AnIntroductiontoPredictiveMaintenance,SecondEdition资料下载.pdf

AnIntroductiontoPredictiveMaintenance,SecondEdition资料下载.pdf

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ANINTRODUCTIONTOPREDICTIVEMAINTENANCESecondEditionThisPageIntentionallyLeftBlankANINTRODUCTIONTOPREDICTIVEMAINTENANCESecondEditionR.KeithMobleyAmsterdamLondonNewYorkOxfordParisTokyoBostonSanDiegoSanFranciscoSingaporeSydneyButterworth-HeinemannisanimprintofElsevierScience.Copyright2002,ElsevierScience（USA）.Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyformorbyanymeans,electronic,mechanical,photocopying,recording,orotherwise,withoutthepriorwrittenpermissionofthepublisher.Recognizingtheimportanceofpreservingwhathasbeenwritten,Elsevier-Scienceprintsitsbooksonacid-freepaperwheneverpossible.LibraryofCongressCataloging-in-PublicationDataMobley,R.Keith,1943.Anintroductiontopredictivemaintenance/R.KeithMobley.2nded.p.cm.Includesindex.ISBN0-7506-7531-4（alk.paper）1.PlantmaintenanceManagement.I.Title.TS192.M6242002658.202dc212001056670BritishLibraryCataloguing-in-PublicationDataAcataloguerecordforthisbookisavailablefromtheBritishLibrary.Thepublisheroffersspecialdiscountsonbulkordersofthisbook.Forinformation,pleasecontact:

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@#@/10987654321PrintedintheUnitedStatesofAmericaCONTENTSChapter1ImpactofMaintenance11.1MaintenanceManagementMethods21.1.1Run-to-FailureManagement21.1.2PreventiveMaintenance31.1.3PredictiveMaintenance41.1.4OtherMaintenanceImprovementMethods61.2OptimizingPredictiveMaintenance101.2.1CultureChange101.2.2ProperUseofPredictiveTechnologies121.2.3ItTakesMoreThanEffectiveMaintenance171.2.4SmallPlants201.2.5LargePlants21Chapter2FinancialImplicationsandCostJustification232.1AssessingtheNeedforConditionMonitoring242.2CostJustification252.2.1Poor-QualityProductasPlantPerformanceDeteriorates272.2.2IncreasedCostofFuelandOtherConsumablesasthePlantConditionDeteriorates272.2.3CostofCurrentMaintenanceStrategy272.3JustifyingPredictiveMaintenance292.3.1InstallationCost292.3.2OperatingCost312.3.3Conclusions312.4EconomicsofPreventiveMaintenance322.4.1BenefitsversusCosts33vChapter3RoleofMaintenanceOrganization433.1MaintenanceMission433.1.1OptimumAvailability433.1.2OptimumOperatingCondition443.1.3MaximumUtilizationofMaintenanceResources443.1.4OptimumEquipmentLife443.1.5MinimumSparesInventory443.1.6AbilitytoReactQuickly443.2EvaluationoftheMaintenanceOrganization443.2.1ThreeTypesofMaintenance453.3DesigningaPredictiveMaintenanceProgram503.3.1FailureData513.3.2ImprovingEquipmentReliability523.3.3ImprovementProcess543.3.4FailuresThatCanBePrevented553.3.5MaintenancetoPreventFailures553.3.6Personnel563.3.7ServiceTeams563.3.8HowtoStart58Chapter4BenefitsofPredictiveMaintenance604.1PrimaryUsesofPredictiveMaintenance614.1.1AsaMaintenanceManagementTool614.1.2AsaPlantOptimizationTool694.1.3AsaReliabilityImprovementTool694.1.4TheDifference704.1.5BenefitsofaTotal-PlantPredictiveProgram70Chapter5Machine-TrainMonitoringParameters745.1Drivers755.1.1ElectricMotors755.1.2SteamTurbines775.2IntermediateDrives785.2.1Chains785.2.2Couplings795.2.3Gearboxes815.2.4V-Belts835.3DrivenComponents865.3.1Compressors865.3.2Fans925.3.3Generators935.3.4ProcessRolls945.3.5Pumps95viAnIntroductiontoPredictiveMaintenanceChapter6PredictiveMaintenanceTechniques996.1VibrationMonitoring996.1.1TechnologyLimitations1006.2Thermography1056.2.1TypesofThermographicSystems1066.2.2InfraredThermographySafety1076.3Tribology1086.3.1LubeOilAnalysis1086.3.2WearParticleAnalysis1096.3.3LimitationsofTribology1096.4VisualInspections1116.5Ultrasonics1116.6OtherTechniques1126.6.1ElectricalTesting112Chapter7VibrationMonitoringandAnalysis1147.1VibrationAnalysisApplications1147.1.1PredictiveMaintenance1157.1.2AcceptanceTesting1157.1.3QualityControl1167.1.4LooseorForeignPartsDetection1167.1.5NoiseControl1167.1.6LeakDetections1167.1.7AircraftEngineAnalyzers1167.1.8MachineDesignandEngineering1167.2VibrationAnalysisOverview1177.2.1TheoreticalVibrationProfiles1177.2.2ActualVibrationProfiles1187.2.3InterpretationofVibrationData1207.2.4Vibration-MeasuringEquipment1217.3VibrationSources1227.3.1RotatingMachinery1227.3.2Reciprocatingand/orLinear-MotionMachinery1247.4VibrationTheory1257.4.1PeriodicMotion1257.4.2MeasurableParameters1297.5MachineDynamics1327.5.1Mass,Stiffness,andDamping1337.5.2DegreesofFreedom1427.6VibrationDataTypesandFormats1467.6.1DataTypes1467.6.2DataFormats1507.7DataAcquisition1527.7.1VibrationDetectors:

@#@TransducersandCables1527.7.2DataMeasurements156Contentsvii7.7.3TransducerMountingTechniques1577.7.4AcquiringData1607.8VibrationAnalysesTechniques1617.8.1Trending1617.8.2ComparativeAnalysis1627.8.3SignatureAnalysis164Appendix7.1Abbreviations165Appendix7.2Glossary166Appendix7.3References171Chapter8Thermography1728.1InfraredBasics1728.2TypesofInfraredInstruments1748.2.1InfraredThermometers1748.2.2LineScanners1758.2.3InfraredImaging1758.3Training1758.4BasicInfraredTheory1768.4.1ElectromagneticSpectrum1768.4.2HeatTransferConcepts1778.5InfraredEquipment1788.6InfraredThermographySafety1798.7InfraredScanningProcedures1798.8TypesofInfraredProblems1798.8.1MechanicalLooseness1808.8.2ComponentFailure1808.8.3CommonProblemsFoundandWhattoScan180Appendix8.1Abbreviations183Appendix8.2Glossary183Appendix8.3ElectricalTerminology187Appendix8.4MaterialsList193Chapter9Tribology2029.1LubricatingOilAnalysis2039.1.1OilAnalysisTests2039.1.2WearParticleAnalysis2059.1.3Ferrography2079.1.4OilAnalysisCostsandUses2079.2SettingUpanEffectiveProgram2089.2.1EquipmentAudit2099.2.2LubricantAuditProcess2119.2.3BaselineSignature2129.2.4Monitoring2139.2.5ProgramEvaluation215viiiAnIntroductiontoPredictiveMaintenanceChapter10ProcessParameters21710.1Pumps21810.1.1CentrifugalPumps21810.1.2Positive-DisplacementPumps22210.2Fans,Blowers,andFluidizers22510.2.1CentrifugalFans22510.2.2BlowersorPositive-DisplacementFans22810.3Conveyors22910.3.1Pneumatic22910.3.2Chain-TypeMechanical22910.4Compressors22910.4.1Centrifugal22910.4.2Rotary-TypePositiveDisplacement23110.4.3ReciprocatingPositiveDisplacement23510.5MixersandAgitators24010.6DustCollectors24010.6.1Baghouses24010.6.2CyclonicSeparators24010.7ProcessRolls24110.8Gearboxes/Reducers24210.8.1NormalWear24610.8.2AbnormalWear24610.9SteamTraps24910.10Inverters24910.11ControlValves24910.12SealsandPacking25110.12.1MechanicalSeals25110.12.2PackedBoxes254Chapter11Ultrasonics25611.1UltrasonicApplications25611.1.1AirborneNoiseAnalysis25611.1.2LeakDetection25711.1.3MaterialsTesting25711.2TypesofUltrasonicSystems25711.3Limitations258Chapter12VisualInspection25912.1VisualInspectionMethods26012.1.1HumanSenses26112.1.2Sensors26112.1.3SpectrometricOilAnalysis26312.2Thresholds263ContentsixChapter13OperatingDynamicsAnalysis26713.1ItsNotPredictiveMaintenance26713.1.1TechnologyLimitations26813.1.2LimitationtoMaintenanceIssues26813.1.3InfluenceofProcessVariables26913.1.4TrainingLimitations27013.1.5UnderstandingMachineDynamics27113.1.6InterpretingOperatingDynamics281Chapter14Failure-ModeAnalysis28514.1CommonGeneralFailureModes28614.1.1CriticalSpeeds28614.1.2Imbalance28814.1.3MechanicalLooseness29014.1.4Misalignment29314.1.5Modulations29414.1.6ProcessInstability29614.1.7Resonance29714.2FailureModesbyMachine-TrainComponent30114.2.1Bearings:

@#@RollingElement30214.2.2Bearings:

@#@Sleeve（Babbitt）30314.2.3ChainsandSprockets30414.2.4Gears30614.2.5JackshaftsandSpindles30914.2.6ProcessRolls31214.2.7Shaft31814.2.8V-Belts318Chapter15EstablishingaPredictiveMaintenanceProgram32515.1Goals,Objectives,andBenefits32515.2FunctionalRequirements32615.2.1ManagementSupport32715.2.2DedicatedandAccountablePersonnel32715.2.3EfficientDataCollectionandAnalysisProcedures32715.2.4ViableDatabase32815.3SellingPredictiveMaintenancePrograms33015.3.1SixKeystoSuccess33015.4SelectingaPredictiveMaintenanceSystem33415.4.1FundamentalSystemRequirements33515.5DatabaseDevelopment34315.5.1EstablishingDataAcquisitionFrequency34315.5.2SettingUpAnalysisParameters34415.5.3SettingBoundariesforSignatureAnalysis34415.5.4DefiningAlertandAlarmLimits34515.5.5SelectingTransducers346xAnIntroductiontoPredictiveMaintenance15.6GettingStarted34815.6.1Training34915.6.2TechnicalSupport350Chapter16ATotal-PlantPredictiveMaintenanceProgram35216.1TheOptimumPredictiveMaintenanceProgram35316.1.1PredictiveTechnologies35316.1.2TheOptimumPredictiveMaintenanceSystem35516.2PredictiveIsNotEnough35616.2.1EffectivePlanningandScheduling35616.2.2PreventiveMaintenanceTasks35716.2.3Motivation37316.2.4RecordKeeping38016.2.5SpecialConcerns38316.3Conclusion387Chapter17MaintainingtheProgram38917.1TrendingTechniques38917.2AnalysisTechniques39017.2.1BroadbandAnalysis39017.2.2NarrowbandAnalysis39117.2.3Root-CauseFailureAnalysis39217.3AdditionalTraining39217.4TechnicalSupport39317.5ContractPredictiveMaintenancePrograms393Chapter18World-ClassMaintenance39418.1WhatIsWorld-ClassMaintenance?

@#@39418.2FiveFundamentalsofWorld-ClassPerformance39518.2.1ImprovingEquipmentEffectiveness39518.2.2InvolvingOperatorsinDailyMaintenance39518.2.3ImprovingMaintenanceEfficiencyandEffectiveness39618.2.4EducatingandTraining39618.2.5DesigningandManagingEquipmentforMaintenancePrevention39618.3CompetitiveAdvantage39618.4FocusonQuality39718.5FocusonMaintenance39818.6OverallEquipmentEffectiveness40218.7ElementsofEffectiveMaintenance40618.7.1Commitment40618.7.2Cost40818.7.3Culture408Contentsxi18.7.4CustomerFocus40918.7.5ManagementCommitment41018.7.6Cha