[...]... Maintenance 10 Chapter 3 Maintenance Skills Assessment 26 Chapter 4 Safety First, Safety Always 50 Chapter 5 Rotor Balancing 57 Chapter 6 Bearings 71 Chapter 7 Chain Drives 12 0 Chapter 8 Compressors 13 3 Chapter 9 Control Valves 18 0 Chapter 10 Conveyors 203 Chapter 11 Couplings 215 Chapter 12 Dust Collectors 245 Chapter 13 Fans, Blowers, and Fluidizers 2 61 Chapter 14 Gears and Gearboxes 283 Chapter 15 Hydraulics... Library of Congress Cataloging-in-Publication Data Smith, Ricky Industrial machinery repair : best maintenance practices pocket guide / Ricky Smith and Keith Mobley p cm ISBN 0-7506-76 21- 3 (pbk : alk paper) 1 Machinery Maintenance and repair 2 Industrial equipment–Maintenance and repair I Mobley, Keith II Title TJ153.S6355 2003 6 21. 8 16 –dc 21 2003040435 British Library Cataloguing-in-Publication Data A... Road, 6th Floor Burlington, MA 018 03 Tel: 7 81- 313 -4700 Fax: 7 81- 313 -4882 For information on all Butterworth–Heinemann publications available, contact our World Wide Web home page at: http://www.bh.com 10 9 8 7 6 5 4 3 2 1 Printed in the United States of America Contents Acknowledgments Chapter 1 Chapter 2 Introduction: Why Use Best Maintenance Repair Practices? vii 1 Fundamental Requirements of Effective... and Gearboxes 283 Chapter 15 Hydraulics 314 Chapter 16 Lubrication 327 Chapter 17 Machinery Installation 348 Chapter 18 Mixers and Agitators 353 Chapter 19 Packing and Seals 3 61 vi Contents Chapter 20 Precision Measurement 386 Chapter 21 Pumps 395 Chapter 22 Steam Traps 432 Chapter 23 V-Belt Drives 4 41 Chapter 24 Maintenance Welding 460 Appendix A 539 Index 5 41 Acknowledgments Ricky Smith wants to offer... by 20–80% 10 0% 20 vs 1 Premature coupling failure Premature bearing and seal failure in motor and driven unit Excessive energy loss 10 0% 7 vs 1 Premature belt failures through rapid belt wear or total belt failure Premature bearing failure of driven and driver unit Belt creeping or slipping causing speed variation without excessive noise Motor shaft breakage 10 0% 20 vs 1 Continued Table 1. 1 continued... best maintenance repair practices 4 Management is not supportive, and/or does not understand the consequences of not following the best practices (real understanding must involve a knowledge of how much money is lost to the bottom line) Table 1. 1 Best maintenance repair practices Maintenance task Standard Required best practices Lubricate Bearing 1 2 3 Lubrication interval: time based ± 10 % variance 4... Sticking hydraulic Premature or 10 0% 30 vs 1 unknown hydraulic pump life Sustaining hydraulic competency by maintenance personnel Length of equipment breakdown causes lost production Introduction: Why Use Best Maintenance Repair Practices? 5 MAINTENANCE The act of MAINTAINING MAINTAIN KEEP in an existing state PRESERVE from failure or decline Keep Preserve Protect Figure 1. 1 Maintenance In order to solve... Industrial Machinery Repair: Best Maintenance Practices Pocket Guide Ricky Smith and R Keith Mobley Amsterdam Boston London New York Oxford Paris San Diego San Francisco Singapore Sydney Tokyo Butterworth–Heinemann is an imprint of Elsevier Science Copyright © 2003, Elsevier Science (USA) All rights reserved No part of this publication may be reproduced,... must be willing to admit to a maintenance problem and actively pursue a solution You may be asking, what are the “Best Maintenance Repair Practices”? Here are a few that maintenance personnel must know (See Table 1. 1.) Looking through this abbreviated Best Maintenance Repair Practices table, try to determine whether your company follows these guidelines The results will very likely surprise you You... the organization’s basic beliefs, the reasons why an organization does not follow these best practices in the repair of their equipment must be identified “Only Permanent Repairs Made Here” A few of the most common reasons that a plant does not follow best maintenance repair practices are: 1 Maintenance is totally reactive and does not follow the definition of maintenance, which is to protect, preserve, . Bearings 71 Chapter 7 Chain Drives 12 0 Chapter 8 Compressors 13 3 Chapter 9 Control Valves 18 0 Chapter 10 Conveyors 203 Chapter 11 Couplings 215 Chapter 12 Dust Collectors 245 Chapter 13 Fans,. Bearings 71 Chapter 7 Chain Drives 12 0 Chapter 8 Compressors 13 3 Chapter 9 Control Valves 18 0 Chapter 10 Conveyors 203 Chapter 11 Couplings 215 Chapter 12 Dust Collectors 245 Chapter 13 Fans,. Fluidizers 2 61 Chapter 14 Gears and Gearboxes 283 Chapter 15 Hydraulics 314 Chapter 16 Lubrication 327 Chapter 17 Machinery Installation 348 Chapter 18 Mixers and Agitators 353 Chapter 19 Packing