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Industrial Machinery Repair: Best Maintenance Practices Pocket Guide 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, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Recognizing the importance of preserving what has been written, Elsevier-Science prints its books on acid-free paper whenever possible. 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 0-7506-7621-3 (pbk : alk. paper) 1. Machinery–Maintenance and repair. 2. Industrial equipment–Maintenance and repair. I. Mobley, Keith. II. Title. TJ153.S6355 2003 621.8
16–dc21 2003040435 British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. The publisher offers special discounts on bulk orders of this book. For information, please contact: Elsevier Science Manager of Special Sales 200 Wheeler Road, 6th Floor Burlington, MA 01803 Tel: 781-313-4700 Fax: 781-313-4882 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 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 vi Contents 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 Appendix A 539 Index 541 Acknowledgments Ricky Smith wants to offer his thanks to the following individuals who contributed to the writing of this book. Bruce Hawkins, Life Cycle Engineering; Darryl Meyers, former U.S. Army Warrant Officer; Steve Lindborg, Chemical Lime Company; Robby Smith (his brother), International Paper Corporation; and J.E. Hinkel, Lincoln Electric Company. Ricky also wants to thank Life Cycle Engineering, where he is currently employed, for the opportunity to write this book; Alumax–Mt. Holly—currently Alcoa– Mt. Holly—where he worked as a maintenance technician, for all the training and the chance to expand his knowledge; and Dr. John Williams, who always believed in him. Industrial Machinery Repair: Best Maintenance Practices Pocket Guide