Introduction to Predictive Maintenance

By: R. Keith Mobley

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Hardcover | 26 September 2002 | Edition Number 2

At a Glance

Hardcover
456 Pages

Edition Type
Revised

Dimensions(cm)
23.5 x 15.88 x 2.54

Hardcover

RRP $183.95

$168.75

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This second edition of An Introduction to Predictive Maintenance helps plant, process, maintenance and reliability managers and engineers to develop and implement a comprehensive maintenance management program, providing proven strategies for regularly monitoring critical process equipment and systems, predicting machine failures, and scheduling maintenance accordingly.

Since the publication of the first edition in 1990, there have been many changes in both technology and methodology, including financial implications, the role of a maintenance organization, predictive maintenance techniques, various analyses, and maintenance of the program itself. This revision includes a complete update of the applicable chapters from the first edition as well as six additional chapters outlining the most recent information available.

Having already been implemented and maintained successfully in hundreds of manufacturing and process plants worldwide, the practices detailed in this second edition of An Introduction to Predictive Maintenance will save plants and corporations, as well as U.S. industry as a whole, billions of dollars by minimizing unexpected equipment failures and its resultant high maintenance cost while increasing productivity.

A comprehensive introduction to a system of monitoring critical industrial equipment
Optimize the availability of process machinery and greatly reduce the cost of maintenance
Provides the means to improve product quality, productivity and profitability of manufacturing and production plants

Industry Reviews

"Mobley has written several books on individual predictive technologies and is a leading consultant on industrial maintenance practices. His latest book will satisfy anyone who wants to understand and begin implementation of predictive maintenance." --Plant Engineering, March 2003 "The primary audience for this book will be plant managers, process engineers, and managers of maintenance operations, but the book provides useful backround information for anyone interested in the maintenance issues involved in keeping manufacturing operations running efficiently." --JCT Coatings Tech, March 2004

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Non-Fiction Industry & Industrial Studies Industrial Relations, Health & Safety Health & Safety Issues Engineering & Technology Technology in General Engineering in General Instruments & Instrumentation Engineering Industrial Chemistry & Manufacturing Technologies Business & Management Management & Management Techniques Management of Specific Areas

Management of Real Estate

Impact of Maintenance	p. 1
Maintenance Management Methods	p. 2
Run-to-Failure Management	p. 2
Preventive Maintenance	p. 3
Predictive Maintenance	p. 4
Other Maintenance Improvement Methods	p. 6
Optimizing Predictive Maintenance	p. 10
Culture Change	p. 10
Proper Use of Predictive Technologies	p. 12
It Takes More Than Effective Maintenance	p. 17
Small Plants	p. 20
Large Plants	p. 21
Financial Implications and Cost Justification	p. 23
Assessing the Need for Condition Monitoring	p. 24
Cost Justification	p. 25
Poor-Quality Product as Plant Performance Deteriorates	p. 27
Increased Cost of Fuel and Other Consumables as the Plant Condition Deteriorates	p. 27
Cost of Current Maintenance Strategy	p. 27
Justifying Predictive Maintenance	p. 29
Installation Cost	p. 29
Operating Cost	p. 31
Conclusions	p. 31
Economics of Preventive Maintenance	p. 32
Benefits versus Costs	p. 33
Role of Maintenance Organization	p. 43
Maintenance Mission	p. 43
Optimum Availability	p. 43
Optimum Operating Condition	p. 44
Maximum Utilization of Maintenance Resources	p. 44
Optimum Equipment Life	p. 44
Minimum Spares Inventory	p. 44
Ability to React Quickly	p. 44
Evaluation of the Maintenance Organization	p. 44
Three Types of Maintenance	p. 45
Designing a Predictive Maintenance Program	p. 50
Failure Data	p. 51
Improving Equipment Reliability	p. 52
Improvement Process	p. 54
Failures That Can Be Prevented	p. 55
Maintenance to Prevent Failures	p. 55
Personnel	p. 56
Service Teams	p. 56
How to Start	p. 58
Benefits of Predictive Maintenance	p. 60
Primary Uses of Predictive Maintenance	p. 61
As a Maintenance Management Tool	p. 61
As a Plant Optimization Tool	p. 69
As a Reliability Improvement Tool	p. 69
The Difference	p. 70
Benefits of a Total-Plant Predictive Program	p. 70
Machine-Train Monitoring Parameters	p. 74
Drivers	p. 75
Electric Motors	p. 75
Steam Turbines	p. 77
Intermediate Drives	p. 78
Chains	p. 78
Couplings	p. 79
Gearboxes	p. 81
V-Belts	p. 83
Driven Components	p. 86
Compressors	p. 86
Fans	p. 92
Generators	p. 93
Process Rolls	p. 94
Pumps	p. 95
Predictive Maintenance Techniques	p. 99
Vibration Monitoring	p. 99
Technology Limitations	p. 100
Thermography	p. 105
Types of Thermographic Systems	p. 106
Infrared Thermography Safety	p. 107
Tribology	p. 108
Lube Oil Analysis	p. 108
Wear Particle Analysis	p. 109
Limitations of Tribology	p. 109
Visual Inspections	p. 111
Ultrasonics	p. 111
Other Techniques	p. 112
Electrical Testing	p. 112
Vibration Monitoring and Analysis	p. 114
Vibration Analysis Applications	p. 114
Predictive Maintenance	p. 115
Acceptance Testing	p. 115
Quality Control	p. 116
Loose or Foreign Parts Detection	p. 116
Noise Control	p. 116
Leak Detections	p. 116
Aircraft Engine Analyzers	p. 116
Machine Design and Engineering	p. 116
Vibration Analysis Overview	p. 117
Theoretical Vibration Profiles	p. 117
Actual Vibration Profiles	p. 118
Interpretation of Vibration Data	p. 120
Vibration-Measuring Equipment	p. 121
Vibration Sources	p. 122
Rotating Machinery	p. 122
Reciprocating and/or Linear-Motion Machinery	p. 124
Vibration Theory	p. 125
Periodic Motion	p. 125
Measurable Parameters	p. 129
Machine Dynamics	p. 132
Mass, Stiffness, and Damping	p. 133
Degrees of Freedom	p. 142
Vibration Data Types and Formats	p. 146
Data Types	p. 146
Data Formats	p. 150
Data Acquisition	p. 152
Vibration Detectors: Transducers and Cables	p. 152
Data Measurements	p. 156
Transducer Mounting Techniques	p. 157
Acquiring Data	p. 160
Vibration Analyses Techniques	p. 161
Trending	p. 161
Comparative Analysis	p. 162
Signature Analysis	p. 164
Abbreviations	p. 165
Glossary	p. 166
References	p. 171
Thermography	p. 172
Infrared Basics	p. 172
Types of Infrared Instruments	p. 174
Infrared Thermometers	p. 174
Line Scanners	p. 175
Infrared Imaging	p. 175
Training	p. 175
Basic Infrared Theory	p. 176
Electromagnetic Spectrum	p. 176
Heat Transfer Concepts	p. 177
Infrared Equipment	p. 178
Infrared Thermography Safety	p. 179
Infrared Scanning Procedures	p. 179
Types of Infrared Problems	p. 179
Mechanical Looseness	p. 180
Component Failure	p. 180
Common Problems Found and What to Scan	p. 180
Abbreviations	p. 183
Glossary	p. 183
Electrical Terminology	p. 187
Materials List	p. 193
Tribology	p. 202
Lubricating Oil Analysis	p. 203
Oil Analysis Tests	p. 203
Wear Particle Analysis	p. 205
Ferrography	p. 207
Oil Analysis Costs and Uses	p. 207
Setting Up an Effective Program	p. 208
Equipment Audit	p. 209
Lubricant Audit Process	p. 211
Baseline Signature	p. 212
Monitoring	p. 213
Program Evaluation	p. 215
Process Parameters	p. 217
Pumps	p. 218
Centrifugal Pumps	p. 218
Positive-Displacement Pumps	p. 222
Fans, Blowers, and Fluidizers	p. 225
Centrifugal Fans	p. 225
Blowers or Positive-Displacement Fans	p. 228
Conveyors	p. 229
Pneumatic	p. 229
Chain-Type Mechanical	p. 229
Compressors	p. 229
Centrifugal	p. 229
Rotary-Type Positive Displacement	p. 231
Reciprocating Positive Displacement	p. 235
Mixers and Agitators	p. 240
Dust Collectors	p. 240
Baghouses	p. 240
Cyclonic Separators	p. 240
Process Rolls	p. 241
Gearboxes/Reducers	p. 242
Normal Wear	p. 246
Abnormal Wear	p. 246
Steam Traps	p. 249
Inverters	p. 249
Control Valves	p. 249
Seals and Packing	p. 251
Mechanical Seals	p. 251
Packed Boxes	p. 254
Ultrasonics	p. 256
Ultrasonic Applications	p. 256
Airborne Noise Analysis	p. 256
Leak Detection	p. 257
Materials Testing	p. 257
Types of Ultrasonic Systems	p. 257
Limitations	p. 258
Visual Inspection	p. 259
Visual Inspection Methods	p. 260
Human Senses	p. 261
Sensors	p. 261
Spectrometric Oil Analysis	p. 263
Thresholds	p. 263
Operating Dynamics Analysis	p. 267
It's Not Predictive Maintenance	p. 267
Technology Limitations	p. 268
Limitation to Maintenance Issues	p. 268
Influence of Process Variables	p. 269
Training Limitations	p. 270
Understanding Machine Dynamics	p. 271
Interpreting Operating Dynamics	p. 281
Failure-Mode Analysis	p. 285
Common General Failure Modes	p. 286
Critical Speeds	p. 286
Imbalance	p. 288
Mechanical Looseness	p. 290
Misalignment	p. 293
Modulations	p. 294
Process Instability	p. 296
Resonance	p. 297
Failure Modes by Machine-Train Component	p. 301
Bearings: Rolling Element	p. 302
Bearings: Sleeve (Babbitt)	p. 303
Chains and Sprockets	p. 304
Gears	p. 306
Jackshafts and Spindles	p. 309
Process Rolls	p. 312
Shaft	p. 318
V-Belts	p. 318
Establishing a Predictive Maintenance Program	p. 325
Goals, Objectives, and Benefits	p. 325
Functional Requirements	p. 326
Management Support	p. 327
Dedicated and Accountable Personnel	p. 327
Efficient Data Collection and Analysis Procedures	p. 327
Viable Database	p. 328
Selling Predictive Maintenance Programs	p. 330
Six Keys to Success	p. 330
Selecting a Predictive Maintenance System	p. 334
Fundamental System Requirements	p. 335
Database Development	p. 343
Establishing Data Acquisition Frequency	p. 343
Setting Up Analysis Parameters	p. 344
Setting Boundaries for Signature Analysis	p. 344
Defining Alert and Alarm Limits	p. 345
Selecting Transducers	p. 346
Getting Started	p. 348
Training	p. 349
Technical Support	p. 350
A Total-Plant Predictive Maintenance Program	p. 352
The Optimum Predictive Maintenance Program	p. 353
Predictive Technologies	p. 353
The Optimum Predictive Maintenance System	p. 355
Predictive Is Not Enough	p. 356
Effective Planning and Scheduling	p. 356
Preventive Maintenance Tasks	p. 357
Motivation	p. 373
Record Keeping	p. 380
Special Concerns	p. 383
Conclusion	p. 387
Maintaining the Program	p. 389
Trending Techniques	p. 389
Analysis Techniques	p. 390
Broadband Analysis	p. 390
Narrowband Analysis	p. 391
Root-Cause Failure Analysis	p. 392
Additional Training	p. 392
Technical Support	p. 393
Contract Predictive Maintenance Programs	p. 393
World-Class Maintenance	p. 394
What Is World-Class Maintenance?	p. 394
Five Fundamentals of World-Class Performance	p. 395
Improving Equipment Effectiveness	p. 395
Involving Operators in Daily Maintenance	p. 395
Improving Maintenance Efficiency and Effectiveness	p. 396
Educating and Training	p. 396
Designing and Managing Equipment for Maintenance Prevention	p. 396
Competitive Advantage	p. 396
Focus on Quality	p. 397
Focus on Maintenance	p. 398
Overall Equipment Effectiveness	p. 402
Elements of Effective Maintenance	p. 406
Commitment	p. 406
Cost	p. 408
Culture	p. 408
Customer Focus	p. 409
Management Commitment	p. 410
Change	p. 410
Management Philosophy	p. 410
Risk Taking	p. 410
Information	p. 410
Roles	p. 410
Teamwork	p. 410
Strategy	p. 410
Tasks	p. 411
Decision Making	p. 411
Stability	p. 411
Innovation	p. 411
Trust	p. 411
Problem Solving	p. 411
Responsibilities	p. 412
Optimum Availability	p. 412
Optimum Operating Condition	p. 412
Maximum Utilization of Maintenance Resources	p. 412
Optimum Equipment Life	p. 413
Minimum Spares Inventory	p. 413
Ability to React Quickly	p. 413
Three Types of Maintenance	p. 413
Corrective Maintenance	p. 413
Preventive Maintenance	p. 414
Maintenance Improvement	p. 415
Advantages and Disadvantages	p. 416
Supervision	p. 419
Functions of Supervision	p. 419
Characteristics of Effective Supervision	p. 421
Working without Supervision	p. 422
Standard Procedures	p. 424
Reasons for Not Using Standard Procedures	p. 424
Creating Standard Procedures	p. 425
Standard Procedures Are Not Enough	p. 426
Workforce Development	p. 426
Lack of Basic Skills	p. 426
Workforce Maturity	p. 426
Unskilled Workforce Pool	p. 427
Manufacturing Extension Partnership	p. 427
U.S. Department of Labor Employment and Training Administration	p. 428
Apprenticeship Programs	p. 428
Training Grants	p. 429
America's Job Bank	p. 432
Table of Contents provided by Syndetics. All Rights Reserved.

Introduction to Predictive Maintenance

At a Glance

Hardcover

Industry Reviews

Shipping

How to return your order

Defective items

You Can Find This Book In

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