Contents
Acknowledgments
Chapter 1 Introduction: Why Use Best Maintenance
Repair Practices? 1
Chapter 2 Fundamental Requirements of Effective
Preventive/Predictive 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 120
Chapter 8 Compressors 133
Chapter 9 Control Valves 180
Chapter 10 Conveyors 203
Chapter 11 Couplings 215
Chapter 12 Dust Collectors 245
Chapter 13 Fans, Blowers, and Fluidizers 261
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 and Seals 361
Chapter 20 Precision Measurement 386
Chapter 21 Pumps 395
Chapter 22 Steam Traps 432
Chapter 23 V-Belt Drives 441
Chapter 24 Maintenance Welding 460
Fundamental Requirements of
Effective Maintenance
Effective maintenance is not magic, nor is it dependent on exotic technolo�gies or expensive instruments or systems. Instead, it is dependent on doing simple, basic tasks that will result in reliable plant systems. These basics include:
Inspections
Careful inspection, which can be done without “tearing down” the machine,saves both technician time and exposure of the equipment to possible dam�age. Rotating components find their own best relationship to surrounding components. For example, piston rings in an engine or compressor cylin�der quickly wear to the cylinder wall configuration. If they are removed for inspection, chances are that they will not easily fit back into the same pat�tern. As a result, additional wear will occur, and the rings will have to be replaced much sooner than if they were left intact and performance-tested for pressure produced and metal particles in the lubricating oil.
Human Senses
We humans have a great capability for sensing unusual sights, sounds,smells, tastes, vibrations, and touches. Every maintenance manager shouldake a concerted effort to increase the sensitivity of his own and that should personnel’s human senses. Experience is generally the best teacher. Often,however, we experience things without knowing what we are experiencing.
A few hours of training in what to look for could have high payoff.Human senses are able to detect large differences but are generally notsensitive to small changes. Time tends to have a dulling effect. Have you ever tried to determine if one color was the same as another without having a sample of each to compare side by side? If you have, you will understand the need for standards. A standard is any example that can be compared to the existing situation as a measurement. Quantitative specifications, photo�graphs, recordings, and actual samples should be provided. The critical parameters should be clearly marked on them with displays as to what is good and what is bad.
The Industrial Machinery Repair Best Maintenance Practices Pocket Guide is an essential resource for maintenance technicians, engineers, and plant managers. This concise yet comprehensive guide is designed to support professionals in maintaining and repairing industrial machinery effectively, minimizing downtime, and extending equipment lifespan. Here's an overview of what the guide typically covers:
Key Features of the Pocket Guide
Preventive Maintenance (PM):
- Details on establishing regular maintenance schedules.
- Guidelines for inspections, lubrication, and routine adjustments.
- Checklists to identify wear, corrosion, and other early warning signs.
Predictive Maintenance (PdM):
- Insights into using modern diagnostic tools like vibration analysis, thermography, and ultrasonic testing.
- Tips on monitoring equipment conditions to predict potential failures.
Troubleshooting Techniques:
- Step-by-step methods for diagnosing mechanical, electrical, and hydraulic issues.
- Common fault codes and their resolutions.
- Logical flowcharts to streamline repair processes.
Safety Practices:
- Emphasis on Lockout/Tagout (LOTO) procedures.
- Personal Protective Equipment (PPE) requirements for repair tasks.
- Risk assessment strategies for hazardous equipment.
Tool and Spare Parts Management:
- Recommendations on maintaining an organized inventory of tools and critical spares.
- Guidelines for selecting quality replacement parts to ensure machine reliability.
Lubrication Best Practices:
- Information on selecting the correct lubricants for different machinery.
- Dos and don’ts for grease and oil application.
- Best practices for avoiding contamination.
Documentation and Record-Keeping:
- Importance of logging maintenance activities for compliance and performance tracking.
- Examples of efficient record-keeping formats.
Training and Skills Development:
- Encouragement of regular training for maintenance staff.
- Highlighting the importance of staying updated on industry standards and emerging technologies.
Benefits of Using the Guide
- Efficiency: Simplifies the maintenance process, ensuring that tasks are performed correctly and on schedule.
- Reduced Downtime: Proactive practices minimize unexpected breakdowns.
- Cost Savings: Helps avoid expensive repairs or replacements by catching issues early.
- Improved Safety: Promotes a safer work environment for maintenance personnel.
The Industrial Machinery Repair Best Maintenance Practices Pocket Guide is a valuable tool for anyone involved in the upkeep of industrial equipment, helping facilities achieve peak operational efficiency.
