Contents

Contributors Preface xv

xi

Section 1. Organization a n d Administration of the Maintenance Function 1. 2. 3. 4. 5. 6. 7. 8. Organization and Scope Principles of Organization Operating Policies by Which Management Should Be Guided Operating Practices to Reduce Maintenance Work Reports from Maintenance Area and Centralized Maintenance Control Considerations in Using Outside Contractors Preventive Maintenance Section 2. M a n a g e m e n t and Administration of Maintenance Personnel 1. Maintenance Trades and Supervisory Training Part I. Maintenance-Trades Training Part II. Supervisory Training 2. Programmed Instruction for Maintenance 3. Rating and Evaluating Maintenance Workers 4. Incentive Payment of Maintenance Workers 5. Human Factors in Maintenance Section 3. Establishing the Controls of Maintenance 1. 2. 3. 4. Work Authorization and Control Work Measurement Work Scheduling and Controls Estimating Repair and Maintenance Costs 3-1 3-9 3-53 3-63 vll 2-1 2-1 2-15 2-21 2-29 2-37 2-57 '.. 1-1 1-17 1-21 1-35 1-43 1-49 1-55 1-63

viii 5. 6. 7. 8. 9.

Contents Preparing the Maintenance Manual Work Simplification in Maintenance Computerized Labor Reporting Computerized Preventive Maintenance Small-Plant Maintenance Control 3-73 3-91 3-107 3-117 3-133

Section 4. M a i n t e n a n c e of Pollution-Control Equipment 1. 2. 3. 4. 5. Introduction to Pollution-Control Equipment Maintenance Air-Pollution-Control Equipment Maintenance Water-Pollution-Control Equipment Maintenance A Program of Plant Solid-Wastes Management and Volume Reduction Noise Control and Maintenance 4-1 4-3 4-17 4-31 4-37

Section 5. The Economics of Maintenance M a n a g e m e n t 1. Maintenance Costs and Budgets 2. Cost Control for Effective Operation 5-1 5-19

Section 6. Maintenance of the Plant Facility 1. 2. 3. 4. 5. 6. 7. 8. Maintenance of Built-Up Roofs Painting Repair and Treatment of Concrete Floors Design of Concrete Industrial Floor Surfaces Maintenance of Elevators and Special Lifts Concrete-Floor Maintenance Maintenance and Cleaning of Brick Masonry Structures Plant Facility Security 6-1 6-9 6-27 6-31 6-39 6-49 6-55 6-67

Section 7. Maintenance of Electrical Equipment 1. 2. 3. 4. 5. 6. 7. 8. Electric Motors Maintenance of Control Components Maintenance of Tube-Type Electronic Industrial Controls Maintenance of Electric Brakes Maintenance of Industrial Batteries (Lead-Acid, Nickel-Cadmium, Nickel-Iron) Power-Distribution Equipment Illumination Solid-State Electronics 7-1 7-35 7-63 7-69 7-79 7-105 7-131 7-167

Section 8. Maintenance of Mechanical Equipment 1. 2. 3. 4. 5. 6. 7. 8. Plain Bearings Rolling Bearings Friction Clutches Flexible Couplings for Power Transmission Chains for Power Transmission Cranes-Overhead and Gantry Chain Hoists V-Belt Drives 8-1 8-11 8-33 8-49 8-61 8-71 8-77 8-87

Contents 9. Mechanical Variable-Speed Drives 10. Gear Drives and Speed Reducers

ix 8-95 8-109

Section 9. Maintenance of Service Equipment 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Air-Conditioning Equipment Ventilating Fans and Exhaust Systems Dust-collecting Equipment Heating Equipment Power-Plant Equipment Centrifugal Pumps Reciprocating Air Compressors Automatic Sprinkler Systems Valves Piping Portable Electric Tools Portable Air Tools Scaffolds and Ladders The Conservation and Effective Use of Plant Utilities 9-1 9-35 9-59 9-71 9-101 9-161 9-173 9-185 9-197 9-213 9-249 9-261 9-269 9-287

Section 10. Maintenance of Industrial Trucks 1. Maintenance of Electric Industrial Trucks 2. Maintenance of Internal-Combustion Engine Industrial Trucks 10-1 10-9

Section 1 1 . Maintenance Storekeeping and Stores Facilities 1. Maintenance Stores and Inventory Control 2. Maintenance Storerooms : 11-1 11-19

Section 12. Lubrication 1. Lubricants 2. Lubricating Systems, Devices, and Procedures 3. The Conservation of Petroleum Products 12-1 12-19 12-29

Section 13. Instruments and Instrumentation 1. 2. 3. 4. Mechanical Instruments for Measuring Process Variables Electrical Instruments for Measuring, Servicing, and Testing Numerical Control Vibration: Its Analysis and Correction 13-1 13-37 13-61 13-115

Section 14. Industrial Sanitation and Housekeeping 1. 2. 3. 4. 5. Organizing the Sanitation Personnel Maintaining Plant Sanitation Industrial Housekeeping Cleaning Industrial Plant Offices Clean Rooms-Construction and Maintenance 14-1 14-17 14-37 14-49 14-55

Contents Section 15. Maintenance Welding 1. Arc Welding in Maintenance 2. Gas Welding in Maintenance 15-1 15-53

Section 16. Corrosion and Chemical Cleaning 1. Corrosion Control 2. Chemical Cleaning 16-1 16-13