Allianz @

Allianz Versicherungs-AG Berlin/Munchen

Handbook of Loss Prevention

Springer-Verlag Berlin Heidelberg New York 1978

Title of the Original German Edition: Handbuch der Schadenverhiitung

Translated from the German by Peter Cahn-Speyer Dipl.-Ing., Kew-Surrey/Great Britain

ISBN-13: 978-3-642-66422-9 e-ISBN-13: 978-3-642-66420-5 DOl: 10.1007/978-3-642-66420-5

This work is subject to copyright. All rights are reserved, whether the whole or part of the materials is concerned specifically those of translation, reprint­ing, re-use of illustrations, broadcasting, reproduction by photocopying ma­chine or similar means, and storage in data banks. Under §54 of the German Copyright Law where copies are made for other than private use, a fee is payable to the publisher, the amount of the fee to be determined by agree­ment with the publisher.

© 1978 Allianz Versicherungs-Aktiengesellschaft, Berlin/Munchen, Munche­ner Ruckversicherungs-Gesellschaft, Munchen, and Springer Verlag, Berlin Heidelberg. Softcover reprint of the hardcover 1 st edition 1978

The use of registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use.

Typesetting, printing and bookbinding: Universitatsdruckerei H. StUrtz AG, Wurzburg. 2362/3321-543210

Preface

The German original of this Handbook of Loss Prevention was compiled during the course of many years' work by the engineers of the Department for Engineering Insurances, the scientists of the Allianz Centre for Technology and representatives of industry. It is based on the loss experience and practical loss research studies of­the Allianz over a period of more than five decades.

The Handbook of Loss Prevention is a supplement to the technical literature from the field of engineering in the form of a collective work comprising examples of damage to machinery and technical plant and pertinent pointers on loss prevention. It hus ranks among the recognised handbooks for engineers in the filds of planning, design, manufacture and operation.

The great interest and wide acclaim according the German edition of this handbook by industry in 1972 confirm the traditional aims of the Allianz in placing loss prevention in technical plants in the foreground of their service to clients.

The English edition of the handbook under review here enables this valuable engineering know-how to be made available at international level, with the object of preventing losses by the exchange of ideas and experience. The literature references have been taken over from the German edition in unchanged form, in order to bring to the atten­tion of English-speaking experts a bibliography, which is little known outside Germany.

Munich, April 1978 The Editor

Authors

Authors of friendly companies

Bartel, A.A. (Dow Corning GmbH, Miinchen) Briicher, A. (Kraftwerksunion AG, Miilheim/Ruhr) Ehrlenspiel, K. (Bayer. Berg-, Hiitten- u. Salzwerke AG, Sonthofen) Gottiing, H. (Technical University Miinchen, Miinchen) Hebel, G. (Brown, Boveri & Cie AG, Mannheim) Kranich, L. (Rheinkraftwerk Albbruck-Dogern AG, Albbruck) Renz, H. (TELA Versicherungs-AG fUr Techn. Anlagen, Miinchen) Winkler, K. (Rheinkraftwerk Albbruck-Dogern AG, Albbruck)

Authors of the Allianz Versicherungs-AG

Abinger, R. Blaschke, D. Bohnstedt, 1. Bollmann, G. Breidert, H. Breitfeld, H. Delp, G. Effertz, P.-H. Essler, R. Fenzl, G. Franze, H.-G. Gugat, A. Haase, W.

Heimsch, R. Heinz, A. Horenburg, O. Huppmann, H. Jager, K. Kirsch, H. Kleinmann, P. Kober, A. KrauB, O. Krebber, B. Kugler, H. Leopold, J.

Maatz, H. Neumann-Spallart, H. Reiche, R.H. Ritter, W.-D. Schindler, D. Schmidt, E. Schulze, M. Splittgerber, E. Wissel, Chr. Witt, D. Wittrisch, G. Wuttke, H.

Authors and co-workers of this book want to express their gratitude to the managing director Dr.-Ing. H. Braun for his purposeful promo­tion and generous support in planning and realizing this work.

Contents

1. Aims and Possibilities of Loss Prevention

1.1. 1.1.1. 1.1.2. 1.1.3.

1.2.

Loss Prevention by Allianz. . . . . The Allianz Engineering Office. . . The Allianz Centre for Technology . Exchange of Experience by Allianz .

Basis and Methods of Loss Prevention .

3 3 4

12

13

1.3. General Recommendations for Loss Prevention 17 1.3.1. Loss Prevention in the Manufacturer's Works 17 1.3.1.1. Loss Prevention during Planning. . . . . . 17 1.3.1.2. Loss Prevention during Construction and Execution 18 1.3.1.3. Transport and Storage, Assembly, Commissioning and

Test Runs. . . . . . . . 19 1.3.1.3.1. Transport . . . . . . . . 20 1.3.1.3.2. Erection and Assembly Site 21 1.3.1.3.3. Transport and Lifting Gear 23 1.3.1.3.4. Climatic Conditions . . . 24 1.3.1.3.5. Safeguarding of Building Sites against Theft 26 1.3.1.3.6. Safety Measures against Fire. . . . . . . 26 1.3.1.3.7. Easily Understandable, Unambiguous Instructions and

Assurance that they will be Followed during the As-sembly Process and during Test Operation. . . .. 29

1.3.2. Loss Prevention by the User. . . . . . . . . .. 31 1.3.2.1. Loss Prevention before Acceptance (Test Operation) 32 1.3.2.2. Loss Prevention during Operation . . . . . . .. 32

2. Electrical Machines, Power Cables and Supervisory In-stallations. . . . . . . . . . . . . . . . . . . 39

2.1. Turbo-Generators................ 39 2.1.1. Planning of Turbo-Generator Installations. . . .. 40 2.1.2. Commissioning and Operation of Turbo-Generators 41 2.1.3. Inspection of Turbo-Generators . . . . . . . .. 44

2.2. Three-Phase Motors . . . . . . . . . . . . .. 48 2.2.1. Planning of High-Voltage Three-Phase Motor Installa­

tions . . . . . . . . . . . . . . . . . . . . .. 48 2.2.2. Installation and Commissioning of Three-Phase Mo-

tors. . . . .. 50

VIII Contents

2.2.3. Operation and Maintenance of Three-Phase Motors 51 2.2.4. Inspection of Three-Phase Motors 54

2.3. Salient-Pole Machines. 57 2.3.1. Operation of Salient-Pole Machines. 57 2.3.2. Inspection of Salient-Pole Machines 58

2.4. Direct-Current Machines . 63 2.4.1. Supervision and Maintenance of Direct-Current Ma-

chines, with Particular Reference to Commutation 63 2.4.2. Inspection of Direct-Current Machines 67

2.5. Three-Phase Transformers . 71 2.5.1. Planning and Commissioning of Transformers 71 2.5.2. Supervision of Transformers . 74 2.5.3. Inspection of Transformers 76

2.6. High-Power Cables . 80 2.6.1. Planning of Cable Networks. 80 2.6.2. Storage of Cables 81 2.6.3. Laying of Cables. 81 2.6.4. Commissioning of Cables 83 2.6.5. Operation and Maintenance of Cables 83

2.7. Equipment for Protection, Measurement, Regulation and Control. 86

2.7.1. Planning and Design 86 2.7.2. Commissioning and Operation . 87

3. Electronic Data-Processing (EDP) Equipment 91

3.1.

3.2. 3.2.1.

3.2.2.

3.2.2.1. 3.2.2.2. 3.2.2.3. 3.2.2.4. 3.2.2.5. 3.2.2.6.

3.2.2.7.

Prevention of Damage to EDP Equipment by the Manu­facturer. . . . . . . . . . . . . . . . . . . .. 93

Prevention of Damage to EDP Equipment by the User. 94 Planning, Erection and Installation of the Computer Centre . . . . . . . . . . . . . . . . . . . .. 94 Measures for Preventing Damage to EDP Equipment during Installation . . . . . . . . . .' . . . . 98 Operational Measures. . . . . . . . . . . . . 98 Automatic Supervisory and Protective Equipment 101 Supervisory Duties of Personnel 106 Maintenance. . . . . . . . . . . . . . . .. 106 Inspections . . . . . . . . . . . . . . . .. 107 Constructional Work in the Vicinity-Rebuilding in the Computer Centre. . . . . . . . . . 108 Protective Measures for Data Carriers . . . . . . . 108

4. Steam Generators . . . . . . . . . . . 111

113 4.1. 4.1.1.

4.1.1.1.

Water-Tube Boilers ........ . Manufacture, Assembly and Commissioning of Water­Tube Boilers. . . . . . . . . . 113 Demands on Planning and Design . . . . . . . . . 113

Contents IX

4.1.1.2. Demands on Manufacture, Assembly and Commission-ing. 114

4.1.2. Prevention of Damage to Water-Tube Boilers by the Operator 116

4.1.3. Inspection and Revision. 118

4.2. Furnaces 120 4.2.1. Planning and Design 120 4.2.2. Assembly and Commissioning of Furnaces. 120 4.2.3. Operation of Furnaces 121

4.3. High-Speed Steam Generators 124 4.3.1. Guidelines for the Prevention of Damage to High-Speed

Steam Generators 124 4.3.2. Inspection and Revision. 126

4.4. Large-Water-Space Boilers. 128

4.5. Steam-Carrying Pipelines 131 4.5.1. Planning and Design of Pipelines . 131 4.5.2. Manufacture, Assembly and Commissioning . 132

5. Fluid-Flow Machines. 137

137 5.1. 5.1.1.

5.1.1.1.

5.1.1.2. 5.1.1.3. 5.1.2.

5.1.2.1. 5.1.2.2.

5.1.2.3. 5.1.2.4. 5.1.2.5.

5.1.2.6. 5.1.2.7. 5.1.3. 5.1.4. 5.1.4.1. 5.1.4.2. 5.1.4.2.1.

5.1.4.2.2. 5.1.4.2.3.

5.1.4.2.4.

Steam Turbines. . Directives for the Prevention of Damage during the Planning Stage. . . . . . . . . . . . . . . . Determination of the Limits of the Delivery Specifica-tion . . . . . . . . . . . . . . Determination of Measuring Points. . . . . . . . . Conceptual Layout of the Machine. . . . . . . . . Guidelines for the Prevention of Damage during Design and Manufacture. . . . . . . . . . . . . . . . .

141

142 142 142

144 The Steam Strainer. . . . . . . . . . . . . . . . 144 Emergency Stop Valves, Control Valves for Live, Re-heat, Cross-over and Pass-out Steam 145 The Control and Protection System 147 Rotors, Rotor Discs . . . . . . . 148 Turbine Casings with Fasteners, Baseplates, Bearing Pedestals . . . . . . . . . . . . . . . 152 Radial and Axial Bearings with Oil Supply . 154 Moving and Stationary Blading . . . . . . 156 Loss Prevention during Assembly and Commissioning. 158 Directives for Loss Prevention during Operation 160 Condition of Steam. . . . . . . . . . . . 160 Supervisory and Protective Equipment . . . 160 Protection from Underspeed, Overspeed and Reverse Running . . . . . . . . . . . . . . . . 160 Protection from Non-Permissible Steam Pressures . . 161 Protection from Inadmissibly High and Low Steam Temperatures and Non-Permissible Steam-Temperature Changes . . . . . . . . . . . . 161 Protection from Inadmissible Loads . . . . . . . . 162

X Contents

5.1.4.2.5. Protection from Axial-Clearance Bridging through Damage to Axial Bearings (see 8.3. Bearings) and through Inadmissible Relative Elongation . . . . . . 162

5.1.4.2.6. Protection from Radial-Clearance Bridging . . . . . 162 5.1.4.2.7. Protection from Inadmissibly Rough Running, with

Consequent Damage to Bearings and Damage by Clear-ance Bridging . . . . . . . . . . . . . . . . . . 162

5.1.4.2.8. Protection from Disturbances Emanating from the Oil Supply and the Radial and Axial Bearings. . . 163

5.1.5. Loss Prevention by Inspection and Revision. . 163 5.1.6. Guidelines for Loss Prevention during Repairs. 168

5.2. 5.2.1. 5.2.2. 5.2.3. 5.2.4.

5.3. 5.3.1. 5.3.1.1. 5.3.1.2. 5.3.2.

5.3.2.1. 5.3.2.2. 5.3.2.3.

5.3.2.4.

5.4. 5.4.1.

5.4.2.

5.4.3.

5.4.4. 5.4.5.

5.5. 5.5.1.

5.5.1.1. 5.5.1.2. 5.5.1.3.

5.5.1.4.

5.5.2.

5.5.3.

Condensing Plant. . . . . . . . Manufacture of Condensing Plant . . . . . Operation of Condensing Plant. . . . . . . Inspection and Revision of Condensing Plant Optimum Supervision.

Centrifugal Pumps . . . . . . . . . . . Boiler Feed Pumps .......... . Planning and Design of Boiler Feed Pumps Experience during the Operation of Boiler Feed Pumps Axial-Flow Cooling-Water Pumps with Adjustable Blades .................... . Planning and Design of Cooling-Water Pumps ... . Assembly and Commissioning of Cooling-Water Pumps Experience in the Operation of Axial-Flow Cooling­Water Pumps . . . . . . . . . . . . . . . . . . Maintenance and Inspection of Axial-Flow Cooling­Water Pumps . . . . . . . . . . . . . . . . . .

Turbo Compressors and Blowers . . . . . . . . . . Planning, Design and Manufacture of Turbo-Compres­sors and Blowers. . . . . . . . . . . . . . . . . Assembly and Commissioning of Turbo-Compressors and Blowers. . . . . . . . . . . . . . . . . . . Optimum Supervisory and Protective Equipment on Compressors and Blowers. . . . . . . . Maintenance of Compressors and Blowers. Revision of Compressors . . . . . . . .

Gas Turbines. . . . . . . . . . . . . . Guidelines for Prevention of Damage to Gas Turbines during Manufacture . . Planning of Gas Turbines . . . . . . . . . . . . . Design of Gas Turbines. . . . . . . . . . . . . . Guidelines for Loss Prevention during the Manufacture and Assembly of Gas Turbines. . . . . . . . . . . Requirements for the Commissioning of Gas-Turbine Installations . . . . . . . . . . . . . . . . . . . Guidelines for Loss Prevention during the Operation of Gas Turbines . . . . . . . . . . Revision of Gas-Turbine Installations. . .

170 170 177 180 182

184 185 186 189

195 196 199

199

201

203

206

217

218 218 219

221

226 226 228

230

231

232 232

5.6. 5.6.1. 5.6.2.

5.6.2.1. 5.6.3.

Contents XI

Water Turbines . . . . . . . . . . . . . . . . . 235 Guidelines for Loss Prevention by the Manufacturer . 237 Guidelines for Prevention of Damage to Water Turbines during Operation. . . . . . . . . . . . . . . . . 238 Guidelines for the Supervision of Water Turbines. . . 238 Guidelines for Loss Prevention by Inspection and Revi-slon ...................... 239

5.6.4. Guidelines for Loss Prevention by Correct Rapair (Examples) . . . . . . . . . . . . . . . . . . . 243

6. Selected Lifting and Loading Equipment. 247

6.1. Slewing Cranes and Loading Bridges. 248 6.1.1. Guidelines for the Planning of Lifting Equipment. 249 6.1.2. Design and Manufacture 250 6.1.3. Assembly and Commissioning 260 6.1.4. Operation of Slewing Cranes and Loading Bridges 261 6.1.5. Measures for the Prevention of Storm Damage to Crane

Installations . 264 6.1.5.1. Precautionary Measures . 264 6.1.5.2. Measures during Non-Operational Periods or Imminent

Storm Conditions 267 6.1.6. Protective Devices for Crane Installations . 268 6.1.7. Maintenance, Inspection and Revision of Crane Installa-

tions 271 6.1.8. Repair of Crane Installations 282

6.2. Tower Cranes 289 6.2.1. Guidelines for the Planning of Tower Cranes 289 6.2.2. Erection, Commissioning and Dismantling of Tower

Cranes 292 6.2.3. Guidelines for the Operation of Tower Cranes 298 6.2.4. Inspection of Tower Cranes 300 6.2.4.1. First Inspection 300 6.2.4.2. Inspection after Structural Modifications 301 6.2.4.3. Regular Inspections by Skilled Persons 301 6.2.4.4. Regular Inspections by Experts. 301

7. Industrial Furnaces. . . . . . . . 303

7.1. General Concepts and Damage Survey . 303 7.1.1. Terminology ofIndustrial Furnace Construction 303 7.1.2. Survey of Damage . . . . . . . . . . . . . 303

7.2. Planning, Design, Manufacture and Assembly of Indus-trial Furnaces . . . . . 306

7.2.1. Guidelines for Planning. . . . . . . . . 306 7.2.2. Guidelines for Design. . . . . . . . . . 307 7.2.3. Guidelines for Manufacture and Assembly. 309

7.3. Commissioning of Industrial Furnaces . 312 7.3.1. Measures Prior to the First Heating up . . 312

XII Contents

7.3.2. Preliminary Measures during Heating up or Switching on . . . . . . . . . . . . . . . . . . . 313

7.4. Operation of Industrial Furnaces . . . . . . . . . . 315 7.4.1. Continuous Supervision of Operational Data ..... 315 7.4.2. Operational Data to be Checked and Recorded at Ap­

proximately Hourly Intervals . . . . . . . . . . . 315 7.4.3. Functional Checks to be Carried out at Longer Inter-

vals, e.g., during a Scheduled Shut-down Period. 316

7.5. Guidelines for Shut-downs and Revisions. . 318 7.5.1. Inspection of the Basic Furnace Structure. 318 7.5.2. Inspection of Brickwork/Rammed Linings. 318 7.5.3. Inspection of the Tubing of Tube Furnaces 318

8. Selected Components and Machines. . . . . 321

8.1. 8.1.1.

8.1.2.

8.2. 8.2.1. 8.2.2.

8.3. 8.3.1. 8.3.1.1. 8.3.1.2. 8.3.2. 8.3.3. 8.3.3.1. 8.3.3.2. 8.3.4.

8.3.5.

Threaded Fasteners . . . . . . . . . . . 321 Design, Manufacture and Assembly of Threaded Fas-teners. . . . . . . . . . . 322 Threaded Fasteners in Service . . . . . . . 323

Shafts and Axles . . . . . . . . . . . . . 326 Design and Manufacture of Shafts and Axles 326 Shafts and Axles in Operation . . . 330

Plain and Rolling Bearings. . . . . . . . . 333 Choice of the Most Suitable Bearing . . . . 333 Guidelines for the Choice of Rolling Bearings . 334 Guidelines for the Choice of Plain Bearings . . 334 Guidelines for the Production of Plain Bearings 336 Guidelines for the Installation of Bearings . 337 Rolling Bearings . . . . . . . . . . . . . . 337 Plain Bearings. . . . . . . . . . . . . . . 337 Commissioning of Bearings for Large Machine Installa­tions . . . . . . . . . . . . . . . . . . . . . . 337 Guidelines for the Operation of Large Machine Installa-tions . . . . . . . . . . . . . . . . . . . . . . 338

8.3.5.1. Supervision of the Installation before Commissioning. 338 8.3.5.2. Monitoring and Safety Facilities . . . . . . . . . . 339 8.3.5.2.1. Monitoring and Safety Equipment for Rolling Bearings 340 8.3.5.2.2. Monitoring and Safety Equipment for Plain Bearings 343 8.3.5.2.3. Inspection of Bearings . . . . . . . . . . . . . . 348

8.4. 8.4.1.

8.4.1.1. 8.4.1.2. 8.4.1.3. 8.4.2. 8.4.2.1. 8.4.2.2. 8.4.2.3.

Couplings . . . . . . . . . . . . . . . . . . . . 351 Guidelines for Loss Prevention during the Manufacture of Couplings. . . . . . . . . . 352 Couplings with Drawn-on Flanges 353 Gear-Type Couplings. . . . . . 353 Flexible Couplings . . . . . . . 354 Guidelines for Loss Prevention during Assembly 354 Alignment of Couplings. . 354 Concentric-Running Check 355 Radial Misalignment . . . 356

Contents XIII

8.4.2.4. Tolerances for the Alignment Check 357 8.4.2.5. Guidelines for Final Assembly . 357 8.4.l Guidelines for the Commissioning of Couplings 359 8.4.4. Supervisory and Protective Equipment for Couplings 360 8.4.5. Guidelines for the Inspection and Revision of Couplings 360

8.5. Stationary Gearing 361 8.5.1. Types of Damage to Gearing 363 8.5.1.1. Damage by Broken Teeth . 363 8.5.1.2. Damage to Tooth Flanks 364 8.5.1.3. Damage to Plain Bearings of Gears . 369 8.5.1.4. Other Damage to Gear Transmissions. 371 8.5.2. Planning and Design of Gearing 372 8.5.3. Manufacture of Gear Transmissions 372 8.5.4. Acceptance, Installation and Commissioning of Gear

Transmissions 373 8.5.4.1. Alignment. 373 8.5.4.2. Load-Bearing Pattern . 373 8.5.4.3. Selection of Lubricants 375 8.5.4.4. Oil-Supply Requirements Specific to Gearing 375 8.5.4.5. Vibrations. 376 8.5.4.6. Gear Noise 376 8.5.5. Loss Prevention during Operation 377 8.5.6. Inspection of Gears. 378 8.5.7. Revision of Gears 378 8.5.7.1. Spur, Bevel and Worm Gearing 378 8.5.7.2. Planetary Gears 379 8.5.8. Emergency Repairs . 379

8.6. Oil-Supply Systems for Machine Installations . 381 8.6.1. Requirements for Components of Oil-Supply Systems . 381 8.6.1.1. Requirements for Oil Tanks. 381 8.6.1.2. Integrated Oil-Supply Systems . 382 8.6.1.3. Main Oil Pumps . . . . . . . . . . 383 8.6.1.4. Requirements for Auxiliary Oil Pumps 383 8.6.1.5. Requirements for Oil Coolers 385 8.6.1.6. Requirements for Oil Filters. 385 8.6.1.7. Requirements for Fittings . 385 8.6.1.8. Requirements for Oil-Vapour Exhausters 386 8.6.1.9. Requirements for Oil Accumulators. 386 8.6.1.10. Requirements for Pressure-Carrying Oil Pipelines. 387 8.6.2. Supervision and Protection of Oil-Supply Systems 388 8.6.2.1. Supervisory and Protective Equipment for the Oil-Sup-

ply System 388 8.6.2.2. Prevention and Extinction of Oil Fires 389 8.6.3. Commissioning of Oil-Supply Systems 391 8.6.4. Inspection and Revision of Oil-Supply Systems. 392

8.7. Diesel Engines . 394 8.7.1. Planning, Design, Manufacture and Assembly of Diesel

Engines. 394 8.7.2. Operation of Diesel Engines . 398 8.7.3. Revision of Diesel Engines 400

XIV Contents

8.8. 8.8.1.

8.8.1.1. 8.8.1.2. 8.8.1.3. 8.8.1.4. 8.8.1.5. 8.8.1.6. 8.8.1.7.

8.9. 8.9.1.

8.9.2.

8.9.3.

8.9.4.

8.10. 8.10.1. 8.10.2.

8.10.3.

8.10.4.

Printing Machines . . . . . . . . . . . . . . . . 405 Loss-Prevention Guidelines for Users of Printing Ma-chines. . . . . . . . . . . . . . . . 405 General Guidelines for Loss Prevention . 405 Operation of Printing Machines . . . . 405 Lubrication of Printing Machines. . . . 407 Maintenance and Cleaning of Printing Machines 407 Maintenance of Formes. . . . . . . . . . 408 Overhaul of Printing Machines. . . . . . . 408 Protection of Printing Machines against Fire. 409

Frame Saws. . . . . . . . . . . . . . . 410 Guidelines for Loss Prevention during Planning and De-sign .................. ' .... 410 Guidelines for Loss Prevention during Manufacture, As-sembly and Commissioning ............ 413 Guidelines for Loss Prevention by the User of Frame Saws. . . . . . . . . . . 413 Guidelines for Repair Work. . . . . 416

Chipboard Presses . . . . . . . . . 418 Loss Prevention by the Manufacturer . 420 Guidelines for Loss Prevention during the Erection of Chipboard Presses . . . . . . . . . . . . . . . . 421 Guidelines for Loss Prevention by the User of Chip­board Presses . . . . . . . . 421 Revision of Chipboard Presses. . . . . . . . . . . 422