AnIntroductiontoPredictiveMaintenance,SecondEdition资料下载.pdf

1、AN INTRODUCTION TOPREDICTIVE MAINTENANCESecond EditionThis Page Intentionally Left BlankAN INTRODUCTIONTO PREDICTIVEMAINTENANCESecond EditionR.Keith MobleyAmsterdamLondonNew YorkOxfordParisTokyoBostonSan DiegoSan FranciscoSingaporeSydneyButterworth-Heinemann is an imprint of Elsevier Science.Copyrig

2、ht 2002,Elsevier Science（USA）.All rights reserved.No part of this publication may be reproduced,stored in a retrieval system,or transmitted inany form or by any means,electronic,mechanical,photocopying,recording,or otherwise,without the prior written permission of the publisher.Recognizing the impor

3、tance of preserving what has been written,Elsevier-Science prints itsbooks on acid-free paper whenever possible.Library of Congress Cataloging-in-Publication DataMobley,R.Keith,1943.An introduction to predictive maintenance/R.Keith Mobley.2nd ed.p.cm.Includes index.ISBN 0-7506-7531-4（alk.paper）1.Pla

4、nt maintenanceManagement.I.Title.TS192.M624 2002658.202dc212001056670British Library Cataloguing-in-Publication DataA 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:#Manager of Spe

5、cial SalesElsevier Science225 Wildwood AvenueWoburn,MA 01801-2041Tel:#781-904-2500Fax:#781-904-2620For information on all Butterworth-Heinemann publications available,contact our World WideWeb home page at:#http:#/10 9 8 7 6 5 4 3 2 1Printed in the United States of AmericaCONTENTSChapter 1Impact of

6、Maintenance11.1Maintenance Management Methods21.1.1Run-to-Failure Management21.1.2Preventive Maintenance31.1.3Predictive Maintenance41.1.4Other Maintenance Improvement Methods61.2Optimizing Predictive Maintenance101.2.1Culture Change101.2.2Proper Use of Predictive Technologies121.2.3It Takes More Th

7、an Effective Maintenance171.2.4Small Plants201.2.5Large Plants21Chapter 2Financial Implications and Cost Justification232.1Assessing the Need for Condition Monitoring242.2Cost Justification252.2.1Poor-Quality Product as Plant Performance Deteriorates272.2.2Increased Cost of Fuel and Other Consumable

8、s as the Plant Condition Deteriorates272.2.3Cost of Current Maintenance Strategy272.3Justifying Predictive Maintenance292.3.1Installation Cost292.3.2Operating Cost312.3.3Conclusions312.4Economics of Preventive Maintenance322.4.1Benefits versus Costs33vChapter 3Role of Maintenance Organization433.1Ma

9、intenance Mission433.1.1Optimum Availability433.1.2Optimum Operating Condition443.1.3Maximum Utilization of Maintenance Resources443.1.4Optimum Equipment Life443.1.5Minimum Spares Inventory443.1.6Ability to React Quickly443.2Evaluation of the Maintenance Organization443.2.1Three Types of Maintenance

10、453.3Designing a Predictive Maintenance Program503.3.1Failure Data513.3.2Improving Equipment Reliability523.3.3Improvement Process543.3.4Failures That Can Be Prevented553.3.5Maintenance to Prevent Failures553.3.6Personnel563.3.7Service Teams563.3.8How to Start58Chapter 4Benefits of Predictive Mainte

11、nance604.1Primary Uses of Predictive Maintenance614.1.1As a Maintenance Management Tool614.1.2As a Plant Optimization Tool694.1.3As a Reliability Improvement Tool694.1.4The Difference704.1.5Benefits of a Total-Plant Predictive Program70Chapter 5Machine-Train Monitoring Parameters745.1Drivers755.1.1E

12、lectric Motors755.1.2Steam Turbines775.2Intermediate Drives785.2.1Chains785.2.2Couplings795.2.3Gearboxes815.2.4V-Belts835.3Driven Components865.3.1Compressors865.3.2Fans925.3.3Generators935.3.4Process Rolls945.3.5Pumps95viAn Introduction to Predictive MaintenanceChapter 6Predictive Maintenance Techn

13、iques996.1Vibration Monitoring996.1.1Technology Limitations1006.2Thermography1056.2.1Types of Thermographic Systems1066.2.2Infrared Thermography Safety1076.3Tribology1086.3.1Lube Oil Analysis1086.3.2Wear Particle Analysis1096.3.3Limitations of Tribology1096.4Visual Inspections1116.5Ultrasonics1116.6

14、Other Techniques1126.6.1Electrical Testing112Chapter 7Vibration Monitoring and Analysis1147.1Vibration Analysis Applications1147.1.1Predictive Maintenance1157.1.2Acceptance Testing1157.1.3Quality Control1167.1.4Loose or Foreign Parts Detection1167.1.5Noise Control1167.1.6Leak Detections1167.1.7Aircr

15、aft Engine Analyzers1167.1.8Machine Design and Engineering1167.2Vibration Analysis Overview1177.2.1Theoretical Vibration Profiles1177.2.2Actual Vibration Profiles1187.2.3Interpretation of Vibration Data1207.2.4Vibration-Measuring Equipment1217.3Vibration Sources1227.3.1Rotating Machinery1227.3.2Reci

16、procating and/or Linear-Motion Machinery1247.4Vibration Theory1257.4.1Periodic Motion1257.4.2Measurable Parameters1297.5Machine Dynamics1327.5.1Mass,Stiffness,and Damping1337.5.2Degrees of Freedom1427.6Vibration Data Types and Formats1467.6.1Data Types1467.6.2Data Formats1507.7Data Acquisition1527.7

17、.1Vibration Detectors:#Transducers and Cables1527.7.2Data Measurements156Contentsvii7.7.3Transducer Mounting Techniques1577.7.4Acquiring Data1607.8Vibration Analyses Techniques1617.8.1Trending1617.8.2Comparative Analysis1627.8.3Signature Analysis164Appendix 7.1 Abbreviations165Appendix 7.2 Glossary1

18、66Appendix 7.3 References171Chapter 8Thermography1728.1Infrared Basics1728.2Types of Infrared Instruments1748.2.1Infrared Thermometers1748.2.2Line Scanners1758.2.3Infrared Imaging1758.3Training1758.4Basic Infrared Theory1768.4.1Electromagnetic Spectrum1768.4.2Heat Transfer Concepts1778.5Infrared Equ

19、ipment1788.6Infrared Thermography Safety1798.7Infrared Scanning Procedures1798.8Types of Infrared Problems1798.8.1Mechanical Looseness1808.8.2Component Failure1808.8.3Common Problems Found and What to Scan180Appendix 8.1 Abbreviations183Appendix 8.2 Glossary183Appendix 8.3 Electrical Terminology187A

20、ppendix 8.4 Materials List193Chapter 9Tribology2029.1Lubricating Oil Analysis2039.1.1Oil Analysis Tests2039.1.2Wear Particle Analysis2059.1.3Ferrography2079.1.4Oil Analysis Costs and Uses2079.2Setting Up an Effective Program2089.2.1Equipment Audit2099.2.2Lubricant Audit Process2119.2.3Baseline Signa

21、ture2129.2.4Monitoring2139.2.5Program Evaluation215viiiAn Introduction to Predictive MaintenanceChapter 10Process Parameters21710.1Pumps21810.1.1Centrifugal Pumps21810.1.2Positive-Displacement Pumps22210.2Fans,Blowers,and Fluidizers22510.2.1Centrifugal Fans22510.2.2Blowers or Positive-Displacement F

22、ans22810.3Conveyors22910.3.1Pneumatic22910.3.2Chain-Type Mechanical22910.4Compressors22910.4.1Centrifugal22910.4.2Rotary-Type Positive Displacement23110.4.3Reciprocating Positive Displacement23510.5Mixers and Agitators24010.6Dust Collectors24010.6.1Baghouses24010.6.2Cyclonic Separators24010.7Process

23、 Rolls24110.8Gearboxes/Reducers24210.8.1Normal Wear24610.8.2Abnormal Wear24610.9Steam Traps24910.10Inverters24910.11Control Valves24910.12Seals and Packing25110.12.1Mechanical Seals25110.12.2Packed Boxes254Chapter 11Ultrasonics25611.1Ultrasonic Applications25611.1.1Airborne Noise Analysis25611.1.2Le

24、ak Detection25711.1.3Materials Testing25711.2Types of Ultrasonic Systems25711.3Limitations258Chapter 12Visual Inspection25912.1Visual Inspection Methods26012.1.1Human Senses26112.1.2Sensors26112.1.3Spectrometric Oil Analysis26312.2Thresholds263ContentsixChapter 13Operating Dynamics Analysis26713.1It

25、s Not Predictive Maintenance26713.1.1Technology Limitations26813.1.2Limitation to Maintenance Issues26813.1.3Influence of Process Variables26913.1.4Training Limitations27013.1.5Understanding Machine Dynamics27113.1.6Interpreting Operating Dynamics281Chapter 14Failure-Mode Analysis28514.1Common Gener

26、al Failure Modes28614.1.1Critical Speeds28614.1.2Imbalance28814.1.3Mechanical Looseness29014.1.4Misalignment29314.1.5Modulations29414.1.6Process Instability29614.1.7Resonance29714.2Failure Modes by Machine-Train Component30114.2.1Bearings:#Rolling Element30214.2.2Bearings:#Sleeve（Babbitt）30314.2.3Ch

27、ains and Sprockets30414.2.4Gears30614.2.5Jackshafts and Spindles30914.2.6Process Rolls31214.2.7Shaft31814.2.8V-Belts318Chapter 15Establishing a Predictive Maintenance Program32515.1Goals,Objectives,and Benefits32515.2Functional Requirements32615.2.1Management Support32715.2.2Dedicated and Accountabl

28、e Personnel32715.2.3Efficient Data Collection and Analysis Procedures32715.2.4Viable Database32815.3Selling Predictive Maintenance Programs33015.3.1Six Keys to Success33015.4Selecting a Predictive Maintenance System33415.4.1Fundamental System Requirements33515.5Database Development34315.5.1Establish

29、ing Data Acquisition Frequency34315.5.2Setting Up Analysis Parameters34415.5.3Setting Boundaries for Signature Analysis34415.5.4Defining Alert and Alarm Limits34515.5.5Selecting Transducers346xAn Introduction to Predictive Maintenance15.6Getting Started34815.6.1Training34915.6.2Technical Support350C

30、hapter 16A Total-Plant Predictive Maintenance Program35216.1The Optimum Predictive Maintenance Program35316.1.1Predictive Technologies35316.1.2The Optimum Predictive Maintenance System35516.2Predictive Is Not Enough35616.2.1Effective Planning and Scheduling35616.2.2Preventive Maintenance Tasks35716.

31、2.3Motivation37316.2.4Record Keeping38016.2.5Special Concerns38316.3Conclusion387Chapter 17Maintaining the Program38917.1Trending Techniques38917.2Analysis Techniques39017.2.1Broadband Analysis39017.2.2Narrowband Analysis39117.2.3Root-Cause Failure Analysis39217.3Additional Training39217.4Technical

32、Support39317.5Contract Predictive Maintenance Programs393Chapter 18World-Class Maintenance39418.1What Is World-Class Maintenance?#39418.2Five Fundamentals of World-Class Performance39518.2.1Improving Equipment Effectiveness39518.2.2Involving Operators in Daily Maintenance39518.2.3Improving Maintenan

33、ce Efficiency and Effectiveness39618.2.4Educating and Training39618.2.5Designing and Managing Equipment for Maintenance Prevention39618.3Competitive Advantage39618.4Focus on Quality39718.5Focus on Maintenance39818.6Overall Equipment Effectiveness40218.7Elements of Effective Maintenance40618.7.1Commitment40618.7.2Cost40818.7.3Culture408Contentsxi18.7.4Customer Focus40918.7.5Management Commitment41018.7.6Cha