathing with oxygen. Guidelines about useful storage of mineral fertilizers are distributed to all warehouses , the final users (farmers) will be informed in a proper manner. This information is distributed to all fire brigades of Austria. I4} Oi OS и л т t p . i a l s а л « « * Ц ATP Г * C. О Ч к Conio ¿¡псы L^oJ Д P P L¡ 1 * n СЫ h ^r NC**K Inlfrnílt. fodf-|cbitcv. C Se H * ! ¿ r lo 4 i V Cul j Ыb ; « e « a r < : t i J J.C lO i St C ■'.& iA CAS c.ts a l i 0.Ч0 A aS oi i t e IS. ÍA a s a.is Cj 0 ¡ 6. ss .1 i. c f c :- íc C ^ S У\ e u s ч-л O lí c ~ Si ro c » >a>5 CeMVflOA ChA»A /fate hoiticari) *u%~ \Z 35 A i К !ci * Me.os vi •f. i*icr: У A l* Hn.il- Chtcn*\ u 0,4 U l . f U u A j J C u / . f i s ; 14 Cr Ha S |о,м O.V>[«i?D A,*i 1 i *1SSo XAoCrHí Kb it i c-« 10 Í .0 4< - 10 I ‘2 ) [V a n i * l* h JftM Ä.TWr.-Ot .»/»«Л. * 1 * / ч е х XIOGrM: MoT; * « no» Л1 a ) jy _ i___ i l) £i*of T; * 3 a 0 5 » ■: 5 Crii* ti o Ti JSK IM .Л A,0 SS -re n d e n t Qc 0 ^ • ¡ g j ЬЯ4Ч 1 J Q A. 4 sfì xlO Crt¡¿MeHb4ffC cm V. 3 ? « «Л 4 M l i A lo CrHL it 4 F a 42 Z 26 / 4 5 CohAVIOK i4 *U X Л. V X A Ai C 'N H 1 JoiZ FF • r i i a i l ' A2. V9 1- 4 X vu ■к j ___ !___ < 6S Co »>»» ! ¡ I Í •4 V !»<<>, s £¿á AS УУ 41 V j 1 i 1 i l 1 1 o г ~s_ L ■ lM i\ 6 - f l lCÙHJ » 4 j -,4 i A,2 T> A b i i 1 !. •Set-JAó o f lliijv 1 О i- t, Í Hi i l f t - v 2ítfNií(?.eHU| |ql Ì1.7S /.s lo / | i i i i i 1 ¡■(•¿У -Itnrrp.:al о>гвл.ясе * I < V- f - i Kiìh/VJnr «e. -f,»» (^^1^ >A>- (m ,o ; i ; ? a) Injunctions cf authorities: u-j- to the very closed Location of Chenie Linz to the town L.nr -.e ~avs very severe injunctions concerning pollution contrail. I"1 tnp rLan-ing -state of a "ex riant -e rave *o declare the volume, chemicol a-aiysis, d .st ::-t?'-:, *s~:.e: =t .re z * all effluents. .3 are obliged to rontroll this ef#ii;ants i"> a r ? t ; r : " ; c »ay and to sncw this notes to the -outhotities. Examples: Continuous recording of SC?-concertration of tue .?ste gas :r suiphuric acid riants.Hust determination at least "'our ti-es rer ..ear. Analyses of effluent -ater from a ifrerent points cf me sewace-s.. s tan. b' "ethocs of gas ciaani-g in dept. ATP < 3e3„~rsit>ility : Ther« is a separate departne~t in cur ccrja^y respans it e fzz • e n i e i_ i interrai pcilctian tcntroil ina co<"p»tent for all t~e г rtarts ta ai. tba I The scotched economizer ia a construction of Bheinatahl Eoo GmbH. Characteristicst seamless eteelpipes fin-tubes of cast iron two-piece elbows (cast iron) with asbestos sealing, filling the hollow between interior and exterior elbow with iron -file-chips, housing gastlght welded water in- and outlet proteoted with oast iron and stuffing box. The first ECO-design in the Monsant-plant of Chemie Linz AG woo'*w w *■“* 01» + r\ +-V>o *‘*v WJovefom o+■ PVtS +,* +•'-o**‘0 q crr\Tt c* • ^-in^p------1 QAS y - WP V*ovP---- - three steam generators between the passes of the converter (coolin g the SCte/SO^-gas) and one economizer a f t e r the 4 . pass in a construction as shown above. All tubes and elbows are inside the housing protected with cast iron against corrosion. We can recommend this system and v/e warn against a construction with flanges. In Europe there are only a few experienced manufacturer of this tubes i.g. Poster Wheeler, Great Britain Rheinstahl ECO GmbH, Hilden, Germany. The steel pipes either will be shrin’xed into the cast iron fin-tubes or the diameter of the steel pipes will be increased in consequence of overpressure after fitting with the cast iron fin-tubes. The cast iron shield has to be very tight avoiding condensation and corrosion. AC ID -D I S T R I B U T I O N : In our acid plants v/e have different acid distributors: Monsanto p lan t: D istrib u tio n cup with o v e rflo w w eirs. The material of the cup is Meehanite C33 with <3.3/® C, >2.7/ Si, 0.6/ Kn, 0.3/ Cr, >0.5/ Cu. Anhydrite plant: Trough distribution system in cast iron with downcomers in ceramic. Experiments with down comers in stainless steel 1.4580 and cast iron have been not satisfactory. FRINZIPLE SKETCH 0? A CLOSED AND DUSTFREE BELT-CONVEYOR DELIVERY-STATION In the f e r t i l i z e r p la n ts o f Chemie Linz AO and Donau Chemie AG. 1 oonvoyor frame 2 I sheet detail housing 3 matorial feed duct 4 rubber belt 5 r o l l e r 6 rearward rubber apron, 12 mm thick 7 front rubber apron, 4 mn thick, soft rubber e latoral inside rubber apron, 4 mm thick, soft rubber all the aprons are 9 lateral outside rubber apron, 12 mm thick readjustable 10 clarop-bow to fasten the aprons exhaust duct to a dust preciplator 112 1) < butterfly valre to regulate the exhaust flow. ( 0 lO C »rcjyiidüli CCll bolt tciioion ) nutnm atiC ; load <38 001100nd regulated belt ,e ns ion no slide slipping best possible efficiency / Whip i ínóínC TWtoue C CcOMiVfL7o£auL£ D Ho.'iMewr FOÄ. iei.7 TewsoJ FUNCTION : The e n g in e to rq u e B p ro d u ce s a c o u n te r to rq u e o f same size C f v/hich causes a movement of the engine D around point 1 . This means extended shaft distance - and load depended increase of belt tension. Best power transmission is managed by this turnable engine foundation in connection v/ith polished-cambered pulley and special adhesion belt SLIPPAGE : sliding slippage is not possible because of exact belt- tension adjustment by engine torque. •al-j UikeL this moans : higher efficiency low erinitial belt tension lower stress in shaft bearings longer v/orking period BELTING : cover material : Pclyamid t i e ro d j single polyamid to join closely camber. High te; tre a d t chromium leather ^ m ..j,,- ^ coefficient of friction (•'0 ,6 ) * NOTICE ! : • By changing the engine you have to make sure of rig h t rotation, same weight and sine of engine and lim itation of whip movement (cr.r.-or of b elt damage! ). AT?/' 4 FITTINGS used by ATP Medium : SULPHURIC ACID p ro d u ce r : Rheinhtitte - V/estern Germany typ e : gate valve - AZ 1915 s iz e : DN 15o , Pn 6 m a te r ia l : N r. 136« s t u f f in g b o x-N r.4 4 1 0 , TFE-asbestos sacking. speciality : two-pieco casing, seating parts easily to regrinbjexchangeable wear parts, no pressure on stuffing box if valve is closed, low pressure drop because of low turbulence, use ! for circulation pump to absorber-93/o / 12o°C. working period : several years p ro d u ce r T u f lin typ e nrocess valve with TFE-sleeves s iz e DN 70 m a te r ia l ductil iron - fully TFE-llned. s p e c ia lit y rotating plug in a TFE-sleeve which is locked in the body. Without stuffing box and lubrication, seals are not exposed in either open or closed position use : outlet of acid dilution - 72-76 % working period Medium : PHOSPHORIC ACID up to 3o °C up to 5 5 p ro d u c e r : E rhard typ e : diarhragm valve FD (rubber squeeze valve). £¿20 • DU 125 , Pn 10 m a te ria l : cast iron - rubber lined diaphragm - soft rubber speciality : without stuffing box, exchangeable rubber l i n i n g and dinnhragm , liftin g lim itation, use : t h r o t u l e vnlve iu acid pipes. working period p ro d u c e r D U rh o ld t typo ty r e v a lv e s iz e DU 50, PN 10 m a te r ia l : cast-iron for casing with anticorrosive protection Layer; re si taint rubber tyre. (TiU - silvered rubber parts for sulphuric acid), i c i a l i i y i without stuffing box, exchangeable rubber parts I u -e : 3 top valve for phosphoric acid. v.oriih.g -.ri o<1 : Mediyn »rPTx-ST.UPWY------f . »= 1 .^ ^ tn * - 1.7 • ; ■ / i l o to ViO °C b lcalc ìurrnhosphate armonitttni tra te calcium nitrato, -doride and 20 % r a t e r X p ro d u ce r : W o rce ste r type 4466 T ball valve c iz e : DN 1oo ( 25 ) m a te r ia l : N r. 4401 for body, ball and shaft. TFE f o r s e a lin g s specially : no maintenance, no greasing, exchangeable wear parts use ; S iof-valve for NPK-circulatbn. working period : a bout 2 month. p ro d u ce r : ----- Chemie Linz designed. typ o : s iz e : DN 30 material t: N r. 4580 tube in Si-casting, TFE-sealing speciality : exchangeable tube and disk simple construction. use : Throttle valve for NPK-slurry to spharodizer. working period I 3 - monb p ro d u ce r : T u f lin typ o : D 127 througway valve s iz e : DN5o r a t e r i a l s stainless steel for body ( 13-lo-Mo ) TFE for ring, sleeve and diaehragm. speciality : no maintenance and lubrication use : slurry circulation working period : several weeks p ro d u ce r : Geeos W-Germany typ e : PR- p lu g v a lv e s iz e : DN lo o m a te ria l m tfe-sealing speciality : no stuffing box lubrication box for a ll tine greailnq - use j slurry pipe to spheirodizer 9k 1 1 — ~RTT 0" Г" :гл by ATP (¿J 1 Vedl ил : SULD:;'JRIC ACID CF.:r:RIFfJC-AT, PUVFS ( h o r iz o n ta l) P roducer Ochsner - Austria tv ne : U-IOR c a p a c ity : loo m3/h - 2o m (5o°C) 93(S m a te r ia l : Cr-casting ('.7i- a llo y e d ) speciality: hydraulic shaft sealing; useable for high in le t p re s s u re . use : circulation rump - acid store. fu n c tio n : hydraulic sealing by auxiliary im peller. in operation no contact of shaft and stuffing box because of axial shaft movement. working period : about 12 month (temporary working). P roducer RheinhUtte - Western geraany typ e RE 153/265 0 ^ % c a p a c ity 2.ko cr/h - 2o m (up to 12o °C - 93 % ) m a te r ia l N r. M 3 6 s p e c ia lit y Hydraulic sealing - im peller with backside vanes use circulation numn for absorbing tower fu n c tio n stillstand - double stuffing box and special ring valve working - hydraulic sealing working period : about 12 month (continuous working). P roducer RheinhUtte - Western Germany tyo e RE 3o/25o c a p a c ity 5 o m /h - 2 o m ; 6 o°c ; 66-73 % . m a te r ia l 1S75 S i-casting s p e c ia lit y divided, removeable casing in steel casting- wear resisten Si-parts for acid contact. hydraulic sealing - im ueller with backside vanes. double stuffing box and special ring valve. working period : . SUBMERSIBLE PUMPS ( v e r t i c a l ) . P roducer RheinhUtte - Y/estern Germany type GVS 150/ 265 c a p a c ity 113 a V h - 15m ; lo o °C ; 98 % m a te r ia l N r. /¡136 , carbon shaft box. s p e c ia lit y use circulation numD - ¿rying and absorbing tower. working period : about 12 month ( continuous working ) . Mo 24.um : L ir iD SUT.PHUR s u -íeetsisí;: ru::?s P roducer Rheinhutte - Western Gcrmany type GVS 25/22o c a p a c ity ?Tb rnô/h - /(.5 m l i q i d s u lc h u r, 135 °C m a c e ri-l cu.ut iron, stecl rhaft, shaft protcction box Nr./fo 3k a ; e c ia x it y cto.-sm heated ca sin g ( 3»5 b a r ) UT,0 s u l - hur to lbrnaoo. v.-:rvi:v* no rio] : a bout 12 v ) -.onth ( continuou:; woruinr, ). n OH A i f - f . * * - SL M edlun : NPK - SLURRY loo °C , spez. rei (it 1,5 - 1 ,7 CENTRIFUGAL PUMPS ( Giudee pumps w ith p a ckin g f l u i d ) P ro d uce r Klein ( Jeumont Schneider ) - France typ e v;d 1 go g c a p a c ity I’O cP /h - If3 a , l/ f 5 o rom m a te r ia l n r LiiGo or G-X 1 oCrNiMo 27 5- shaft : nr 45 3o plate v/elding with C elsit 5oNb speciality: special designed im peller stuffing box with TFE-packing and sealing liquid, exchangeable rear disks and rings. use IPK-slurry to spharcdicer and circulation. period of working : about 4 month (continuous working). Producer : Worthington typ e : 2 CNG 1o4 c a p a c ity : 3o a v h - 6 bar , iRoo rpa material : "V.'orthite" - 2oCr/25Ni+2,5Mo - nb stabilized and thermal treated, shaft nr. 4586 speciality: variable sp lit of impeller by movement of the casing cap. use : NPK-siurry circulation. p e rio d o f 7/orking : about 4 month (continuous working). Medium : PHOSPHORIC ACID H^Po^-slurry - J>0 % P20ej , 3% H2S0^ , 6o'o liquid - k o 'i so lid , 80 °C , y = 1 ,7 SUBMERSIBLE PUMPS ( c e n t r if u g a l, v e r t i c a l) P roducer Ochsner - Austria type MOVS - 38 / 2oo c a p a c ity 24o m5/h - 13,7 m 9 7 o rpm m a te ria l nr. 4500 s p e c ia lit y exchangeable wear disks and rings use : H7 P0,-slurry to evaporation cooler period of vorkina : 2 - 5 month ( continuous working) * IW Ù x 1 i ».Ks+Ji *.• x W ÀU X ^ :lJpOla - C lu r iy 0 Ç î r r v ?T '* r 2 rV'iri'. (centrifugal, vortical) Producer : Encival - Belguaj T yro : 5o BAV B So C - .m c ity : : 1+1 oJ/h - 18 n , H 5 o rpra m a te r ia l : n r . 45oo , n r . h5?7 speciality: impeller v.-ith backside vanes exchangeable vrear disks and rings, use : slurry to filter working period : about 5 month ( continuous working ). Medium * Washing Water ( 5 t H2 Si P61 2-3 i> SiO - Waate Gas Cleaning. -jf» 1,05, t » 30 - 50 °C Centrifugal Pimp, (horizontal) Producer* Ochsner - Austria îÿpe * S-tlor 2213/50 H Capacity* 25 m3/b - 45 m - 2S00 rpa Material t all parte with fluid contact - rubber lined, shaft protectionring Nr. 4550 Specialixy: hydraulic sealing (patent Mackensen) Use t circulation pump for v/aate gaa cleaner Working period o r O i^ Tc ;ep ;he wear and tear of ro lle rs,tyres and gearboxes of .r. inclined,rota’ing drum as lew as possible ycu have tc- xeep up a continuous movement in longitu • inai axis- ur. and down. T his axial r.overncnt should be lim i ted by two orison■‘al ro lle rs. The period of moving up and down (distance i.e . 60 on) should be about S hours. There are different possibilities to Manage this movement: 1 . h y d r a u l ic The k iln or drum slowly is pushed up and down by hydraulic cylinders in certain periods. 2. CROCCIRd 0? TRH ROLLERS You start shifting the rollers at the station which is nearest to the impulsion or horizontal rollers and you continue downwards if necessary. You always have to lif t the"running up roller* on this side of the tyre where you intend the drum to move along. Lon1t lif t too much ana always keep the ro lle r shafts of one station parallel otherwise abrasion would increase. You s tric tly have to control temperature of bearings ( 60 °C ). If the drum is in position high and won't come down you have to lubricate the ro lle r surfaces. ioLLtH. k£4;to«n*L fot. kt&H f •*»*»»! Ч-IMÍ J ÍW.',¿ ’»ЭМ^ЧЧ Fi l j ?iCf« ÙX L j m £ i W fc7 СЛ. R oot.9 h OÍ? k A C \rit>St¿7C EITLUUir » .й И 1 * А С -Д А Г (О 0 VA't*. « T u - p ‘ o o t H P ( 2>¡H 4 Ü s o ? c í z o h f > ¿ £ DA А Г А m c A a J o rt r lo * o i t i S Q n ñ l T Ç CK7?/ao#v^ç £ ♦ *N3J.SA$ -Г*оцчЭ9!а j j 1 25 22 1.25 Mi i'1 I 1 If, i- ; ' I ! ' I' -Г, .. , ?K0lfH*rh£HL CHEMIE UNZAG UnMrZaidMn B w fb w te r H a u a n if Tag BTH fcm pfingtr (Ourtfucfttêg« an) 4 . UNIDO-Vorkshop Maintenance Problems of the Urea Plant The major problem in an urea plant is the sealing of the high pressure section. It is of vital importance that the surfaces and the lense are very clean. The lense hardness must be less than the hardness of the piping. The gasket of the reactor manhole is an aluminium-tefion tape gasket. A second point are the high pressure pumps. We use pumps designed and fabricated by Worthington (Hamburg). After 1 1/2 year of service ve can say that they vork satisfactory. The piston packing lasts about one year. The valves have to be changed about every six month. The packing (details give the attacked drawings) has to be prepressed. Valves fail mainly because of spring breaks. This can be influenced by the spring material and the spring geometry. The CCg-compressor - which is maintained by ATH - had problems mainly because of vibrations. Material problems existed mainly during the start-up-phase. The welds of the reactor lining had to be repaired (lining material is 316L). . / 2 A » /1 b - 2 - Until now the large width belts in the prilling-tover are not satisfacotry. We have to change them after about 1 1/2 year, which is a too short time of service. We plan to substitute these synthetic belts by rubber b e l t s • In the urea storage the main problem was the sack-welding- machine. This was mainly a problem of adjusting the welding température and the lenght of the cooling zone on the sack-welding-machine. о \ 'oun ro r : ns"-. ! /I Г ' ' 1 c X Vn:a? lía st 4--- r UREA PLANT Our nsv urea plant t/as b u ilt in 1975/1976 and substitutes an old 300 ft con/day plant. The start up vas early 1977- The design capacity is 1C0C n tcn/day. It is a SNAM P30GETTI PROCESS. A f t e r overcoming various start up problems, ve can say that the performance of the plant is good. Since 1973 ire reached an on-stream £ a cto v of 330 days per year. Mayor equip ament and its vendors: equip ament______vendor COg--Compressor (5 Stage reciprocating compressor) GKH (BRIO ■IIT^-rUir.ps 7 Plunger pump Worthington (3RD) C arb o n a t Pumps 5 P lu n g e r pump W o rth in g to n (BRD) E je c to r . Vacuum System ¡Ccerting (BRD) Reactor V0E3T ALPINE (A) Carbamate ‘separator i» ;i Stripper F3M Milano (I; Centrifugal pumps 0chsuer Lins (A) Salt Conveyor System Hut 3cccherau (A) Scrapper Schaae BRD) Weighing System Sac’c '.'clchuc; Machine Libra 3RD) T I I CHEMIEUNZAG rZat^Mn Ha>W Tag TBV Empttngar (D uniiactilig« an) 4. UNIDO-Workshop A ctivities, Duties and Organization of the C ivil Department The main task of the c iv il department are: - Planning of c iv il constructions of small and large p r o je c ts - Maintenance of buildings, streets, steel constructions, severs, railway tracks etc. - Administration of a ll documents, static calculations and plans concerning c iv il activities. Contact with public authorities concerning questions of public or CHEMI3 LIN'Z in t e r e s t s . Planning and adm inistration are done by the planning group which is divided in 5 subdivisions. - industrial plants construction and statics - building-, storage- and pharmaceutical plants construction - steel constructions - sewers, streets, railway tracks and surveying - water installations, heating and ventilation, insulation of a ir condition equipment The planning group consists of about 30 staff members. Up to the sum of 200 m illion Schillings (about 15 m illion Dollars) of erection costs a year, this group is able to do the whole work alone. If there are some extensive projects at the same time, outside planning bureaus support the planning group. Supervision and repairing are done by the supervision group. On the one hand the 15 members of the supervision grpup have to supervise the erection and repairing done by outside con- •/2 A 23 /1 b TBW - 2 - tractors, and on the other hand they have to direct the 7 repairing groups: - bricklayers, floor tilers and roofers (20 men) special bricklayers (refractory brickwork, acid- and lyc resistant brickwork), coating (20 men) sewermen (20 men) - carpenters and scaffold carpenters (20 men) - painters (houses and steel constructions) (20 men) - insulating group (pipes, boilers, furnaces etc.) (20 men) - railway track repairing group (10 men) Every group is led by a forman and an assistant forman. Some five workers, bricklayers scaffold carpenters and insulating workers are within reach day and night for emergency in production plants. During the winter track workers are also within reach, because the switches can be blocked by snow and ice. To give a picture of the work that has to be done by these 150 men it is necessary to know some data about the CHSMIE LINZ plant in Linz. 2 The plant area is about 1,5 km . Some 350 buildings and other constructions of civil character 2 stand there. Approximately 120 000 m of roofs are to be kept in good condition. A special problem is the coating of the countless sfeel constructions, pipes t..id boilers in an aggressive atmosphere. About 15 km of streets, 15 km main sewers and 35 km railway tracks with some 120 switches are to be repaired continuously. About 100 million Schillings (7 million Dollars) are spent for maintenance every year. One half of the work is done by the CHEMIE LINZ repairing team, the other one is done by out side contractors. ./ 3 TBW J — The repairing group is kept as small as possible. The number of the workers is just as high as it must be, allowing the group to do: - all emergency jobs in a quick way, even during night and weekend - all jobs that are too small in scope or too difficult to survey for outside contractors. - all jobs that need special workers or special knowledge of the u n its . The main jobs given to outside contractors are: - roofing of large roofs - coating of steel contructions - housepainting - repairing of streets and railway tracks. Translation - aid * HS 34 Tradenames of PUR-foam for insulating H5 45 purposes (esp. cold insulation), available at Chemie Linz (See adress at the end of the page. HS 34 or HS 45 is one component of a 2-conponent system for producing a hard foam (unit-weight 20 - 30 kg/n3, free foaming). Because of its slow reaction it is especially good for hand made foams and for great vo.urainas. rJS 23 Teil 2 is the second component. Componding ratio 1 : 1 Processing charakteristice manuel with HD-machine 1 HS 45 HS 34 HS 45 HS 34 starting time sec. 40 i 5 60 - 90 12 ± 2 25 ± 5 setting time sec. 120 ± 10 300 - 450 50 ± 5 160 ± 20 growing time min. ca. 3 ca. 6-10 ca.1-2 ca. 5 Mould release properties 30 mm thick sheets can be released after 10 min (HS 45) or 20 min (HS 34) in a 35°C metal mould (density 0,06 g/cn^, mould foaming). Dimensional stability Total stability from - 20°C up to 120°C. Less than 3 % volumia growing (24 hours). Coefficient of thermal conductivity At a density of 0,03 g/m^ thermal conductivity is 0,02 W/km. Water imnerrion Less than 1,5 %. Storing stability 6 month Spezially used for Different insulations, e.g. cooling boxes, boats, technical insulations, foaming of holes. For more information ask CHF'IIT, MV/, Ad. CHBHIEUNZA6 UftMr Ztfcfwn BurMtcr TEL EmpM .g«r (Ourdi*dilig* an) 4 . UNDIO-Workshop 1« Balancing 1*1« Introduction Unbalanced centrifugal forces and monentuns are not wanted fo ri - high dynamic bearingforce3 —» reduce of useful life - Vibrations — fatig’Ja-breacking3 - Reduction of friction - Reduction the value of produce (employment) - Noisy machines - Influence to personal Balancing is the process of attempting to improve the mass distribution of a body so that it roxatea in its bearings without unbalanced centrifugal forces. 1.2. Measuring of Unbalance: Unbalance is a v e to r th e re fo r the amount and the angle o f unbalance must be measured. 1.2.1« Centrifuga?. Balancing Machines: (a balancing machine that provides for the support and rotation of a rotor and for the measurement of once per revolution vibratory forces o f motions due to unbalance in the rotor) a) Soft Bearing (above resonance) balancing machine (having an operating speed above the n a tu ra l frequency of the suspension-and-rotor system) " 1 a balancing machine having an opera tin g speed a t ;.he n a tu ra l frequency of the suspension-ar.d-rotor system. - Comgensating_(null force) Balancing Machinei a balancing machine with a built-in calibrated force system with counteracts the unbalanced forces in the rotor. /2 r 1 - Direct Reading Balancing Machine: a balancing machine vhich indicates the unbalance directly. b) Hard Bearing (below resonance) Balancing Machine: a balancing machine having an operating speed below the natural frequency of the suspension and rotor system. It is to use dynamometer and to use very rigid foundation and construction of the machine. c) Field Balancing: The process of balancing a rotor in its own bearings and supporting structure which full rotation. Measure are given with field balancing equipment. Under such conditions the information required v to * perform balancing is derived from measurements of vibratory forces or motions of the supporting structure and/or measurement: of other responses to rotor unbalance. 1.2.2- Indicating Systems: - Vattnetric indicating system - Voltmetric indicating system with phase-sensitive rectifier - Voltmetric pyotem with stroboscope and filte r - Voltmetric indicating system with marking of ungular position on the rotor its e lf - Compensator with mechanical or electric indication 1.2.3« Motion Transducer: - Piezzo-motion transducer: measure voltage is proper- t 1 of the r.cc icy - Electrodynamic-motion transducer: measure voltage is propor tional of the velocity - Inductiv-motion transducer: measure voltage is propor tional of the disolacement /3 r - 3 - 1.3, Balancing Proceeding 1.3.1. Static Balancing (is a condition of unbalance for which the central principal axis is displaced only parallel to the shaft axis) For disk-shaped rotors the use of only one correction plane nay be sufficient, provided the bearing distance is sufficiently large and the disk rotates with sufficiently small axial ru n -o u t. S ingle plane balancing can be done on a p a ir o f k n ife edges w ith o u t ro ta tio n o f the ro to r (Gravitational (non rotating) balancing machine) but is now more u s u a lly done on c e n trifu g a l balancing machines. 1*3«2* Dynamic Balancing (is a condition in which the central principal axis is not coincident with the shaft axis) At [ 2 ... Correction plane i A. _ ... Measuring plane ' 1 . Bunt Is a run with the original unbalance. Measuring the vectors T and 1 1f0 2 ,0 ' 2 . Bunt A known tria l mass (m^) is mounted in plane E^. Measuring the vectors y an 3. Bunt A known t r i a l mass (m2 ) is mounted in plan 2^, Measuring the vectors A ^ > Remove the t r i a l mass and 1 ,2 2,2 * note the position with 0°too. Evaluation» m Graphic evaluation» it's used rare because it's pro traced and f a l li b l e . •/4 4 • Numerical evaluation« equations see a t " S ta tic and Dynamic Balancing". I t #s calculated by programable calculating machine in the best way. 1.4* Balance Quality of Rotating Rigid Bodies Even after balancing« the rotor w ill possess residual unbalance. By means of the measuring equipment avilable today unbalance may now be reducded to rather low lim its. However, it would be uneconomical to exaggerate the quality requirements. To what extent the unbalance must be reduced, and where the optimal economic ar.d technical compromise on balance quality has to be struck, can, in individual cases, be correctly determined only by extensiv measurement in the laboratory or in the fie ld . General we can sayt 2 The residual unbalance force« F - m.r.w m ... unbalance mass AcceptaMLity limit« F - G/lO G... rotor weight it follows« |m « 10 * ^8 te(kg)j G(N)j r(m){ n (min“^) | r«R For example« G - 100 kg r - 100 m s 10 . 5 ^ 3 002 - 3.10-5 kg = 5 8 n » 6000 min* Terms o f reference are given by VDI 2060« On the basis of section 1.4* balance quality grades have been established which permit classification of the ouality reouirements. Each quality grade Q comprises a range of pemissiable residual imbalances (e.w). See figure 1. The quality grade Q equivalent to the centre of gravity-velocity. The oentre of gravity-displacement are given by« • - £ Q (mm/s)| w (s_1)| e (mm) The permissible residual unbalance« m - 6 G m (g ) | e (mm)j G (k g ), r (m) • h 5 For «ample i G " 100 kg r m 100 am e m 0^)4 on n - 6000 min ^ Q - 2 ,5______b - 4 g In general, for rig it rotors with two correction planes, one-half of the recommended residual unbalance is to be taken for each plane. For disk-shaped rotors the fu ll recommended valus holds for one plane. 2» Measuring Vibration 2.1. Introduction High vibration are not wanted at the arguments like 1*1. 2.2. Hints for Measuring It's possible to measure displacement, velocity or acceleration. For evaluate J 2 / ns d s \ (35 T m d .. t ’t a ■ TT7 d t‘ ) the vibration it's best to measure the rms-value of vibration velocity rms J T ( t ) d t rms ■ f T The vibration severity of a machine is to be meas’ i at operational speed. For variable-speed machines the neasurene -r.c lid be made at many speeds in order to locate the resonance frequencies which may possibly cccur. The machine support may significantly affect the vibration levels measured on the machine. During testing the machine should be either mounted on its operational foundation or - in case it i3 a small assembly - soft mounted respr. suspended on springs. Test should be made preferably in x, y, z directions (choose the bearings of the machine) * /6 6 2.5» Evaluation. Standards: Comparing the measured values with the lim it values specified in the Recommendations, w ill permit an eastimation of the severity of vibration to be carried out readily. A machine may be qualified according to the examples of Quality Judgement (see "Vibration Signature Analysis-Techniques and Instrument Systems"). At firs t the tested machine has to be classified according to one of the six specified machine classes. Subsequently the lim it values for the quality groups "good” , "allowable", "just tolerable" and "not permissible", can be taken from the appropriate table. By comparing the measured vibration severity with these lim it values an easy evaluation of the v ib ra to ry s ta te can be made. Up to now, Examples o f Q u a lity Judgement have been established by the International Standard Organisation VDI 2C56 for the Machine Classes K to T. The machine in Classes D and S vary considerably in their vibration oharacteristics and for this reason a classification in the same manner as with the firs t four clas^ es has not yet been possible. For further explanations refer to the detailed discription of the proposed VDI 2056, ISO 2372, BS 4675. Specifying of Machine Classes Class Kj Individual parts of engines and machines, integrally connected with the complete machine in its normal operating condition (production electrical motors of up to 15 kW are typical examples of machines in this category) Class Mi Medium-sized machines (typically electrical motors w ith 17 to 75 kW output) without special foundations; rig id ly mounted engines or machines (up to 300 JcV) on special foundations. Class Gi Large prime movers and o th e r la rg e r machines w ith rotating mass mounted in rigid and heavy foundations which are relatively s tiff in the direction of vibration measurement. /7 7 Cl&as Ti Large prise movers and other large machines with rotating mass mounted on foundations vhich are rela tively soft in the direction of vibration measurement (for example, turbogenerator sets« especially those with lightweight substructures) Class Di Machines and mechanical drive systems with unbalanceable inertia effects (say, due to reciprocating parts), mounted on foundations vhich are relatively s tiff in the direction of vibration measurement. Class St Machines and mechanical drive systems with unbalanceable inertia effects (say, due to reciprocating parts), mounted on foundationr, which are relatively soft in the direction of vibration measurement; machines with rotating slack-coupled masaes such as beater shafts in grinding m ills; machines, like centrifugal machines, with varying unbalances capable of operating as self- contained units without connecting components; vibrating screen, dynamic fatique-testing machines ani vibration- exciter used in processing plants. /u * • i - i ■» * -« • ^ * J* 312 3. Auswuchfgenouigkeit Balance qv*IIty 1 gred* Kotor type* — General example* m m /i G G 4000 4000 Cronkthoft-driv*» 3 gf rigidly mounted alow morine dietel engine* wirh uneven number of cylinder* G 1 400 1600 Cronkthoft-drivet of rigidly mounted large two-cycle engine* G 630 AX Crankshaft-drives of r»gidly mounted laige four-cycle engine» Cronkthoft-drive» of elastically mounted marine dietel em-i*ie» G 250 250 Cronkthoft-drive» of rigidly mounted tost four-cylinder diesel engine* *) G 100 IX Cronkthoft-drive» of fest diesel engines with six or more cylinder» 6) Complete engines (gotoline or diesel) for con, truck» and locomotive* 3) G 40 40 Car wheel», wheel rim*, wheel set», drive shaft» Cronkthoft-drivet of elastically mounted fast four-cycle engina (gasoline or dietel) with six or more cylinder* Cronkthoft-drivet for engine» of con, trucks and locomotives G i6 16 Drive thofti (propeller shafts, cordon thofn) with tpeciol requirements Porn of crushing machinery — Ports of ogrlcul*uot machinery Individual components of engines (gasoline or diesel) for can, trucks and locomotives Cronkthoft-drivet of engines with six or mure cylinden under special requirement* G 6 ,3 6 ,3 Port* of procett plant machines “ Morine main turbine gear» (merchant service) Centrifuge drum» — Font — Assembled aircraft got turbine roton — Fly wheels Pump i'-'pellen - Machine-tool and general machinery porn Normal electrical armatures Individual components of engines under special requirement* G 2 ,5 2 ,5 Got and steam turbines, including morine main turbine» (merchant service) Rigid tu*bo-aenerator roton — Roton — Turbo-compressor» Machine-tool drive» Medium and lorge electricol ormoturei with tpeciol requirements Small e le c tric a l armatures — Turbine-driven pump» G 1 1 Tope recorder ond phonograph (gramophone) drives Grinding-mochine drive* Small electrical ermoture* with special requirement» G 0 ,4 0 ,6 Spindles, disks, ond armaturet of precision grinders Gyrotcope* 1) i; * 2 ” n/60 ~ n/10, if n it meotured in revolution* per minute and x in rodion» per second. 2) In general, for rigid roton with two correction planet, one-holf of the recommended re*i^»ol iun- bo I one* it to b* token for eoch plon«; thet* volu*i apply utuolly for ony rwo orbitrorily cho»*n planes, but the t'ot* of unbolonce moy b* improved upon at the bcoringt. (Set 3.2 and 3.4.) for dlsk-shop«d roton the full recommended volu* Soldi for one plone (tee taction 3). 31 A cronkthoft-driv* it on attembly which includet the cronkthaft, a flywheel, clutch, pulley, vibrotion damper, rototinq portion of connecting rod, etc. (tee 3.5). 4) f o r the pvrpotef of thlt International Srandord, slow dietel engine« ore thote with o piiton velocity of lett thon v m /t; fott dietel engine» u*e tliute wlih c p.tton velocity of greater than 9 m /t. 5) In comolete enginet, the rotor mott comprise! the tum of o il mosses belonging to the cronkthoft-drive detcribed in Note 3 obov*. BtId 3.25. TABLE of ISO Stondard 1V40 : Balance qualify grade» for various groups of representative rigid rotors. e I 32. IUE f S Sadr 14 ;Mxmmrsda seii ublne cor unbalance specific residual Maximum ; 1940 Standard ISO of 4 FIGURE Be 3.23. Id 3 10 Acceptable residual unbalance pec unil ol color mass epnig ovros aac qaiygae, . G grades, quality balance various to responding 00; 30 ----- 0 6 6 30 0 30 60 00 00 60 r / n 96000 .n v/m re 16000 6000 3000 1600 360 600 300 160 96 60 1 ------o Tr srie pe o r oton tio to ro ot speed service Turn Mo> ------. Auswuchtgenauigkeit 3. : --- 1 ------r Static and Dynamic Balancing by John V.iu t introduction This note describes how measure 1 ments obtained with simple vibra tion instrumentation can be used when rotating machinery is to be balanced Several straight forward methods of balancing w ill be pre sented that make use of portable B & K Vibration Meters to measure on rotating parts running in their own bearings at normal operating speeds. The various methods will be explained by means of worked ex amples. Fig.V S ialic Balança. Dynamic Imbalanca Standards of balance achieved by the arrangements shown here com pare favourably with the results ob tained from far more complicated and expensive balancing machines. The difference between static bal It is possible to find the Imp of ac ance and dynamic balance is illus tion of the resultant unbalanced Definitions trated in Fig 1 It w ill be observed force by comparing the phase of the Primary Balancing describes the that when the rotor -s stationary oscillating output from the Vibration process where primary forces (static) the end masses may balance meter with a periodc signal ob caused by unbalanced mass compo each other. However, when rotating tained from some datum pos.tion on nents m a rotating object may be re (dynamic) a strong imbalance w ill the rotor Then the imbalance at the solved into one plane and balanced be noted. bearing can be defined as a vector by addmq a mass in that plane only. whose angle gives the line of ac As the object would now be com lion, and length the magnitude ‘ pletely balanced in the static condi Background the unbalanced mass Fortner, if tion (but not necessarily in dynamic) When an unbalanced object ro the resultant unbalanced force at a this is often known as Static Balan tates. it imparts a vibration to its bearing can be resolved into p ri cing. bearings, usually at rotation fre mary and secondary components, it quency or one of the harmonics, w ill be poss ble to ba'ance a rotor Secondary Balancing describes due ¡o the rotating force caused by by removing mass increments along the process where primary forces the unbalanced masses The vibra the radius of the , nbalance, or by i and secondary force couples caused tion at a bearing will be made up adding mass increments on the op by unbalanced mass components in from a component due to unbal posite side a rotating object may be resolved anced (primary) forces m or very into two or more planes and bal close to the plane of the bearing, Many rotating parts which have anced by adding mass increments and a couple component due to un most of their mass concentrated in in those planes This balancing pro balanced (secondary) forces in the or very near o n: plane, such as fly cess is often known as Dynamic other planes If an accelerometer is wheels. gnr dstones. car wheels, Balancing because the imbalance mounted on the bearing housing, etc . can be treated as static balan only becomes apparent when the ob- the vibration can be detected and a cing problems This greatly simpli iect is rotating After dynamic balan signal fed to a vibration meter The fies the calculations as only pri cing. the object would be com vibration level indicated on the me mary forces need be considered, pletely balanced m both static and ter is directly proportional to the re and al! secondary co.m’as are as dynamic conditions. sultant of the out of balance masses sumed to be zero 1 V - y i ' y. t > ♦* •tV Various modifications and addi the Output tu E it-u -i F,it.-r Measurement tions can be made to the instru socket on the 2510 f a t m Practical considerations ment arrangement shown in Fig 2 this arrangement, the External Fit The rotor to be balanced should to improve selectivity, or to take ad lei swm.ii si'uuiu ue m tie easily accessible, and should vantage "f instruments that are al "O ff" so that there >s st i! an .ndca- have provision for mounting trial ready at nand Figures 3 to 8 illus tion of the level on the •?—v r masses at various angles around it trate some of the possibilities The mounting points should prefera If it is impossible to ' i •••■>’ i Hi.;': bly be at the same radius from the The Vibration Meier Type 2511 fj Oise on.a the ;• •• V .'l /,0 1 axis of rotation to simplify calcula can be replaced by the Type 2510 Photodiode c-n be u--J T- s can tion The datum position must be which can measure vibration veloc scan the rotor to pick i.p a tr gger marked on the rotor in such a way ity in the frequency range between mg mark that can be a p-ece of that it triggers a pick-up installed 10 Hz and 1000 Hz When the Type adhesive tape, or a painted patch, aiu'igside it on the stationary part of 2510 is used without a filter, as in with a colour contrasting with the machine A non-contactir.g type of Fig.4. the signal for channel 8 of background Tne Pnotcd.ode must pick-up is recommended, because the Phase Meter can be taken from be connected to a power supply unit this will give the rotor the minimum of disturbance Vibration level measurements can be made m terms u! velocity, or displacement Accelera tion levels will tend to emphasize higher frequencies while displace ment will emphasize low frequen cies. so if neither of these condition is specifically required, velocity measurement is recommended as this gives equal emphasis to all fre quencies Instrumentation The basic measuring arrange ment. shown in F;g 2. consists of an accelerometer, a vibration me ter. and a means of determining the angle of the imbalance releative to the datum position The most effec tive methed of measuring this angle is to use a phase meter as shown, but a stroboscope can also be used (see Fig 3). or the angle can be de duced from the results of several measurements The Magnetic Trans ducer MM 0002 emits a pulse each time the High-// Disc passes, and thus establishes a datum position on the circumference of the rotor. Fig 3 Arrangement using a stroboscope to measure angles The transducer output is fed to the reference channel (A) of the Phase Meter Type 2971 The output from the Accelerometer Type 4338 is fed to the Vibration Meter Type 2511. which displays the vibration level. A signal taken from the "Recorder Output" of the Vibration Meter is fed to channel 8 of the Phase Me ter When the machine is run. a vibra tion level w ill be displayed on the Vi bration Meter, and an angle on the Phase Meter, which together give a vector representing the unbalanced mass and its line of action. Fig.4. Arrangement using th# Vibration Meter 2510 2 v. t 4 • •v \- i .• ■ r to energise the lamp Suitable units are tne Tacho Unit Type 5586. shown in Fig 5. which is also able to indicate the rotational speed (ac curacy better than t 2%). or the less sophisticated Control Unit Type 5533 Another very useful addition to the measuring arrangement is the Tunable Band Pass Filter Type 1621 which ensures that the Phase Meter (or Stroboscope) receives a clean input signal It is recom Fig.5. Arrangement using a Band Pasa Fritar and Photodiode triggering with Tachometer mended for installations where the required triggering signal would oth erwise be buried in noise, or where i high vibration levels occurring at several frequencies cause difficul ties m signal tracking The Filter is connected as external filter to either of the Vibration Meiers (Fig 5. 6, and 7) Note tnat with the Type 2510 the signal for channel B of the Phase Meter is now taken from the Input from External Filter" as i shown in Fig 6. and that the Exter nal Filter switch shetr'd be in posi tion "O n". The Band Pass Filter has two bandwidths. 3% and 23%. that can be tuned continuously from Fig.6. Vibration Meter 2510 used with Filter 1621 0.2 Hz to 20 kHz to match the rota tional speed of the machine. It can also be used to find the relative le vels of vibration at rotational speed and at the various harmonics, be cause with some procedures, the harmonic levels may have to be bal anced too. In use the Band Pass Filter must be very carefully tuned because when it is slightly off tune, so that the vibration signal falls on the shoulder of the filter curve, phase deviation can be introduced. One way to avoid this problem is to tune the desired frequency as accurately as poss ble using the 3% band Fig.7 Recommended srrangement incorporating phase correction Switch W8 0192 i width. and then to switch over to the 23% bandwidth to take advan tage of the wider peak m the filter characteristic while making the band Filter alone The Slope Photo Probe icr Magnetic Transdu phase measurement switches on the Phase Meter are ar cer) is divided, with one part pass ranged with on Channel A and ing directly to irpot A while the A more effective alternative "—" on Channel B. so that when other part passes via the Filter to In method that allows the advantages the inputs are m phase, measure put B The Filter is swept slowly of the 3% bond to be kept while vi ments m the 0 to 360J (0 to 6.28 through the frequency range where bration levels and phase angles are rad) range w ill produce a stable the rotation frequency .S expected being measured makes use of the reading of 130° (3,14 rad) on the to lie When tie center of the an Switch W3 Ci 92 m an arrange digital display, while t.ie pointer on alog meler stops sweeping from ment like that illustrated m Fig 7 the analog meter will be steady in one end of the scale to the other The Switch is used as fellows, to de the middle of the scale at n "Refer and stabilizes m the middle of the termine and eliminate the phase de ence" is selected on the WB 0192 scale at n. the F lt.-r can he finely viation produced by the narrow so that the datum signal from the tuned with tne a.J of the digital 3 T V no * display until a reading of 180° Type 49 f I to measure phase Stopped Ti-g-ther the v»-!ootv (3 1 «1 rja i appears BecauSf the in angles with the arrangement shown and the phase angle give a vect;r put and output of the Filter are now m Fig 3 represent.ng me origm ji imbalance in phase the centre frequency of of the rotor V„ m Fiq 9 the Filter is accurately tuned to the The Vibration Meter was rotation frequency, thereby eliminat switched to measure vibration V e A trial weight of known cuss was ing any phase errors -ntroduced by locity” . to obtain equal emphasis of fixed at a known radius on me rotor the Filter Without changing the Fil both low and high frequencies, the at the same angular ;.ushorn as me ter setting, both slope switches on internal filters m the Vibration Me reference mark A mass with suffi the Phase Meter are set to (or ter were used to restrict the measur cient magnitude to have a pro both to " —"). Measure” is se ing range to frequencies between nounced effect on the rotor mu it be lected on the WB 0192 Switch, so 10 Hz and 1000 Hz. to improve the used for the fust trial In the exam that the Filter operates on the vibra signal to noise ratio Peak-topeak ple. a trial mass of 5 g was fund to tion signal derived from the Acceler measurement with one second time the rotor, and then tne machine ometer The vibration level is indi constant was chosen so that a large was run up to its operating speed cated by the Vibration Meter, while and responsive needle deflection agam The new vibrat on velocity le the angle measured by the Phase could be obtained An AC signal vel was 18 mm s. an ! when me Meter is the actual phase angle of from the "Recorder Output” of the two marks hud been line;] up w ;ti the unbalanced mass referred to a Vibration Meter was fed to one of each other agam by the "Phase De d3ium It should be stressed that the Input” terminals of the Motion viation control [he new p'tase t' s datum is not the same as the Analyzer tu be used as a triggering angle was found to be 1 7 0 ' These plane from which the Phase Meter signal. The Analyzer was switched values represent the resultant effect obtains the triggering signal, be to "External Synchronised” mode of the ir.it.al unbalance and me 5 g cause the Phase Meter is triggered so that the lamp would blink at rota trial mass, which is shown as vec by a zero crossing, while the Vibra tion frequency A position mark was tor V, in Fig 9 tion Meter measures RMS or peak- made on the rotor, with .. lother to-peak. alongside it on the stationary part of Now sufficient information was the machine. available for the vector diagram m Fig 9 to be constructed with vector The machine was run up to its lengths proportional to the mea operating speed (2800 rpm). and a sured vibration velocity level; ob vibration velocity level of J_5 mm s tained from the V.brat.on Veter, indicated by the Meter Because the and angles being those measu-ed flashing of the lamp was synchron by the Motion Analyzer As Vector ised with the rotation, when the ma V, is the resultant of the m.tial im chine was observed by its light, the balance plus the 5g mass vector rotor appeared to be stationary Vt can be found which repre Turning the "Phase Deviation” knob sents the trial mass alcne The F»fl 8. Sifnp'i'nd arrangement using only vi allowed the position mark on the ro length of VT is preport.onal to Ihe bration meter and accelerometer tor to be lined up with the station 5g mass, so that the length of vec ary mark on the machine The tor Vc . the initial imbalance can be "Phase Deviation" control is gradu determined m mass units Tne The greatly simplified measuring ated in 10° steps so that it was pos angle of VT gives the pos.t on at arrangement shown in Fig 8 can sible to estimate a phase angle of which the trial mass was fastened. also yield results that can be used 55°. after which -he machine was so tnat it is a simple matter to deter- in balancing a rotor The procedure is not quite the same as for the other measuring arrangements, it w ill be explained m Example 3 As the methods used witn the other ar rangements are all basically similar to each other, worked examples will not be presented for each arrange ment All the measuring arrangements described and illustrated here are equally suitable for both static and dynamic balancing Static Balancing Examples Example 1. To statically balance a rotor using a Motion Analyzer Fig 9. Vector d.flc-xrn for Exjmplo 1 4 'A• ^> 8 t s 4** * 0 J m..ne the angle the initial imbalance makes with the position of the trial mass so that the angular position fOt inc CuiTiperi'iSaiiny fndSS tldii diSci be found The original imbalance is given by V, M0 *r So the compensating mass m comp = 2 6 9 And its position is given by ¿-c c v p = ~ -?•■*• t- „ * 180° = -198-' • 55° - 180° = - S?3 referred to the position ot the Trial Mass The positive angle mea-s that the compensating mass is to be fas tened at 37° from the trial mass po sition m a positive direction, that is. in the direction of rotation. After the rotor has been balanced by this procedure, it is recom mended that the vibration level be measured again to check the stan dard of balancing obtained Often, due to non-linearities or inaccura cies in the practical measuring ar rangement, the rotor will not have been sufficiently well balanced by one application of the balancing procedure When the level of the re- S'dual imbalance is unacceptably The machine was stopped, and a As the angle indicated is nega high, the whole balancing proce 2^g trial mass fixed to it When the tive. the compensating mas., s to dure must be reiterated, until an ac machine was running again, the vi be fastened at 31c m tne negative ceptable level is achieved bration velocity level was found to direction from the fia l mass, v.n.cn have decreased to 1,8m m /s, and is the opposite direction from the ro Example 2. To statically balance the phase angle was found to have tation a rotating machine using the ar changed :o * 42°, rangement shown in Fig 5 to mea Example 3. To statically balance sure vibration levels and phase The vector diagram in Fig 10 was a rotating machine, using only a Vi angles drawn so that the position and bration Meter, and an Acceierome- Measurement of peak-to-peak vi magnitude of the compensating bration velocity level was selected mass could be determined on the Vibration Meter, and a band 3 ' width of 3°o on the Band Pass Fil The original imbalance is given by ter The machine was run up to its normal operating speed (1490 rpm on the Tacho Unit), after which the M" ’T T s 2 ’ 2 03* band pass filter centre frequency was adjusied to give the highest in So the compensating mass dicated level of vibration velocity on ^ comp = 2.03 g the Vibration Meter A vibration le vel of 3.4m m -s was recorded, and And its position is given by wnen the bandwidth was broad ¿COMp = -327° . 116’ . 180» ened to 23%, the Phase Meter indi = — 31° referred to the Fig IT Position« of th# tn«l m«u usmd m cated * 116° trial mass position •V. ter in the arrangement shown m Fig 8 This method requires four vibra tion measurements to be made at the bearing A trial mass will be re quired which can be mounted at the same radius in three different posi tions at 90° from each other, as shown in Fig 11 The machine was run. to estab lish the vibration velocity level caused by the original 'imbalance, this was found to be V „ = 2.6 mm s A 10g trial mass was fastened to the rotor m position 1 . and the machine run again. This gave a vibration level of V , - 6.5 mm s due to the combined ef fect of the trial mass and the initial unbalanced mass Before the next run. the trial mass was moved 180° round the rotor and fastened at the same radius m position 2 . The machine was run, and the vibra tion level was found to have dec reased to V 2 = 1.9 m m /s It was now possible to start to draw the vector diagram, however only the vecter lengths were V.r22 + vo2-2VT2VoCOS« than that from the trial mass alone known, but not the angles. Ne VT. then V., would lie above the vertheless. circles could be drawn V t2 — VTI axis (shown as full line about a common centre, each hav VVI 2 » VVT1 2 + V 0 2 - ,ivT12 V Vv0 coscosp 3 in Fig 13) If the vibration level ing a radius equivalent to a vector were less than VT. V . would lie be length, i e the measured vibration and as cos 0 = cos ( 180° — a) low the V f2 — VT, axis shown level Referring to the Geometry dia with broken line m F g 13 gram in Fig 12. two circles have = — cosc been drawn with radii proportional Equation 2 simplifies to. As a result of mounting the trial to V , and V 2 the two resultants of mass m position 3. when the ma the original imbalance and the trial Vt 1’*V 02 + 2Vt , V0 cosa chine was run. a vbrat on velocity mass fastened m two positions at level of V 3 = 5 5 mm s was re 1 80" from each other A radius has corded. thereby indicating that the So that V.T i also been drawn at an arbitrary T2 original imbalance vec.or should he angle m each circle Identica1 paral above the VT2 — VT, a«is / v , 2 + V„ 2V„ lelograms have been constructed us ing each radius as a diagonal, and Substituting the vibration values taking the line ficm the centre of V 2 - V 2 of V0 . V, . and V i into eg u.ition 4. the circles to the midpoint of the and a = cos' -1 1 2 4V V line joining the ends of V , and V2 ,VT v0 .. . 6 52 • 1 9 J - 2 - 2.62 as a common side VT = \ - However, as cosa = cos(—o) it is It w ill now be seen that if the no* immediately obvious whether - 4 m m /s angles of V ( and V 2 can be ar the vector for the original imbal ranged to produce a common side ance. V0 lies above or below the And now using equation 5. with length equivalent to VG . then V j2 — VT1 axis (1 e the line join the diagram will give a true repres ing trial mass position 1 with posi 6.5- - 1.9J a = c o s -' ------entation of the vectors, so that the tion 2) Therefore it was necessary other side in each parallelogram to make another test run, with the must be equivalent to Vy. the vibra trial mass fastened m position 3. to tion caused by the trial mass alone give Vector V3 . Strictly it was not = cos t 0 9233 in positions 1 and 2 Furthermore, necessary to draw this vector, as if the following relationships exist. the vibration level were greater x : 21.74- 6 Fig. 13. Victor diagram for Exampia 3 And because V„ has been found ported m two bearings both stati ternatively. a single set of equip to lie above the VT2 — VT, axis, cally and dynamically, i e a balan ment can be used, w.tri the acceler i e at 21,74’ from position 1 to- cing problem in two planes The ometer being moved from one bear wards position 3. the compensation measuring arrangement shown in ing to the other, or the Vibration mass must be fastened ai 21.74° Fig 7 was employed m this exam Meter can oe swelled between below position 2 ple, and the basic method used can two accelerometers, one at each I be extended to solve balancing piob- bearing ♦ The magnitude of the balancing lems in more than two planes A1 mass is found as before. To avoid special emphasis of high The procedure is the same as m or low frequencies, v.bration veloc MComp =M0 =^2.«MT the foroyu.nq examples, finding the ity was chosen as the measure o* vi effect of a Known trip1 mass at bration level on the Vibration Me = 2,6 « 10 tached to the rotor, except that now ter, and the 3 ’ s hanrl-w dtn selected 4 measurements have to be made in on the Tunable Bunt! Pass Filter two planes (at the two bearings) The Phase Meter upper frequency li = 6,5 g Two sets of measuring instruments mq was set at '2KHr ta eliminate Dynamic Balancing can be used, with a set at each unwanted n.gh frequency Signals, bearing to determine the vibration while the lower limit was set at Examples levels and phase angles produced, "2 Hr" to take advantage of the Example 4, To balance a ma so that all necessa'y data can be ob longer averaging time to obtain a chine that has a rigid rotor sup tained from only three test runs A l steadier phase indication 7 r As a first step, the vibration veloc ity levels and phase angles had to Povr.v* 'be measured at each bearing to es tablish the magnitude of the origi nal imbalance The Wb 0 i9 2 Switch was put on "Reference" set ting. and the Phase Meter slope switches set to on Channel A and "—" on Channel 8 The ma chine was run. and the filter tuned slowly through the rotational fre quency until a steady reading of Fig. 14. Th« rotor, »howing tha maasunng pl«n«s 180° was displayed on the Phase Meter, indicating that the Filter was accurately tuned on the rotational Trial Mass Measured Effect of Trial Mass frequency The Phase Meter slope switches were both set on Size -md Location Plane 1 Plane 2 (they could both have been set on "—"). and the WB 0T92 switched None 7.2 m m /s 238° v -0 1 3.5 m m /s 296° V? 0. to "Measure" so that the acceler ometer signal was passed through 2.5 g on Plane 1 4.9 m m /s 1 14° V i 1 9.2 m m /s 347° Vj m the Filter The Vibration level (V) CD O and the phase angle (y) were mea 2.5 g on Plane 2 4.0 m m /s V i 2 1 2.0 m m /s 292° V 2 2 sured at both bearings. Then a ' known trial mass was mounted at a Tabi« 1. M «aturad vibration l«v«ls and phas« anglas known radius on the rotor near one of the bearings, and a test run ------è—« made to find the effect of the trial mass, both on the nearby bearing, V V y a Jb and on the other bearing too. The 0 —3.82 machine was stopped, and the trial 7.2 238° - 6. 12 ) mass moved to the same radius and 114° angle near the other bearing. v ,.1 4.9 - 2.0 -4 .4 8 ) Another test run was made to find the effect on the bearings of the V 1.2 4.0 79° - 0.76 - 3.93) trial mass in its new position. \> ri 0 13.5 296° ♦ 5.92 -1 2 .1 3 ) The results have been arranged V 2.1 9.2 347° - 8.96 - 2 .0 7 ) in Table I and a vector notation for each measurement has also been in V 2.2 12.0 292° - 4.5 - 1 1.13] cluded The notation represents the . complete vector, both vibration level (V,., v, o ) ♦ 1.82 . 1060) (length) and phase angle, in one convenient term It also indicates * V i 0 a id ''20 ■ but which have opposite phase angles Mathematically the Which Sirr'c 1 to problem is to fmd two vector operators Q, (with vector length Q, and phase angle qt ) and Q 2 (Q2 and q2) which satisfy the following equations: Q1 = + 0 ’ 463 + 0.9033| - 9- C ------11 - - -,„H I ± * - V Eqn 6 the vector le rg ’ h and phise «V,., - ' V o » * 3 , + *V,.2 - V 1 0 ) x 3 2 1.0 are found - V2 0 ) x Q j a — V Eqn 7 1.1720 (mm si < ^2 . — V2.0* x + ,V 2.2 2.0 V = These expressions can be solved as a pair of equations with 2 unknowns and 7, ♦ 50.4" Q, and Q2 First find Q, in terms of Q 2. Therefore the balancing masses to counteract the original imbalance - V,.0 - (VU - V1.0,)tQ2 Eqn 8 of the rotor are as follows = _ ^,0^1.1 - Vo> -Vi.o»V2.i- v2.o: = 2 93g at - 50 4- ^ 2 ,1 ~ ,2 - V , ,q> ~ b = V sin y Eqn. 12 Masses w in these values were fastened m the respective planes on so that the values m Table 2 can be calculated the rotor at the calculated angles, and at the rad.us used previously Substituting real and imaginary values into Equation 9: for the tr.ai •’-asses A test '. n w is made to assess tie quality of the -* (>5.92 - 12,13)1(^1,82 + 10,60)) - (-3,82 - 6.12j)(+3.04 + 10.06j) balance Its rese ts were as follows ° 2_ (+3.04 + l0.06j)(+4,58+ 10.05j) - (-1.42 + 1,00j)(+1.82 + 10.60j) Plane 1 v.oration level - Which simplifies to: 0.5 mm's, wh-ch represents a re duction m v E-at on velocity level of Q = +0,1598 - 1.1264j 93% from the original 7,2 mm. s Which can be reconverted to polar coordinates by weans ol the following Plane 2 v O'at on level = equations 0.4 mm s. w i sh represents a re V = + v a2 + b2 Eqn 13 duction m vibrat on velocity level of 97% from the or. ¡.iai 1 3.5 mm s for a > 0 7 - tan 1 — - 9 0 ° < 7 < + 90° Eqn 14 a As an added test, the two balance masses were rr',v>-d tiro . ¡“- an for a < 0 7 « 130° + tan- 1 — + 90° < 7 < + 270° Eqn 15 a angle of 10 to find the import in-:« of the phase angle determine:.on So that vector length. V2 M 1,1376 Imm/i) When tar- ma-f.ne was run ag 1 1 the vibration velocity le1 •' at Plane and phase angle. 7? * — 8 1.9a 1 was found to be I c ■ s. with 2.2m m s at P’a ie 2 " : results Now these values can be substituted into Equation 8 so that Q can be illustrate the vjlue of the eail> ac found curate phase angle determination - - (-3,82 -6 ,1 2 )) - (+4,48+ 10,05j)(+0,1598 - 1.1264j) possible with the Type 2971 Phase Q’ " (+1.82+10,6(1 Meter y ii.te. ’ - ,*5» ,* t •> i'4v‘ J>. *V ♦ » * r Fig. 16. Victoria! representation of tha vibration lavats Example 5. Dynamic balancing using a computer to make the calcu Trial Mass Measured Effect of Trial Mass lations In Example 4. calculations were made with the aid of a pocket Size and Location Plane 1 2 electronic calculator, and the calcu None 1 70 m m /s 1112" V , 0 53 mm s 73‘- j V 2 0 lation process took about an hour to complete A computer program in 1.1 5 g on Plane 1 235 m m 's 1 9 4 ' V , , 58 mm s 68 - V 2 i BASIC is available to speed up the calculation procedure Fig 16 1.1 5 g on Plane 2 185 mm/s j 115' ; V, 2 77 mm s j 1 04 : 1 V 2 ; shows the program, the entry of data for a particular balancing prob Tabl«3. Measured vibration lavala and phvsa angles lem. plus the calculated vector lengths, and phase angles of the re sult ance the rotor were calculated as in Plane 1 vibration level - 22 mm/s. Table 3 contains the vibration le the previous example: an improvement of 87:^. vels and phase angles recorded for a machine being balanced using a Plane 1 MCqMP Plane 2 vibration level = 8.5 mm/s. measur.ng arrangement similar to an improvement of 34 o that shown m Fig 3 = 1.721 « 1.1 5 g In this example me slightly The data for calculation must be = 1 ,9 8 g at 2 3 6 ,23 worse balance quality can be attrib entered into the computer m the fol uted to the use cl a Motion Anal lowing order. V10. Y\ o . V20. Plane 2 MCOWp yzer Type 4911 to determine the y2 0 • V1 1 ■ /1 I • V2 ' K2 1 - phase anqV-s As rr«-nt.oned earlier, v 1 2 • Y I 2 • V 2 2 3n<* Y 2 2 T h e = 0.931 » 1.1 5g if the standard of balance achieved vector lengths and phase angles for by adding (tie balance masses ac each plane are shown entered at = 1.07 g at 1 2 1.8° cording to the results of tee first :,er statement 499 m the program. To ies of measurements is not suffi tal elapsed time to enter the data When masses with these values cient. the measurement and balan and make the calculation was of the had been fastened at the correct cing sequence can b e repeated for order of two minutes angles and radius on the test rotor, the new unbalanced condition new vibration levels were mea The compensation masses to bal sured : 10 M. ♦'V L r « l k 2YN2AL W 1326 LIST QP i g y i.l y \ t « y \ w # A.J#y\kfC//( C C. - - «100 12 CIM X(2.2)»LC2.2).M(2.2)»:: C C* 2 >. :>»°t2.2> 14 DIM Sf2.2>.Tt2.2>.Ut2.2>.V C2,2) . 2C F2? Y3 I T0 t 3C HEAD AtYl.LtY) 35 LET 5tY>*BCY)»ATM( I)/ A5 AC NEXT Y 5C LET Ct 1. I ) 3 At 1 ) *C0 S t DC 1 ) ) 6C LET Ct I. 2)»At l)«£IMtDt l ) ) 62 LET Ct 2. IX-Ct I. 2) tl Iru 65 LET Ct 2. 2 > 3Ct I. 1) 7 C LET DC 1» 1)3 At 2)»C0£tEt 2)1 4 75 LET Dt I. 2)«At 2) »5 IN t bt 2) ) 8C LET Ct 2. IX-Ct 1. 2) 85 LET Dt 2. 2) 3Ct 1. I) 9C LET £C 1# 1) * AC 3)*Cd5CBC 3)) QP 95 LET Et 1. 2)3At 3)»SINtBt 3)) ICC LET Et 2» 1)=-Et 1. 2) K| 4 • I 0 r i «100 1C5 LET Et 2. 2) *Et 1. 1) I 1C LET Ft 1. 1 ) 3 At A) #C3 S t L>t 4) ) I 15 ¡_ET Ft 1. 2)3At 4>«SINtbt 4) > 12C LET Ft 2. I) =- F t I. 2) 125 LET Ft 2. 213 Ft 1, l) 130 LET Gt 1. 1)3At 5 X C 0 S t b t 5) > 135 LET Gt I. 2) 3 At 5 )•SIN t Bt 5) ) I4C LET Gt 2. 1)«-Gt I. 2) IAS LET Gt 2. 2)-Gt 1» 1) ISO LET Ht I. 1) 3At 6)*C3 £ t Bt 6) ) 155 LET Ht 1. 2)3At 6)«£INtBt 6) ) 16C LET Ht 2, I X - H t I. 2) 165 LET Ht 2, 2)«Ht 1. 1) m t t m 20C MAT I-E-C 2C5 MAT J-F-D MAT K*G-C 2 1C f Q 2 15 MAT L3 F “D 10 >0»l 4 l » 0 •> «100 220 MAT M 3H-B 225 MAT N 3 E-C 230 MAT 03 D*I 235 MAT P3 C*J 24C MAT C=K*L 2A5 MAT P.3M *N 250 MAT £3P-P 255 MAT T3 C-R 26C MAT L3INVt T) 265 MAT V 3 S»U 270 MAT I3 C3M 275 MAT J 3C*X 230 MAT K=I-J 235 ” AT X=K«U t \m * 29 C LET Y 13 £ CP t V t 1. 1)» 2*Vt I. 2 2 ) 3C0 LET Y23£CStXt 1» I)* 2*Xf l. 2 2 : 3 !C IF Vi l, I X C THEN 340 f Q 32C LET Y3= 0 10 4 «100 33C G3T3 ESC 3a C LET Y 3 3 13C 35C IF Xt 2. 2): 0 THE! 33C 3< C LET Y 4 3 0 37C C2T0 390 33C LET v 43 13C 39C LET YC = Y3»(ATTI<<'( 1» 2 > / V < i» i) >) / a ~: c i) • A ACC LET Y63Y4»CATMtXt 1» 2>/Xt i, i >) i/a t m c i > • a A I C p r i n t ••m c c u l l -d a n : a p c l m e i t 3F C !:"» Y2 » Yi ACC PRINT "110 DULL'S AND APGL71EJT 3F C2:'.Y1»YS 499 CATA 170. 112» 53» 73» 235» 9 a , S3» 63» 135» 115. 77. 1CA 5 l C E; c PUN X M 3 DULL'D AND ARGUMENT 0F Cl: 1.72 127 236- 17 •* » M0DULUS «.'0 ARGUMENT 0F C2: .93C379 12 1. 3 A A READY o No m . Stock • Vibration Conforme«. 1974 Monoth U niv«riity. Molbourno. VIBRATION SIGNATURE ANALYSIS - TECHNIQUES ANO INSTRUMENT SYSTEMS R -B .fta n M Bru* Vibration signais measured at the external surfaces of a machine contain a great deal of information as to the internal processes and a number of monitoring and analysis techniques can be applied to extract information from these signals. This paper discusses the area of applicability of the various techniques, which fall into three main categories: (i) Field measurement with portable instruments. (ii) Field recording followed by detailed analysis. (iii) Permanent on-line monitoring. Principles for the selection of suitable instrumentation and data processing systems are discussed, with respect to the types of information which can be ex tracted, the degree of complexity of the machine, and the amount of data to be handled. The most important analysis technique is narrow band spectral analysis, and this esn be carried out by normal swept-frequency techniques, high-speed swept frequency techniques or real-time analysis techniques. Where required, the spec- truti can be obtained in digital form from analogue analyzers or by direct digit al analysis. Other useful techniques include time domain averaging and cepstrum analysis. Practical cases associated with machine health monitoring in a number of chemical plants are included as illustrations and a comprehensive bibliography is given in the paper. It is a well-known fact that an experienced mechanic can detect by ear the development of many, faults in for example an automobile engine, to the extent that the sound "signatures"of many such faults have acquired standard names: "piston slap", "bearing knock", “pinging" etc. The concept of “vibration signature analysis" is in principle very similar: machines in good condition generally tend to have a fairly stable vibration pattern, which can be considered as a "signature". Changes in the internal conditions are often reflected by changes in the vibration pattern which can then be detected by externally mounted pick-ups while the machine is in opera tion. The ability to monitor the condition of machines while in operation is very useful in preven tive or "predictive" maintenance of continuously operating plant such as in the power generating and chemical industries, but the technique could also be of considerable use in machine develop ment. The present paper is a general discussion of the many measurement and analysis techniques which have been and can be applied in "vibration signature analysis". The emphasis is laid on vi bration rather than sound measurement because in the majority of cases this can be used to elim inate the further transmission process from the machine surface to the microphone. Furthermore, most of the information will be present in the vibration signals measured at the bearings, since it is here that most of the dynamic forces are transmitted from the moving parts to the housing. (“Bearings" are taken to include sliding bearings such as cylinder walls in reciprocating ma chines). The three main ways in which vibration measurement and analysis can be used for machine mon itoring are: (i) Field Measurement with portable equipment. (ii) Detailed laboratory analysis usually involving tape recording in the field. (iii) Continuous monitoring with permanently installed pick-ups. Before going into each of them in detail, it is as well to give a general indication of their areas of applicability and thus to put them in perspective. Portable measuring instruments have the advantages of being relatively inexpensive and simple to operate and although they are limited to the measurement of overall vibration level or perhaps selective measurements at a few individual frequencies, this is adequate for the vast number of simple machines on most plants, eg. motors, pumps, fans etc. The signals from more complex machines such as gearboxes, turbines, compressors and recipro cating machines will generally require more sophisticated analysis, at least to realise the full detective and diagnostic power which vibration monitoring can offer. This will mostly be justi fied with the more valuable and critical machines in the continuous process industries, where there are considerable benefits to be gained from more advance knowledge of impending failure and a better indication of its nature so that shutdown time can be minimized. Finally, continuous monitoring will find application with the most critical machines, to guard against rapidly deteriorating situations and allow shutdown before catastrophic failure occurs. It is also useful for guarding against unstable areas of operation such as critical shaft speeds and oil whip in journal bearings. Intermittent detailed analysis can often be used to advantage to supplement continuous mon itoring on the same machine, the former giving more information aDOut normal wear processes and the latter giving protection against sudden failure. In fact, in some industries it will be bene ficial to empty all three types of vibration monitoring in parallel in the same plant. TRANSDUCERS ANO PREAMPLIFIERS. Regardless of the further processing of the vibration signal, it has first to be converted to an electrical signal by a suitable transducer. Three types of transducers are currently in common use, which measure acceleration, velocity and relative displacement respectively. For measurement of absolute motion, acceleration transducers, known as "accelerometers”, are to be preferred for the following reasons. M ) They have a very wide frequency range and dynamic range. (ii) They have small mass and physical dimensions. (iii) They are very rugged, and have no moving parts. (iv) The acceleration signal can easily be integrated electronically to obtain a signal proportional to velocity or displacement, whereas the inverse process of differen tiation is of dubious validity. 4 r Velocity transducers were the first to be developed but have now been superseded by acceler- ' ometers in virtually all respects. relative uisplàcèinérìt transducers are Quite common 1 y built 1 » m j e h i n a t i—- r a - nr • r •i - marily useful in cases where for example maintenance of working clearances is of greatest impor- tance (1) and their use for signature analysis is limited by the frequency restriction inherent in displacement measurement. Accelerometers have a high internal impedance, but this problem is now easily solved by using transistorized preamplifiers which convert from a high to a low impedance and which at the same time can be used for signal conditioning such as amplification and integration. Two types of pre amplifiers are in use, "voltage preamplifiers" and "charge preamplifiers“. The latter, though more expensive, are normally to be preferred as they give an output voltage which is independent of the cable length from the accelerometer. For further information see Ref. (2). PORTABLE INSTRUMENTS. When monitoring with portable instruments, it is desirable to simplify the operation as much as possible so that it can be carried out by people with a minimum of training. It has been found from experience covering many types of rotating machinery that velocity is the best indicator of vibration severity over a wide frequency range. One explanation of this is that constant RMS velocity represents constant vibrational energy ie. components at different frequencies are weighted according to their energy levels. A common method of determining the vi bration severity of a machine therefore, and one embodied in several standards!(3), (4), (5)), is to measure the RMS value of the velocity over a wide frequency band (e.g. 10 - 1000 Hz) in order to include the effects of a large number of possible sources, and cater for a wide range of ma chines operating at different speeds. These standards, in addition to specifying the method of measurement, also give recommended criterion levels, as illustrated in Fig.l. One must be careful not to give these absolute levels too much weight, however, since they are derived as averages over large numbers of machines and do not necessarily apply to any particular one. Reference (1), for example, describes hew measure ment: of mechanical impedance at the bearing housings of a number of machines in the same class revealed a very wide range (>10:1) indicating that the forces resulting in a given velocity level would also vary over this range. Another approach is to use the vibration level when the machine is known to be in good con dition as a standard and take departures from this as the criterion of deterioration. The stand ard criteria (eg. Fig. 1) are still useful as a guide here, since the separation between the dif ferent grades there is 8 dB, and an increase of 20 dB is sufficient to change the classification from "Good“ to “Inadmissible“. 4 5 N o t J iB .* 2 8 Not parmiu.b>a Not perm.jiiW « 1 8 w- N o t ç m m m t t i o i j — Juft tC araOM Juft tolerab«# 1 4 .5 A ltO w a o * 2 J » Juft tolerable A llo w a b le 1 > A llo w a b le S G o o d 1.1 2 - Allowable 0.7 1 G o o d 0 .4 5 • G o o d L*'yt m jrh.net *»< ‘h L j ' j r - e t o » y ^ d tu tn rr.wc h • rV i t ”) ‘J / / Ü / t u v / f ’/i/O o : i f ^ * ♦ • 3 r.’miye t n j : j ' i l 0 .2 8 f 5 - / 5 A * o f u p t o & n e // mtc/unm. up to 3 0 0 m W o o ip o c k t! treq**»* y 9*<** 5 Frequency Analysis It is also possible to do some frequency analysis using portable equipment, and this is use ful for two reasons: (i) A rise in overall RMS level will indicate that something has changed internally but not give any information as to the cause. Frequency information can often indicate the source of a change as discussed under “Detailed Analysis*. (ii) Changes in minor spectral components, which may be the first indication of incipient failure, will not always affect the overall RMS level, but can be picked up by spec trum monitoring. The two requirements are to some extent in conflict, since the first requires a narrow band resolution which would result in too many readings if it were desired to cover the complete spec trum for the second purpose. In practice therefore, some compromise must be made, with emphasis on one or the other factor. A suitable portable battery-operated vibration monitoring set is illustrated in rig. 2, housed in a rugged carrying case. It consists of a vibration meter with inbuilt charge prea-pli- fier, capable of measuring RMS velocity according to the above-mentioned standards, but also ac celeration and displacement. In addition there is a tunable narrow-band filter with bandwioths of 7i and 15S. With respect to the filter, it should be mentioned that bandwidth is not tr.e only fac tor determining the resolution capability. The steepness of the filter characteristic outside the passband, as indicated by the "shape factor" or "Octave selectivity", is also very important. Alternatively, some people prefer to monitor over a frequency range of 3 decades or so (6), so as not to miss changes which could occur at any frequency. Where the results from a large num ber of machines have to be noted down manually, it is not practicable to do this in bandwidths less than one octave. For this case a standard sound level meter with octave band filter set can be used, particularly if it has an integrator allowing measurement of velocity and displacement. The fact that the sound level meter is very useful in its own right will often influence this choice. Use of a 1/3-octave filter set represents a mid-way compromise. OETAILEO ANALYSIS Using a portable tape recorder it is possible to bring the vibration signals into the labo ratory where more detailed analysis can be carried out on them. The laboratory instruments are sometimes taken on-plant or to a control room to which the signals are led by long cables, and this may be suitable for individual measurements but it is not practicable for a regular moni toring scheme. Tape Recording and Playback The tape recording is an important part of the procedure, so it is worth discussing it in some detail. Firstly, the tape recorder itself should be chosen with care. Two recording princi ples are in common use viz. Direct Recording (DR) and Frequency Modulation (FM). Their relative merits are listed in Table 1. 6 DR FM Dynamic Range (narrow band - typical) 70 dB 60 dB Lower Frequency Limit 2.5 Hz* DC Upper Frequency Limit (typical) 50 kHz 10 kHz Amplitude Stability acceptable excellent Phase Linearity poor good Preservation of Recorded Information acceptable good ^Playback speed lOx recording speed. Table 1. Comparison of OR and FM recording techniques. Perhaps the best compromise is a recorder with two channels FM (for most measurements) and two channels OR (for frequencies > 1 0 kHz). It should of course be portable and battery-operated. Since the tape recorder is likely to be the most limiting factor in determining the dynamic range of the system, it is wise to choose that parameter for recording (acceleration or velocity) which has the flattest spectrum, regardless of which is to be used for final evaluation. Conver sion between the parameters is of course straight forward once a narrow band spectral analysis has been carried out. There are several possibilities for playback of the signals for analysis: (i) Continuous playback from the original tape reel. This will require unreasonably long recording times where analysis time is long. (ii) Make up loops by cutting up the original tape reel. This is impractical for large numbers of signals. (iii) Record directly on loop cassettes in the field. Also impractical for large numoers of signals. (iv) Record over from the original tape reel to another recorder with permanently mounted tape loop for analysis. Requires two recorders. In all cases where analysis is made from a tape loop, it may be found desirable to use a spe cial weighting function to eliminate the effects of the tape splice (8, 9). A better solution than (iv) would generally be to use a Digital Event Recorder in place of the second tape recorder since this eliminates the noise cf the splice as such and allows a con siderable reduction of analysis time by frequency transformation (9), as discussed later. Spectral Analysis The most usual analysis performed on the signals will be spectral analysis for the reasons already given, and in the laboratory it is possible to perform relatively narrow Dane analysis over the whole frequency range. It has been found that for many maenmes, the vibration power spec trum is very stable from time to time and even between different machines of the same type. This is the basis of a scheme developed by the U.S. Navy for onboard maintenance, and reported in Ref. (7). Shutdowns were based on departures from the envelope of standard signatures (Fig. 3) and the method was found to be justified by a statistical study of a large number of cases. The question arises, however, as to the best way of presenting the results of such an analy sis, and once again there is a conflict between covering a wide frequency range and requiring a fine resolution for diagnostic purposes. 7 Fig. 3 Vibration Spectrum Envelopes To cover a wide frequency range it is natural to use a logarithmic frequency scale, and then use of a constant percentage bandwidth (which gives uniform resolution) is almost unavoidable. Other reasons for using a logarithmic frequency scale (though not necessarily constant percentage bandwidth) are: (i) Small changes in machine speed from time to time will only cause a lateral shift in the spectrum thus simplifying comparison. (ii) Some relationships can most easily be seen in a log-log representation. On the other hand if the signal being analyzed has a high harmonic content (e.g. gearbox vibrations) then it can be an advantage to obtain the analysis on a linear frequency scale with constant bandwidth which gives uniform resolution and equal separation of the harmonics. This point is discussed further under “Cepstrum Analysis". The answer perhaps lies in using (approximately) constant percentage oandwidth analysis on a logarithmic frequency scale for detection of change, and constant bardwidth on a linear frequency scale for detailed diagnosis of changes. The same analyzer can perform both functions if its “constant" bandwidth can be made to step up automatically with increasing frequency, and if it has both linear and logarithmic frequency sweeps. 8 r Analysis Methods There are three main ways in which the power spectrum can be obtained: (i) thing a narrow band sweep frequency analyzer (constant or constant percentage band- wdth). Analysis time typically 10 to 60 min. (See Ref. (10) for details). (ii) High speed analysis using the same equipment as in (i ) but with the addition of a Digital Event Recorder with which large speed transformations can be made on play back, thus increasing analysis speed considerably (9). Fig. 4 shows a typical in strument setup. Analysis time typically J to 3 min. (iii) Real-time analysis using either the time compression principle (similar to (ii) or Fast Fourier Transform (FF1) techniques, and where the spectrum is continuously dis played on a screen. Fig. 5 shows a 400 line time compression analyzer. Method (i) is only practicable where not many analyses have to be made, but it is worth ex amining the relative merits of (ii) and (iii), which are discussed in some depth below: High Speed Analysis (ii) is somewhat cheaper in instrument cost than real time analyzers, typical ly j trie cost of a Time Compression Analyzer and 1/4 the cost of an r'FT analyzer. The saving is considerably more for people who already have the basic analysis syitern (i). It is also somewhat more flexible, the same setup offering both constant and approx, corstant percentage bandwidth, log and linear frequency scales, and variable resolution up to the equivalent of 2503 lines. It can also be an advantage to be able to use the individual instruments separately; eg. the Digital Event Recorder has a multitude of other uses, and on the few occasions where 25C0 line resolution is not adequate it is still possible to revert to a normal analysis setup to obtain any desired degree of resolution. • ff! t r * - ' ’ ’ y f \ V J 1 i l.. . . - _____ J • • r - 1 • • ZC Fig. 4 Instrument Set-up for High Speed Analysis VX* .-j--»— ■ -J'. r, . ■ -j :T - a ■■■■• Fig. 5 Time Compression Analyzer The same flexibility can be obtained with a real-time analyzer in combination with a general purpose computer, but this is of course even more expensive. Real-Time Analysis (iii) has the principal advantage of being real-time, thus allowing the effects of changing conditions to be observed as they occur. In sore cases, a transient phenomenon con tains most information about the occurrence of damage, eg. turbine blade failure (11). The use of digital averaging of a number of successive spectra to give adequate statistical reliability in the case of random signals can also be a considerable advantage in some cases. With the method (ii) the statistical reliability can only be improved by increasing bandwidth, but even so a 250 line (bandwidth) spectrum can be achieved with an RMS deviation <11 d3. (ST product 10). FFT analyzers have the additional advantage of being able to calculate cross correlations, cross spectra, transfer functions etc. thus providing considerable additional diagnostic power. (12). 9 Spactnum Diagnosis The frequency at which a change in the spectrum occurs gives very important information The types of faults which can be detected and perhaps diagnosed from a frequency analysis (see also (1), (6), (7), (11), (13), (14), (15) ) include unbalance (at shaft speed, primarily radial), misalignment and bent shacts (shaft speed and low harmonics, radial and axial), oil whip (just less than half shaft speed) and developing turbulence (blade and vane passing frequencies). Changes in natural frequencies can indicate crack growth or build-up of fouling. Local faults in rolling element bearings manifest themselves at frequencies corresponding to the rates of impact of the fault but also at higher frequencies (typically 20 - 60 kHz) corresponding to component natural frequencies (16, 13). Fig. 6 (from Ref. (16))shows the effect of induced pitting in an in ner race. Growth of sidebands indicates modulation at frequencies corresponding to the sideband spac- ings. This can for example indicate faults which cause modulation of the tooth meshing pattern in a gearbox (see later example). As another example, blade natural frequencies tend to frequency modulate the corresponding blade passing frequencies, providing another means of detecting these natural frequencies. Fig. 6 Ball Bearing Vibration Spectra (Ref. 16) Cepstrum Analysis Since in a complex spectrum it may still be difficult to see the growth of sidebands b> eye, and in particular to judge the relative importance of various modulating frequencies, this pro vides an application for "Cepstrum Analysis". In simple terms this is a method for detection of periodic components in a spectrum (eg. harmonics, sidebands) and consists in carrying out a fre quency analysis of the (logarithmic or dB) power spectrum itself. The spectrum must c- or. a line ar frequency scale with constant bandwidth. Reference (18) contains a detail . „.scission of the basic concepts,'methods of obtaining the cepstrum, and the application to ,-arbox fault diagnosis Fig. 7 shows how the instruments from Fig. 4 can be used, while numerical (FFT) computation in a general purpose computer can alternatively be used (18). 1 0 f Fig. 7 Instrument Set-ups for Cepstrum Analysis Example The following example illustrates several of the concepts discussed. The measurements were made on a gearbox (mounted between a gas turbine ar>d a generator) immediately prior to and short ly after a maintenance shutdown. The gearbox was primarily shut down to replace the internals, since fretting between the gearwheels and the sha.'t had been detected during an inspection 6 months earlier. The vibration signals before overhaul had also indicated misalignment, which was confirmed and corrected during the shutdown. Fig. 8 shows 3X bandwidth analyses of the two signals compared as velocity, and it can be seen that the realignment has improved the VDI 2056 classification from "Just tolerable/Not per missible" to “Allowable", the overall RMS velocity being dominated by the components at tne two shaft speeds (50 and 85 Hz). 11 - It should be noted that the first signal "Before repair" was recorded as acceleration and integrated to velocity on playback. The noise level of the tape recording can clearly he seen, confirming that it is best to record the parameter with the flattest spectrum. Another point of interest is that at the tooth meshing frequency and its harmonics it is dif ficult to determine from these X spectra that a significant change has occurred. The third har monic has even risen in level slightly after repair. Fig. 9 shows constant bandwidth analyses of the same two signals on a linear frequency scale (this time as recorded since the overall slope of the spectrum is of secondary importance). The presence of sidebands around the tooth meshing frequency and its harmonics is now much more in evidence in the signal taken "Before repair”, whereas the three harmonics stand out clearly "After repair". Fig. 10 shows cepstra corresponding to the spectra in Fig. 9 and this shows up the difference even more clearly and at the sane time confirms that virtually all the modulation is occurring at the speed of the high-speed shaft (85 Hz). a^ojorsssscocniossaassaeosaomaaoaieaoaoooooeoaaaoQ■— * --£ i V-- K--- * -i .7.-- ¡V ft —aogoaoac-aes^.se^&l^a^cotaaoaeosuaoa^^cosssaaa^a — ’ , JT ► Gearbox Pt. 4 — .Gearbox Pt. 4 . _ ...... h o r i z o n t a l ------Horizontal ------: - \ a ) before repair------Jfc>) A fter repair------— — i m ------— — r ------1------ ------M ------1— A. j j - — | i . ■■ ------— ■ | H ------tJ------% 1 -lf ir - h r r -\ ------H ------ Q P 1102 Quafrancy (t) Quefrency (s) Fig. 10 Cepstra corresponding to Fig. 9 Time Domain Analysis Spectral analysis, though very powerful, does not appear to be a universally applicaole tool. For example, in the paper by Priede & Groverfrom Ref. (15) it is mentioned that with reciprocating machines, and in particular diesel engines, the vibration exciting forces tend to be impulsive in nature, thereby exciting the natural frequencies of the engine structure. Faults are tnerefore more likely to show up as changes in the various parts of the time signal rather than as a change in the spectrum (Fig. 11). The time signal also contains information on individual components (eg. particular gear teeth) which is averaged out in the frequency spectrum (13). A technique which can be useful in cases such as these is to overlay digitally the vibration signals from many machine cycles, triggering at the same point each time, and thus enhancing the regularly repeating phe nomena with respect to random fluctuations (13, 14). 12 Fig. 11 Diesel Engine Time Signal (Ref. 15) Data Handling Where it is desired to monitor a large number of machines, it would be very tire consuming to carry out visual comparison of the appropriate vibration characteristics (eg. spectra; and there will be considerable advantage in digital processing of the data. Real-time analyzers normally have the option of a digital output either to a computer or paper tape punch. It is also possible to obtain the spectrum in digital form from the high-speed analysis system shown ir F-,g. 4 oy the addition of a Digital Encoder and Tape Punch (19). The analysis speed is then normally limited oy the puncher and is thus as fast as when the output is obtained in this form from a real-time ana lyzer. One advantage of intermediate storage of data on paper tape is that it can p^c.ide a means of interfacing with large computers (eg. via a time-sharing terminal) with stringent requirements on data format. Where possible, however, considerable time can be saved by direct read-in of the data into the computer. Ref. (19) gives one approach to the problem of programming for automatic spectrum comparison. Other advantages of digital processing of spectra are: (i) It is possible to carry out statistical analysis and thus obtain mc^e valid infor mation about trends, likelihood of failure etc. (Stewart (14) ). (ii) Cepstra can be calculated by an FFT program, possibly written in a nign-level lan guage such as Fortran (18). It should be mentioned that with a suitable input-output device such as a Digital Event Re corder, a mini-computer with external storage (tape, disk, or drum) can be used to preform spec trum analysis by programmed FFT methods, plus all the other data processing mentioord. The main disadvantages are that programming would normally have to be in assembler language, and that pro grammed FFt is slow compared with hardware (typically 1 s). PERMANENT mon i t o r i n g Most permanent monitoring systems monitor a single quantity such as band-limitec 5vu velocity in the same way as a simple portable meter, and most of the same considerations a p . 'he ru'.n difference lies in the extremely high reliability required, and for example special consideration must be paid to ruggedness of cables, avoidance of noise pickup etc. Care must alts c • \ ti"at the monitor does not give false alarms as a result of electrical mains transients, -^--nal me chanical shocks and suchlue. This can be achieved by requiring that the monitored la.el is out side the set limit for the whole of a set time delay. It is also desirable for tn- operator -,.o the event of an alarm to be able to check quickly that the monitor is adjusted and function! g correct iy. 13 Fig. 12 shows a single channel monitor with many desirable features; a rugged waterproof housing, "Alarm", “Trip" and “Min. level" (indicates damage to pickup or cable) circuits each with time delay. All set levels and time delays can be adjusted (though not externally) and in fact the only external button initiates a checking sequence of the set levels and delays. Continuous Spectrum Monitoring For valuable complex machines which are crucial to the operation of a plant, it may be deem ed justified to monitor the vibration spectrum continuously, thereby combining the advantages of both permanent monitoring and spectral analysis. This can virtually only be done with a real-time analyzer, though in this case a 1/3-cctave resolution may be considered adequate, if supplemented with a narrow band analysis facility for diagnosis of changes detected in the 1/3-octave spectrum. Normally, to justify the use of an expensive real-time analyzer, it would have to be used for a number of monitoring points, perhaps several differerr machines. In this case it would be nec essary to multiplex between the various input signals and apply different criteria fcr the eval uation of each spectrum, something which would almost inevitably require the use of a computer (mini or micro). Introduction of a computer makes the use of a narrow band real-time analyzer fea- siole (since simple spectrum comparison is unlikely to be satisfactory (19) ), a m introduces many interesting possibilities. One such possibility envisaged in the foreseeaole future is an opera tion in timesharing mode between fixed and regular calculations on a number of per-anently connect ed channels, and intermittent operator-controlled calculations of various tyoes. These 'ccu'd con sist of special calculations (eg. cepstra) on the connected channels, or simple spect'-.m crecking of additional signals recorded intermittently from a number of other machines, and oro^gnt to the console on a tape recorder. CONCLUDING REMARKS The latter system may seem a little far-fetched, but it could very easily become a.n econom ical proposition if it can be proved that incipient failure can be predicted with a nigh degree of certainty. It is believed that the state of the art is rapidly nearing this point. Perhaps one of the main inhibiting factors in the past has been the lack of certainty in this respect. Plant operators have understandably been reluctant to invest large sums cf money in in struments to determine whether the techniques described herein will work on their machines, and on the other hand the instrument manufacturers have not had much access to operating plant. It is hoped that this paper indicates how it is possible to build up instrument systems from fairly modest beginnings, as experience is accumulated and the need for more sophistication makes itself apparent. It is also hoped that it (and the references) will help to avoid pitfalls which lead to faulty conclusions and thus can do a great deal of harm. 14 à REFERENCES 1. E. Downham & R. Woods, “The Rationale of Monitoring Vibration on Rotating Machinery in Continuously Operating Process riant". ASm L Paper No. 7l-Vibr-96 Journal of Engineering for Industry. 2. J. Trampe Broch, "Mechanical Vibration and Shock Measurements“ (May 1972) A/S 3r'uel & Kjir, Denmark 3. VDI Richtlinien, "Beurteilungsmasst'abe fur mechanische Schwingungen von Maschinen“ VDI 2056, October 1964. 4. BS 4675:1971. “A Basis for Comparative Evaluation of Vibration in Machinery“. British Standards Institute. 5. Deutsche Normen. "Schwingstarke von rotierenden elektrischen Maschinen der Baugrossen 80 bis 315. DIN 45 665. July 1968. 6. C.A.W. Glew, D.C. Watson, “The Octave Band Vibration Analyzer as a Machinery Defect Indicator“, ASME Paper 71-DE-47. 7. R.N. Chapman, "Vibration Analysis applied to Machinery Maintenance“, Naval Engineers Journal, June 1967 pp. 431-437. 8. R.B. Randall, “Frequency Analysis of Stationary Signals recoraed on Tape Loops". 3 A K Application Note 12-036. 9. R.B. Randall, “High Speed Narrow Band Analysis using the Digital Event Recorder Type 7502 B & K Technical Review No. 2, 1973. 10. R.B. Randall, "Analysis Time for Swept Frequency Analysis" B & K Application Note 13-054. 11. R.L. Bannister & V. Oonato, "Signature Analysis of Turbomachinery", Sound and Vibration, September 1971, pp. 14-21. 12. 6.0. Bergland, “A Guided Tour of the Fast Fourier Transform", IEEE Spectrum, July 1959, pp. 41-52. 13. B. Weichbrodt and K.A. Smith, "Signature Analysis. Non-intrusive Techniques for Incipient Failure Identification. Application to 8earings and Gears". General Electric Co. Schenectady, N.Y., Report No. 70-C-364. 14. "Workshop in On-Condition Maintenance", I.S.V.R., Southhampton University 5-5 January 197 15. “Acoustics as a Diagnostic Tool”. Institution of Mechanical Engineers, London, Meeting 20th October, 1970. 16. H.L. Balderston, "The Detection of Incipient Failure in Bearings", Materials Evaluation, June 1969, pp. 121-8. 17. L.D. Mitchell & G.A. Lynch, "Origins of Noise”, Machine Design, May 1, 1969. 18. R.B. Randall, "Cepstrum Analysis and Gearbox Fault Diannosis". B & K Application Note 13-150. 19. R.B.Randall, “High Speed Narrow Band Analysis with Digital Output", B 1 K Application Note 12-192. 15 V U I I A .I I Y F euny ceeain eoiy ipaeet nomograph displacement velocity, acceleration, requency, S Units) (SI j Pipe Vibration Literature by P.W. Hope In recent years there has been an ever increasing amount of attention paid to the behaviour of thin walled tubes under many varying conditions and environments. Such studies are of great importance to the oil and gas industries, and even greater importance to the rapidly expanding nuclear power industry where pipes and tubes have to withstand very high pressures. One important topic for discussion is the Vibrations of the tube walls, which can be initiated in a number of ways, and it resonances are involved, can result in very significant effects. Howsner (1) has reported an investigation carried out to determine the effects of high wind velocities on an oil pipeline crossing a dessert. He found that if the frequency of the forced vibrations due to the transport velocity of the fluid, coincided with the resonant frequencies of the pipe, amplification of the vibrations could be a significant factor in causing the pipe to buckle. Using a similar equation to that derived by Housner, S Naguleswaran and C.J. Williams (2), investigated the more specific problem of the vibrations in the tube walls, both theoretically, and experimentally. Since very high liquid transport velocities were found to be necessary to vibrate a metal pipe significantly a neoprene tube was used in their experiments, and the results extrapolated to apply to metal pipes. They also treated the case of pressure variations in the liquid contained in the tube when there was no transport velocity. The con clusions to be drawn from these investigations, were, that a flowing liquid in a met3l pipe was not a significant factor in causing such pipes to vibrate and buckle, unless, very high flow vélocités were involved, whichin the majority of engineering applications of stiff p:pes has not been found to be the case. Other investigators have come to similar conclusions, although in all the papers little mention has been made of the pressure variations in the tubes caused by pulsating flow. In an investigation carried out by S.S. Chen and also Q.S. Rosenberg, (3) the effects of tr.e conolis force and curvature of the tube walls were evaluated these were found not to be significant at low fluid transport velocities. They did find, however, the existence of unstable oscillations of the tube walls when there was unsteady flow, and they also found that pulsatmq flow caused instability at relatively low transport velocities, they therefore concluded that this coulc* be a problem of importance. v ► t ^ J Other articles were also scanned, but as these were of an older date than the previous articles mentioned, no new informaiton was found. In particular T.B. Benjamin (4) in a lengthy expermenrial and theoretical paper summarizes the early work in this field and derives many of the basic equations used by the later workers. Having noted these conclusions, it has been decided to investigate a number of tubes containing fluid without a transport velocity but with pressure variations set up in the liquid by artificial means; i.e., a vibration exciter. References (1) Housner "Bending Vibrations of a pipeline containing flowing fluid", J. Appl Meh 1954.74.205. Int Ref. HPO 469 (2) S. Naguleswararn & C J .H . Williams "Lateral Vibrations of a tube containing a fluid" j Mech Eng. Eng Sei 10 (3) 2 2 8 -2 3 8 1968 Int Ref., 472 (3) S.S. Chen and G.S. Rosenberg, "Vibration and Stability of a tube conveying fluid" Argone National Laboratories ANL—7762, Int Ref. N71 — 34631 (4) Dynamics of a System of articulated pipes conveying fluid Ptl Theorey Ptl I Experiment By T.B. Benjamin, Roc Rog Soc (London), Series (A ), 261, 457 — 499 (1961) Int. Ref. 470 2 Detection of pressure variations in thin walled tubes by vibration measurements by Hans P. Olesen Introduction Fast pressure variations may seriously increase the fatigue loading of the tubes and other components of a piping system. Therefore, it is important to find a simple way to detect such variations and their distribution over the system. One promising method is to measure the extensional vibrations of the tube walls as the tube expands and contracts with the pressure variations. Naturally, care must be taken that other vibration modes are eliminated in the measurements. The vibration due to pressure variations Fig.1 displays the time varying internal pressure p = Po + Pi sin w t of a tube. Here pQ represents the nominal pressure and p<| the amplitude of the pressure variations which have the frequency f = w/2 n. These pressures force the tube to expand and to vibrate. Provided that the tube can be considered thin walled (wall thickness, t < 0,1 D, diameter) and that the wavelength of the pressure variations is much longer than the tube diameter the following simple expressions can be derived from the sketch of a tube cross section in Fig.2: As the static stresses and strains, introduced by the nominal pressure pQ, are irrelevant for derivation of the vibration values only dynamic stresses and strains are considered. The pressure p sin w t = p j = P2 + P3 is balanced by the elastic and the inertial forces in the tube wall respectively. 3 The elastic stress in the tube wall is: F p2 D 1 P2 D 6 3 — * —— r » —— 0) « n I * t i and 5 * f E » E * -=£-£• E - E • (2) p * D U — ,c. 4D 4 Et . i P2 * 2 Et —r~ * —=- d (3) D2 D2 Where 6 is the dynamic stress N/m 2 F is the unidirectional force developed against the tube wall [N] A is the cross sectional area of material which must stand the force F [m 2 ] 0 is the tube diameter (under nominal pressure) [m] 1 is an arbitrary length of tube [m] t is the wall thickness (under nominal pressure) [m j e is the strain in the tube walls [dimensionless] E is the modulus of elasticy for the tube material [N /m 2 ] P is the tube perimeter [m] d is the displacement of the tube wall [m] The total force used to accelerate the tube material is: F = it D1 P3 = ma = n Dt1 5 a (4) and P2 = S 5 a (5) where m is the mass of a length of the tube [kg] 5 is the mass density of the tube material [kg/m2 ] a is the acceleration of the tube wall [m/sec2] S is the volume of material [m2 ] If the additional pressure needed to accelerate some of the fluid in the tube is ignored, then the total pressuse p^ can be found 4 Et P1 = P2 d + t 6 a ( 6) P3 = D2 As displacement and acceleration, at a given frequency, are related by - w 2 the expression can be changed to: 4 E P1 = + 6 - ta (7) i J A E 2 td ( ) or p1 D 2 —w 8 i Both these expressions show that resonance occurs when 4 E (9) D 2 « 2 Or u 2 * fo ( 10) At this frequency a very little varying pressure produces large accelerations (and displacements). The resonant frequency is reduced when the tube carries heavy fluids, and its value is slightly increased by the bending effect which occurs when the wavelength is not long compared to the tube diameter Dim) 5 '! i *3. ► ' » J The most interesting frequencies, however, are below the resonant frequency and, therefore the pressure may be determined by the last term of equation 7 or the first term of equation 8 up to approximately 1/4 f The useful measuring range for tubes of varying diameters is illustrated in Fia 3. 4 Et 4 Et ( 11) ?1 D2 cj2 3 D2 Q 9 K g c m 2 P j Fifr4. Fig,5. The acceleration-to-pressure conversion is shown as a function of frequency for different tube configurations in Fig.4, and the displacement-to-pressure conversion is plotted in Fig.5. 6 The generation of pressure variations The pressure variations are often produced in the pumps of the system and they will, therefore, often be largest near the pumps. However, the geometrical configurations of the piping system may, in some cases, allow longitudinal resonances in the fluid near the pump frequencies. Thereby, even weak pressure fluctuations may be amplified to significant values. In long, uniform lengths of tube, the pressure variations may be the same along the tube length, as indicated in Fig.Ba. However, most often the tube has a bend or some other reflecting structure which causes standing pressure waves which vibrate some parts of the tube more than others, (see Fig.6b). Trtvtlling prewar* wav« Sanding prw*ur* wav* j/JOJv Practical measurement of pressure variations The tubes of a piping system may be excited into other vibration modes than the extensional mode which is caused by pressure variations. Often the tubes vibrate in bending as well as in extension. However, the frequencies of the two modes may not be the same and the two modes may be separated after a frequency analysis has been taken at a given point. The frequency analysis can be carried out with a simple portable system such as the one shown in Fig.7, or a more sophisticated system (shown in Fig.8) can be used, whereby, automatic recording is performed (see example of recording in Fig.9). V . t -»¿r.' t ; " -J- 0 . 't ; J 2120 or 2010 At the frequency of each vibration peak of Fig.9, a number of measurements are taken on the tube perimeter. As shown in Fig.lOa extensional vibration (pressure variations) result in almost equal signal levr's at different measurement points while bending vibration produces the highest levels in the axis of vibration (Fig.lOb). a b Fij.10. 8 From Figs.4 and 5 it may seem that displacement measurements were simpler than accelerator measurements. This is normally not the case, as displacement transducers are moVe inconvenient to use in the field than accelerometers. The displacement value can, naturally, be obtained by integration of the acceleration signal, but due to the smaii displacement which can be expected, acceleration measurements are recommended. Exam ple In a practical measurement 7,2, 4,8 and 2,4 g was measured at 230 Hz on three tubes respectively, with diameter D 3 0,3 m and wall thickness t * 5 mm. In Fig/ a vertical line is drawn at 230 Hz to cross the tube lines. For the tube in question the tube line must be drawn as shown in the figure, yielding approximately 2.10^ N/m? per g. This indicates pressure variations of 14,4 • 10s, 9,6 • 105 and 4,8 • 10® N/m^ respectively or 14,4, 9,6 and 4.8 kp/cm2 or 202, 136, and 68 psi. Conclusion Vibration measurements in combination with frequency analysis may be a very useful tool when the distribution of pressure variation in a piping system must be determined. A detailed mapping of the measuring results is essential for investigation of geometries which cause standing pressure waves and, thereby, in many cases reduce the safety factor built into the sys.am and, consequently, the plant efficiency. Furthermore, after the "normal" vibration pattern has been thoroughly investigated, regular checks or continuous monitoring may be introduced, to reveal changes in material properties with time due to fatigue loading. 9 s* «• w. -.vi’ .* t - : J CHEMEUNZAG Umar ZtlctMn SiVt»№ Hauwvf T«fl TMP Empflngw (OurdwcKMg* in) 4 . UNIDO-Vorkshop Department for Testing Materials in Chemical Industry — Scope of Work__ The work of a department for testing materials cam be described as follows: 1. The department is reponsible for all materials which are used in the plant op vessels, pipelines, engines, structures. 2. It has to secure that the ¡right material is supplied for a given process or service conditions. 3. It has to control tne vessels and installations in service in view of damages, suggest measures to avoid such damages. 4. It has to secure, that construction and maintenance work is done properly in view of the applied material and the service conditions. Materials used in chemical industry: 1. Most widely used are the metallic materials a) Within this group iron and steel and its alloys have the broadest application, for instance: Carbon s t e e l, c a st iron , steels for boilers and heat exchangers, where no or only small corrosion is to be feared; s te e ls fo r low-temp era tu re service,’ stainless steels, ferritic and austenitic, for corrosive environments ,* steels for high-temperature service: steels, resistant against attack by hydrogen, and so on. •/2 A 23 n b b) Nickel and its alloys, for instance, nickel-rr.olybdanium-alloys of the Hastelloy-type and nickel-chromium-alloys of the Incoloy- and Inconel- group, for corrossive environments or high-temperature service, nickel-copper-alloys in plants for water treatm ent. c) Copper an copper a llo y s These materials are not as far used, as the above mentioned. For instance, heat exchangers in the oilsystems of turbines and compressors are made of these materials. d) Aluminium and its alloys, mainly for storage-tanks and pipelines for not to corrosive media. e) Lead is not used any more on a wider s c a le , one will find them in some parts of sulphuric acid p lan ts. 2. Non metallic materials a) Enameled v e s s e ls , valves and pipes fo r high co rro siv e service or where high purity of the product is demanded, i. e. in the pharmaceutical industry. b) Rubber lined vessels Natural and synthetic rubber is a very good corrosion- resistant material, which can be used in a rather wide range at ambient or slightly elevated tempera tures, i. e. up to 30 degrees centigr. at the utmost. c) Thermoplastics, for instance polypropylene, polyethy lene or others, have as nearly all organic materials a temperature limit of application. d) Fluorir.ated plastics, as Teflon and Viton, vhi.cn nave a high corrosion resistance and a high temperature l i m i t . e) Resines-phenolic, epoxydes e .t.c .-, which can be used as corrosion-, or weather - resistant overlays on the in sid e andoutside o f tanks, v e s s e ls , even heat exchangers. To deal with materials successfully the expert has to know the chemical composition the metallographical structure, the mechanical values, ithe influences - mechanical, thermal, chemical - |upon the material under service conditions. Therefore we have in our department three main kinds of ta sk s: 1. mechanical and metallurgical, 2. non-destructive testing, 3. chemical, that is on the field of corrosion. For the above mentioned problems it is necessary to use a certain range of investigations. 1. Identification of materials: At repaire and maintenance of engines it can become necessary to replace damaged pieces, for instance bolts, small axles e .t.c., the material of vhich is unknown. Therefore one has to make some identification tests: hardness, metallographic structure, tensile- and yield- stren g th . That kind of tests has also to be done, when there is no connection between the delivered material and the certificates of the manufacturer. 2, In v estig atio n of damages: Here the visual investigation of the damaged parts under a binocular microskope is one of the most impcrtand methodes. For instance in case of rupture the •A 4 - operator can find out, wether fatigue of the material, corrosion or mechanical force initiated the cracking of a piece under investigation. 3. Non destructive testing:- Non destructive testing is mainly applied as a control of construction and repair work, that means control of the welding. It is also used for detecting failures in the material, as sheets, pipes, castings, etc. Such defects may be cracks, slag s, piping in castings, e.t.c. In the case of welding-control the investigations have to assure the welding has been done properly, that there are no unduly big and many pores, slags and no cracks. The méthodes in this field are: radiography. X-rays or radio-isotopes, ultrasonic measurenentes, crack detection by magnetic rr.ethode or dye penetrant, control of temperature in case of heat treatment preheating and post weld heat treatment. 4. Corrosion: Control of vessels running under severe conditions by means of visuel investigation, ultrasonic measurements control coupons, which are installed inside the vessels. Selection of the right material for given process- conditions by tests in the laboratory or with coupons in the vessels. It must be pointed out however, that none of the above mentioned méthodes can be used single, but it is necessary to apply two or more méthodes to cleare a case. Therefore the expert in malarial investigation has to keep in mind all these possibilities. - 5 - Further the material testing department has to make proposals upon the application of materials in new installations or plants- up-on issuing standards for material quality, welding procedures, control and investigation-work. As manifold as the work to be dene is, as manifold is the equipment. 1. Mechanical and metallurgical testing Here our department can do the following investigations and tests: a) Measure of yield- and tensile - strength by a testing machine with a load of 20 tons. i b) Measure of hardness by two hardness-testers one for Vickers (Hy) and one for Brinell (Hg). The Vickers-tester works with a diamond, shaped like a pyramid with a quadratic base, which is impressed in to the s u r f a c e o f the material, vhereas the Brinell-tester works by means of a sphere made of hardened steel. Cne gets on impression in the form of a circle c) Measure of impact-strength. d) For metallographical work we have grinding and polishing devices, to rr.anufacture test pieces, which are to by investigated under a metal microscope. e) A binocular microscope for visuel investigation of damaged pieces of equipment. 2. Men destructive testing a) Radiography For this hind of work we have 2 apparates for X-ray with 160, and 240 kilovolts respectively, as well as 3 apparates with radio-isotopes. Ve use Iridium 102. • /6 3. In the field of corrosion there is the usual laboratory equipment- But as already told, we do much investigation work by control coupons in the vessels, which method gives better results, as the coupons are tested directly under service conditions. t Organisation of the Department for Testing .Materials Admirrbtr- Head of Department (Secretary) / r Metallography Corrosion Non Destructive Destructive Testing Testing Welding Metallurgy and Charis try i I \ — i “ : t- r | Engineer (mecli. ) J Engineer (mach.) | Engineer i on-era.) ; " r ' I 5 Inspection Men J 3 Inspection Men 2 Assistant Chemists t 1 i t X-Ray Micrography Corrosion Qualität Char., Iridium 19? Heat Treatment Tensile Test Aijaiysis Ultrasonic Testing Lubricants Magn. Crack Impact Test Paints à Varnishes Detection Hardness Test Dye Penetrant a o K i a e w Whatortiftgy • Equipment for Won Destructive-Testing **• of Ecuipeat Producer Purchase- | Name and Aaresr r iiC « wS 1 adustrie-ROncgenemheit "Sresco" 160 kV/5 mA Rieh. Seifert 4 Co 1 8 1 . 000, - Röntgenverke resco Directional Radiating unit 160 kV/5 ■rA and (1 9 6 5 ) BogenstraQe 41 re sco D ir e c tio n a l R ad iatin g Unit 240 kV/5 mA D-2070 Ahrensburg ammaradiographie-Anlage "Gammamat TI" Sauervein GmbH . .j 7 0 .9 0 0 ,- 40 Ci Ir 192 uma-Radiographic Equipment "Gammamat TI* Postfach 150088 (1 9 7 4 ) D—4000 Düsseldorf 1 tnmaradiographiegerat “Teletron SU 100 A* Nuclear GmbH 8 6 .3 0 0 ,- 100 Ci I r 192 amma-Radiographic Equipment "Teletron SU 100 A" F lo ra s tra fle 16 (1 9 7 6 ) D-4000 Düsseldorf 1 osisleistungsvarnger&t "Gamraatest 1" Graetz Vertriebsgesell s c h a ft mbH ose Rate Alarm "Gammatest 1 ” • ) Postfach 294 D-5990 Altena 1 osisleistungsmeogerat "X 30 B" G raetz » j 1 5 .1 0 0 ,- r^ R ate Meter "X 50 B" (1 9 7 8 ) osisleistungsmeQgerdt "EMB 3" Landis 4 Gyr 1 5 .1 0 0 ,- ose Rate Meter "EMB 3" Breitenfurter Straße 1 4 8 a (1 9 7 8 ) 1230 Vien igital-VanddickemeBgerdt "DM 1" und ■CM 2" Irautkrämer GmbH *) 4 6 .7 0 0 ,- ltrasonic Vail Thickness Gauge "DM 1" and "DM2" Luxemburger Straße 449 (1 9 7 8 ) D-5000 ISln/Ilettenberg Itraschallgerat "USM 2" Irautkräaer GmbH 6 3 .0 0 0 ,- ltrasonic Flav Detector "USM 2 *) (1 9 7 4 ) s?ui5sehangerst "Us t p ^ o"------Irautkräaer GmbH 123.100,- j ♦> (1 9 5 9 ) i ltrasonic Flav Detector "USI? 10" 1 t a t i f l u x Magnaflux Corporation 3 - 7 0 0 ,- • or nondestructive Electrified Inspection 7300 Vest Lawrence Avenue (1 9 7 1 ) j Chicago 31. Illinois 1 andmagnetflux-Gerüt R.P.S. Patents LTD. 8 .0 0 0 ,- inches Sespun Flav Detector Alexandra Palace Station (1 9 5 8 ) London 10 Jfeprüfgerit "Equotip" Proceg SA 2 9 .7 0 0 ,- ardness Tester "Equotip" Riesenbachstraße 57 (1 9 7 9 ) CH-8034 Zürich Svitzerlar.d Tagbares magnet.-elektr. RiBprüfgeràt T ied e EG 2 9 .0 0 0 ,- xede "TVM42" BahnhofStraße 96 (1 9 7 4 ) 'agneto-electric Crack Tester Tiede"TVM 42" D-7031 Essir.gen ) Vendor for Au s tria : M i t t l i EG Kegergasse 7 1030 Wien MiieriaigrÇfanj Name of Equipment P ro d u cer Purchase- Name and Adress Price ÖS Härteprüfgerät nach Vickers Volpert-Verke GmbH *) <%2So&0*~ Kopemikusstraße 11 Hardness testing machine "Vickers" D-6700 Ludwigshafen (1 9 4 1 ) Härteprüfgerät nach Brinell X " _ Cm. ÌCO.OOq- Hardness testing machine " Brinell" (1 9 4 1 ) Schlaghärteprüfgerät "Equotip" Gebrüder Bach GmbH 30. 000,- Portable hardness tester Oswald Redlich Straße 5 (digital reading) A—1217 Wien (1 9 7 9 ) Ileinlasthärteprüfer "Durimet 2" Leitz-Austria 128.800,- Postfach 62 Hardness tester (1 9 8 0 ) (small load instrument) Dr. Karl Lueger Ring 12 A-1014 Wien Z e rre i Bma sc hin e Wolpert-Werke GmbH *) я.1,ох.еосг K opernikusS tra ß e 11 Tensile testing machine D-6700 Ludwigshafen (1941 ) Pendelschlagverk PSW 30 Mohr & Federhaf f 4 Losenhaaen 95.000,- Prüf- und Meßsysteme GmbH Impact strength testing machine Postfach 1502 (1 9 7 5 ) D 68 Mannheim 1 Techno-Endoskope, Modell D 2 e Deutsche Endoskopbau-Gesell- 15.991,- Technical-Endoscope schaft Sass, Wolf 4 Co mbH (1 9 5 9 ) Ritterstraße 12 D B e r lin Technisches Endoskope "TeKZ 5000/S" Technökontroll AG **) 5 3 .o œ ,- Imbisbühlstraße 144 Technical-Endoscope (1 9 7 8 ) CH—8049 Zürich Gl eichsp annung s-Porenp rüfgerät F is c h e r GmbH 4 Co 30.000,- Poroskope, Type H 3 d P o s tfa c h 4 D-7032 Sindelfingen 6 (1 9 7 4 ) "Poroskope"-direct voltage tester f o r p o res Schichtdickenmesser "Diameter", List-Magnetik 4.000,- Type SM 1b V iehveg 17-19 D-7022 Leinfelden (1 9 7 3 ) Overlay thickness measuring instru ment Mettler-Makro-Analysenvaage H 10 V Comesa KG 9.601,- Tegethoffstraße 26 - 28 (1 9 7 0 ) Analytical balance "M ettler H 10 W" A—4020 Linz M ettler Präzisionswaage PC 4400/19 ^ ft _ 25.300,- Precision balance'M ettler PC 4400/19^ (1 9 8 0 ) •) Vendor for Austria: O tto Dohmen Argentinierstraße 42 A—1041 Wien *•> It S i c h le r KG Pernerstorfergasse 5 A-1101 Wien CHEMIE UNZAG UnaarZaicDan B w M t« Hauarut Tag TIB Empfänger {Dureft«c)ilig« vi) 4 . UNIDO-Vorkshop Stress Analysis of Piping System Basic steps of calculation: 1 . Procedure of design starts vith making a freehand isometric piping-sketch. 2. Spot preliminary locations of hanger or supports, locate hangers at or near any concentrated loads (heavy valves, r i s e r s ...... ) P ick up all horizontal bends, to prevent any excessive overh an g. Hanger spacing must be close enough, to prevent excessive sa g g in g . 3. Study building steel 4. Check for interference (pipes, constructions) 5. Calculate distribution of veight .important to obtain zero load at equipment flange 6. Summarize hanger loadings 7. Calculate distribution of expansions to hanger 8 . C a lc u la te d is tr ib u tio n o f equipment movement 9 . Summarize movements 10. Choose hangers or supports for loadings and movements A 23 /1 b CHHMEUHZA6 Unaar Zakftan Baarbaitar Hauaruf Tag TIB EmpfinQ+r (DurctacMtQ* t I! i 4 . 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