Introduction to Predictive Maintenance (eBook)

Front Cover 1
AN INTRODUCTION TO PREDICTIVE MAINTENANCE 4
Copyright Page 5
Contents 6
Chapter 1. Impact of Maintenance 14
1.1 Maintenance Management Methods 15
1.2 Optimizing Predictive Maintenance 23
Chapter 2. Financial Implications and Cost Justification 36
2.1 Assessing the Need for Condition Monitoring 37
2.2 Cost Justification 38
2.3 Justifying Predictive Maintenance 42
2.4 Economics of Preventive Maintenance 45
Chapter 3. Role of Maintenance Organization 56
3.1 Maintenance Mission 56
3.2 Evaluation of the Maintenance Organization 57
3.3 Designing a Predictive Maintenance Program 63
Chapter 4. Benefits of Predictive Maintenance 73
4.1 Primary Uses of Predictive Maintenance 74
Chapter 5. Machine-Train Monitoring Parameters 87
5.1 Drivers 88
5.2 Intermediate Drives 91
5.3 Driven Components 99
Chapter 6. Predictive Maintenance Techniques 112
6.1 Vibration Monitoring 112
6.2 Thermography 118
6.3 Tribology 121
6.4 Visual Inspections 124
6.5 Ultrasonics 124
6.6 Other Techniques 125
Chapter 7. Vibration Monitoring and Analysis 127
7.1 Vibration Analysis Applications 127
7.2 Vibration Analysis Overview 130
7.3 Vibration Sources 135
7.4 Vibration Theory 138
7.5 Machine Dynamics 145
7.6 Vibration Data Types and Formats 159
7.7 Data Acquisition 165
7.8 Vibration Analyses Techniques 174
Appendix 7.1 Abbreviations 178
Appendix 7.2 Glossary 179
Appendix 7.3 References 184
Chapter 8. Thermography 185
8.1 Infrared Basics 185
8.2 Types of Infrared Instruments 187
8.3 Training 188
8.4 Basic Infrared Theory 189
8.5 Infrared Equipment 191
8.6 Infrared Thermography Safety 192
8.7 Infrared Scanning Procedures 192
8.8 Types of Infrared Problems 192
Appendix 8.1 Abbreviations 196
Appendix 8.2 Glossary 196
Appendix 8.3 Electrical Terminology 200
Appendix 8.4 Materials List 206
Chapter 9. Tribology 215
9.1 Lubricating Oil Analysis 216
9.2 Setting Up an Effective Program 221
Chapter 10. Process Parameters 230
10.1 Pumps 231
10.2 Fans, Blowers, and Fluidizers 238
10.3 Conveyors 242
10.4 Compressors 242
10.5 Mixers and Agitators 253
10.6 Dust Collectors 253
10.7 Process Rolls 254
10.8 Gearboxes/Reducers 255
10.9 Steam Traps 262
10.10 Inverters 262
10.11 Control Valves 262
10.12 Seals and Packing 264
Chapter 11. Ultrasonics 269
11.1 Ultrasonic Applications 269
11.2 Types of Ultrasonic Systems 270
11.3 Limitations 271
Chapter 12. Visual Inspection 272
12.1 Visual Inspection Methods 273
12.2 Thresholds 276
Chapter 13. Operating Dynamics Analysis 280
13.1 It’s Not Predictive Maintenance 280
Chapter 14. Failure-Mode Analysis 298
14.1 Common General Failure Modes 299
14.2 Failure Modes by Machine-Train Component 314
Chapter 15. Establishing a Predictive Maintenance Program 338
15.1 Goals, Objectives, and Benefits 338
15.2 Functional Requirements 339
15.3 Selling Predictive Maintenance Programs 343
15.4 Selecting a Predictive Maintenance System 347
15.5 Database Development 356
15.6 Getting Started 361
Chapter 16. A Total-Plant Predictive Maintenance Program 365
16.1 The Optimum Predictive Maintenance Program 366
16.2 Predictive Is Not Enough 369
16.3 Conclusion 400
Chapter 17. Maintaining the Program 402
17.1 Trending Techniques 402
17.2 Analysis Techniques 403
17.3 Additional Trainnig 405
17.4 Technical Support 406
17.5 Contract Predictive Maintenance Programs 406
Chapter 18. World-Class Maintenance 407
18.1 What Is World-Class Maintenance? 407
18.2 Five Fundamentals of World-Class Performance 408
18.3 Competitive Advantage 409
18.4 Focus on Quality 410
18.5 Focus on Maintenance 411
18.6 Overall Equipment Effectiveness 415
18.7 Elements of Effective Maintenance 419
18.8 Responsibilities 425
18.9 Three Types of Maintenance 426
18.10 Supervision 432
18.11 Standard Procedures 437
18.12 Workforce Development 439