Short Course 1

Short Course 1
Machinery Best Practices
• William and
Michael
Forsthoffer
FORSTHOFFER ASSOCIATES, INC. MODULE 1203.01
METS #3 – 2015
MACHINERY BEST PRACTICES SHORT

COURSE
FOR METS - 2015
INTRODUCTION AND
SHORT COURSE OVERVIEW
• INTRODUCTION
• SHORT COURSE STRUCTURE AND FORMAT
• SHORT COURSE OBJECTIVES
• INSTRUCTOR’S BIOGRAPHY
• AGENDA
1
INTRODUCTION
Welcome to our Machinery Best Practices Short Course for Mets 2015.
Based on W. E. Forsthoffer’s Text “Forsthoffer’s Best Practice Handbook for Rotating

Machinery” published by Elsevier in 2011, Michael and William Forsthoffer will present 20
Machinery Best Practices (17 specifically selected for the METS III Attendee’s and 3 or more
if time allows of attendee requested Best Practices). The Best Practices to be presented are
based on our Work in the Middle East, India, Pakistan and Asia since 1990.
This short course will present all of its 220 Best Practices which are designed for the Plant
Machinery Engineers, Reliability Engineers, Maintenance and Operations Personnel. We
have found that one of the major issues in Plants Worldwide is the low implementation rate of
Machinery Reliability Improvement Recommendations. The objective of the Handbook and
this Short course is to present information that we have gathered over the last 25 years
concerning machinery selection, design, installation, commissioning, plant reliability
procedures and communication that will enable plant personnel to attain the highest possible
implementation rate of their recommendations to management.
2
SHORT COURSE STRUCTURE AND FORMAT
During this short course, all principles will be presented in a practical manner. Therefore,
class props (machinery components, interesting “Items”) and “Case Histories” will be used to
reinforce the principles and relationships covered. Since our teaching style is interactive,
practical and, hopefully, interesting, high levels of class participation are both expected and
encouraged. Feel free to bring up “Case Histories” of your own.
Each Best Practice will be presented in the following format:

• The Best Practice that significantly increased Plant Safety, Reliability and Revenue
• The Lesson Learned that resulted in significant reduced Safety, Reliability or Lost
Revenue Issues
• The Benchmarks - where this Best Practice has been used and its results in terms of:
Increased Plant Safety, Reliability and/or Revenue
• We will review the detailed supporting Information to enable plant personnel to make a
successful management presentation.
3
SHORT COURSE OBJECTIVES
The objectives of this Short Course are presented in Figure 1.
SHORT COURSE OBJECTIVES
• PRESENT THE SELECTED REGIONAL “LESSONS LEARNED”
• DEFINE THE FAI GLOBAL BEST PRACTIES FOR THE LL’S
• COVER THE ESSENTIAL INFORMATION NECESSARY TO ASSURE THAT

THE BEST PRACTICES PRESENTED CAN BE IMPLEMENTED AT YOUR
PLANT SITE
• CONDUCT APPROPRIATE CLASSROOM EXERCISES TO ASSURE THAT

ATTENDEE’S UNDERSTAND AND CAN JUSTIFY THE BEST PRACTICES
PRESENTED
FIGURE 1
4
COURSE INSTRUCTORS
WILLIAM E. FORSTHOFFER
William (Bill) E. Forsthoffer is a graduate of Bellarmine College, Louisville, Kentucky, where

he received his Bachelor of Arts degree in Mathematics. Bill continued his studies at the
University of Detroit, Michigan, where he received a Bachelor of Science degree in
Mechanical Engineering.
Bill spent six years at the Delaval Turbine Company, where he Designed and Tested
Centrifugal Pumps and Compressors, Gears, Steam Turbines and Rotary (Screw) Pumps.
Prior to leaving Delaval, Bill held the position of Manager of Compressor Projector
Engineering responsible for the Aerodynamic and Mechanical Design of Centrifugal
Compressors, Lube and Seal Systems and Auxiliaries.
Bill joined Mobil Research and Development Corporation (MRDC) in Princeton, New Jersey in
1974, where he was directly involved with Rotating Equipment Selection, Design, Testing and
Start-Up of Fluid Cat Cracker Units, Reformers, Hot Gas Expanders and Low Density
Polyethylene Plants. From 1980 to 1985, Bill directed the Application, Selection, Design,
Testing, Site Pre-Commissioning and Start-Up of the Yanbu Petrochemical Complex in
Yanbu, Saudi Arabia. Following his overseas assignment, Bill returned to MRDC where he
established a Technical Service Program for Mobil affiliates to provide Application, Trouble-
Shooting and Training Services for Rotating Equipment.
Bill left Mobil in January of 1990 to found his own company. Forsthoffer Associates, Inc.
was founded February 1, 1990 with the company objective being:
"The Optimization Of Rotating Equipment Safety And

Reliability Through Understanding And Vendor-User
Communication"
5
MICHAEL S. FORSTHOFFER
Michael Forsthoffer, a 2003 Graduate of RIT in Mechanical Engineering, has been working with
Rotating Equipment since 1998.
During School
• 2000 - 6 month Co-op – Fluid Systems, NJ – Lube/Seal/Control System Design and

Testing
• Work with FAI from 1998-2002
o Citgo – Corpus Christi Refinery, Texas - Lube/Seal System Problems Resolution
o Compressor Seal Testing and Troubleshooting, DGS, Bushing and Contact Seals
o Saudi Aramco – Rabigh Refinery, KSA – Pump and Compressor Performance
Evaluation
o Citgo, Corpus Christi, Texas – Centrifugal Compressor and Steam Turbine
Performance Evaluation
o Alberta Envirofuels MTBE Plant – Compressor and Steam Turbine Performance
Evaluation
o Methanex Methanol and Ammonia Plants, Kitimat BC Canada – Centrifugal
Compressor Evaluation
• Ammonia
• Syn Gas
• Air Compressor
• 2002 – 6 month Co-op – Dresser Rand, Olean, NY – Aftermarket Service – Aerodynamic
Upgrades, Seal Upgrades, Bearing Upgrades
After School
• 2004 –contract – Dakota Gasification, Beulah, ND – Set up Program for real time
Performance Monitoring of 30 + Compressors.
• 2005-2008 – John Crane, Inc
o Applications Engineer (6 months) – Support Salesmen and perform RCFA for
Northeast Branch.
o On-Site Reliability Engineer (3 years) – Hovensa Refinery, St. Croix, VI –
Mechanical Seal Technical Support for Maintenance and Reliability. This
included field troubleshooting of seals and aux. systems and application of new
seals.
6
MACHINERY BEST PRACTICES SHORT COURSE AGENDA
FOR METS III– 2015
Session Description Section
1 Introduction and Short Course Overview 1

• Short Course Objectives
• Short Course Agenda and Schedule
• Instructor Bio’s
Project Best Practices
BP 1.1 The importance of early input into a project

of Lesson Learned
BP 1.8 The Concept of Pre- Bid Meetings and guidelines
_________________________________________________________________________
2 Pump Best Practices 2
BP 2.7 Operate Centrifugal Pumps in the EROE

(Equipment Reliability Operating Envelope) for
optimum Safety and Reliability
BP 2.16 Centrifugal Pump Minimum Flow Bypass Guidelines
_________________________________________________________________________
3 Compressor Best Practices 3
BP 3.14 Use Centrifugal Compressor performance calculations

and phase angle changes to confirm fouling
BP 3.20 Thrust Bearing pad temperature as well as axial
displacement must be present for excessive thrust pad
load
_________________________________________________________________________
4 Steam Turbine Best Practices 4
BP 5.4 Trend after first stage pressure vs. steam flow and
phase angle change in steam turbines to detect
fouling
BP 5.11 Perform coupled overspeed trip checks for steam
turbines with electronic governors
9
Session Description Section
5 Gas Turbine Best Practices 5
BP 6.1 Always consider Aero Derivative /Industrial Power

Turbine Gas Turbine Units when their size is acceptable
BP 6.3 Size Gas Turbine output power for a minimum of 10%
above the driven machine rated power (Gas Turbine
power at site conditions)
_________________________________________________________________________
6 Lube/Control Oil Best Practices 6
BP 7.11 Always test oil system relief valves on the oil

console and not on a PSV test rig
BP 7.26 Check oil system transient functions immediately
before turnarounds
__________________________________________________________________________
7 Dry Gas Seal Best Practices 7
BP 9.1 End User’s must be proactive in selecting Dry

Gas Seal Systems based on their specific plant
environment
__________________________________________________________________________
8 Installation, Pre- Commissioning, Commissioning & 8

Start-up Best Practices
BP 10.7 Best Practice oil flushing procedure for optimum

results in minimum time
__________________________________________________________________________
9 Preventive and Predictive Maintenance Best Practices 9
BP 11.1 Always use Component Condition Monitoring (CCM)

Trends to minimize PM’s and extend PM intervals
BP 11.3 Optimize pump unit MTBF’s by changing over pumps
every 3 to 6 months
BP 11.7 Always trend all rotating equipment performance along
with mechanical parameters -
IE: Use FAI CCM approach
Class selected BP
Class selected BP
Class selected BP
10

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Short Course 1

Machinery Best Practices

MACHINERY BEST PRACTICES SHORT

• SHORT COURSE STRUCTURE AND FORMAT

• SHORT COURSE OBJECTIVES

Based on W. E. Forsthoffer’s Text “Forsthoffer’s Best Practice Handbook for Rotating

Each Best Practice will be presented in the following format:

The objectives of this Short Course are presented in Figure 1.

SHORT COURSE OBJECTIVES

• PRESENT THE SELECTED REGIONAL “LESSONS LEARNED”

• DEFINE THE FAI GLOBAL BEST PRACTIES FOR THE LL’S

• COVER THE ESSENTIAL INFORMATION NECESSARY TO ASSURE THAT

• CONDUCT APPROPRIATE CLASSROOM EXERCISES TO ASSURE THAT

William (Bill) E. Forsthoffer is a graduate of Bellarmine College, Louisville, Kentucky, where

"The Optimization Of Rotating Equipment Safety And

• 2000 - 6 month Co-op – Fluid Systems, NJ – Lube/Seal/Control System Design and

Session Description Section

1 Introduction and Short Course Overview 1

Project Best Practices

BP 1.1 The importance of early input into a project

2 Pump Best Practices 2

BP 2.7 Operate Centrifugal Pumps in the EROE

3 Compressor Best Practices 3

BP 3.14 Use Centrifugal Compressor performance calculations

4 Steam Turbine Best Practices 4

5 Gas Turbine Best Practices 5

BP 6.1 Always consider Aero Derivative /Industrial Power

6 Lube/Control Oil Best Practices 6

BP 7.11 Always test oil system relief valves on the oil

7 Dry Gas Seal Best Practices 7

BP 9.1 End User’s must be proactive in selecting Dry

8 Installation, Pre- Commissioning, Commissioning & 8

BP 10.7 Best Practice oil flushing procedure for optimum

9 Preventive and Predictive Maintenance Best Practices 9

BP 11.1 Always use Component Condition Monitoring (CCM)

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