Industrial machinery repair: best maintenance practices pocket guide

Ricky Smith, R. Keith Mobley President and CEO of Integrated Systems Inc.0750676213, 9780750676212, 9780080478470

Industrial Machinery Repair provides a practical reference for practicing plant engineers, maintenance supervisors, physical plant supervisors and mechanical maintenance technicians. It focuses on the skills needed to select, install and maintain electro-mechanical equipment in a typical industrial plant or facility. The authors focuses on “Best Maintenance Repair Practices” necessary for maintenance personnel to keep equipment operating at peak reliability and companies functioning more profitably through reduced maintenance costs and increased productivity and capacity. A number of surveys conducted in industries throughout the United States have found that 70% of equipment failures are self-induced. If the principles and techniques in this book are followed, it will result in a serious reduction in “self induced failures”. In the pocketbook format, this reference material can be directly used on the plant floor to aid in effectively performing day-to-day duties. Data is presented in a concise, easily understandable format to facilitate use in the adverse conditions associated with the plant floor. Each subject is reduced to it simplest terms so that it will be suitable for the broadest range of users. Since this book is not specific to any one type of industrial plant and is useful in any type of facility. ·The new standard reference book for industrial and mechanical trades ·Accessible pocketbook format facilitates on-the-job use ·Suitable for all types of plant facilities

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Table of contents :
Contents……Page 6
Acknowledgments……Page 8
Contents……Page 14
Acknowledgments……Page 16
“Only Permanent Repairs Made Here”……Page 18
Preventive and Predictive Maintenance ( PPM)……Page 24
2 Fundamental Requirements of Effective Preventive/Predictive Maintenance……Page 27
Fundamental Requirements of Effective Maintenance……Page 28
Definition of a Skills Assessment……Page 43
Knowledge Area: Safety……Page 44
Knowledge Area: Lubrication……Page 48
Knowledge Area: Bearings……Page 51
Knowledge Area: Chain Drives……Page 54
Knowledge Area: Belt Drives……Page 58
Knowledge Area: Hydraulics……Page 60
Knowledge Area: Couplings……Page 63
Introduction 4……Page 67
The Risk: Performing a Risk Assessment ( the Preventive Management Tool)……Page 68
Lockout/Tagout/Tryout……Page 70
Manual Lifting Rules……Page 71
Machine Guarding……Page 72
Sources of Vibration due to Mechanical Imbalance……Page 74
Theory of Imbalance……Page 77
Balancing……Page 81
Types of Movement……Page 88
Commonly Used Bearing Types……Page 94
Bearing Materials……Page 116
Lubrication……Page 118
Installation and General Handling Precautions……Page 121
Bearing Failures, Deficiencies, and Their Causes……Page 128
Chain Drives……Page 137
Chain Selection……Page 138
Chain Installation……Page 140
Power Train Formulas……Page 143
Chain Length……Page 145
Chain Speed……Page 146
Preventive Maintenance Procedures……Page 148
Centrifugal……Page 150
Performance……Page 154
Positive Displacement……Page 157
Reciprocating……Page 165
Troubleshooting 8……Page 177
Process……Page 197
Fluid Power……Page 207
Troubleshooting 9……Page 217
Pneumatic……Page 220
Mechanical……Page 222
Coupling Types……Page 232
Coupling Selection……Page 244
Installation……Page 247
Lubrication and Maintenance……Page 250
Keys, Keyways, and Keyseats……Page 253
Determining Keyway Depth and Width……Page 254
Keyway Manufacturing Tolerances……Page 255
Key Stress Calculations……Page 256
Shaft Stress Calculations……Page 260
Baghouses……Page 262
Cyclone Separators……Page 270
Troubleshooting 12……Page 277
Centrifugal Fans……Page 278
Fluidizers……Page 292
Centrifugal Fans……Page 293
Blowers or Positive-Displacement Fans……Page 297
Start/stop Operation……Page 299
Spur Gears……Page 300
Pitch Diameter and Center Distance……Page 303
Diametrical Pitch and Measurement……Page 305
Pitch Calculations……Page 308
Backlash……Page 311
Other Gear Types……Page 312
Troubleshooting 14……Page 326
Hydraulic Troubleshooter……Page 331
General Maintenance Person……Page 332
Best Maintenance Hydraulic Repair Practices……Page 333
Preventive Maintenance……Page 335
Measuring Success……Page 338
Recommended Maintenance Modifications……Page 340
“The Foundation of Equipment Maintainability”……Page 344
Lubrication Theory……Page 345
Properties of Oil……Page 349
Best Maintenance Lubrication Practices……Page 363
Foundation……Page 365
Leveling and Elevation……Page 366
Before Mounting……Page 368
Machinery Mounts……Page 369
Configuration……Page 370
Performance……Page 372
Installation……Page 374
Operating Methods……Page 375
Troubleshooting 18……Page 376
Fundamentals……Page 378
Mechanical Seal Designs……Page 384
Installation Procedures……Page 386
Troubleshooting 19……Page 400
Outside Micrometer……Page 403
Standards……Page 404
Vernier Scale……Page 405
Inside Micrometer……Page 406
Dial Caliper……Page 407
Performance Exercises……Page 408
Centrifugal Pumps……Page 412
Summary……Page 423
Positive Displacement Pumps……Page 425
Summary 21……Page 435
Cavitation……Page 436
Recirculation……Page 437
Troubleshooting 21……Page 440
Configuration 22……Page 449
Performance 22……Page 454
Installation 22……Page 455
Troubleshooting 22……Page 457
Introduction 23……Page 458
Belt Selection……Page 460
Power Train Formulas……Page 463
Belt Maintenance……Page 468
Shaft and Sheave Alignment……Page 470
Belt Installation……Page 472
Belt Storage……Page 474
Preventive Maintenance Procedures……Page 475
Introduction 24……Page 477
Shielded Metal ArcWelding (SMAW) “ StickWelding”……Page 480
Flux-Cored ArcWelding (FCAW)……Page 483
Gas-Shielded Metal ArcWelding (GMAW)……Page 488
Gas Tungsten ArcWelding (GTAW)……Page 493
Oxyacetylene Cutting……Page 510
Air-Carbon Arc Cutting and Gouging……Page 511
Plasma Arc Cutting……Page 516
Welding Procedures……Page 518
Plasma ArcWelding……Page 519
Base Metals……Page 520
Control of Distortion……Page 526
Special Applications……Page 527
Selection and Maintenance of Equipment……Page 540
Installation of Equipment……Page 545
Equipment Operation and Maintenance……Page 546
Safety……Page 555
Index……Page 558