Industrial Maintenance Second Edition i)Industrial Maintenance SECONOMUITION bbe MICHAEL E. BRUMBACH AND JEFFREY A. GLADE‘y DELMAR Industral Maintenance. 3€ Michal. Brumbach, Jetey A. Clade Director of Learning Saltions: Sand irk NanagngEetor Larry in Senior Product MaragerjohnFisher Director, Market Development Management Debbe Yarnell Marking Develoment Manager rs Srennan Director, Brand Management jason ‘alos Marketing and Manager: Gin MeNlary Senor Predction Director. Wendy Treoger Production Manager: Mark Semana Senior ar Drect David Arsenault Technelogy Project Manager: joe Piss (© 203, 2098 Delmar, Cngage Leaning wen: 02:200-208 ALL RGHTS RESERVED No part ins work covered y thecorgh hatch ‘vay reproduced trarsmitta, stored, erueedin an formar oy any msene [raphe elton or macharea ielising ot mines ie nhetorenyne. ‘ecoréng, scanning, digelangcapirg, Wea cstrbutin,infermation networks Section 1O7or 1 the 1976 Un tad States Copylant Act without the For oduct informatien and techrology assistance, contact usa Cengage leaning Customer & Sales Seppor., 1 860°354-9706 For permission tose materia fromithistext or prec, ter oh eee olin premrsencnccern fern Further germisions questone cin be malig ta Ppermissonrequesnscengage.com Mcroiot a elteedtradaarkof the Mltesoft Cxpoition, SON: 97e BRITS SAN 0:1-98:1319.0, Delmer Cliton Park NY 20652919 Usa Cengeg Letrning fa leading proviserofcustoninesiearng solitons with oe lations sound he pcb, tusig Singapre the UnteeKingéom, ‘Australi, Mexico, rani ana apa. Locate youocaloficeat: Intereationalceegagecom/ezion Toles mere about Denar st www.cengage.comielmar Purchase ay of ur preductsat your loa collage strear st ourpetered online torewwavcengegebran-cam Printed in the United States of America 1234567 14131211 10PREFACE xi INDUSTRIAL MAINTENANCE SYLLABUS xxi ABOUT THE AUTHORS xv ACKNOWLEDGMENTS xxi Reem GENERAL KNOWLEDGE 1 1, Safety 3 Objectives 3 1-1. Workplace Safety 4 1-2. Hazardous Material Handling 12, 1-3 Ladders and Scatfolds 19 Summary 2 Review Questions 2B 2. Tools 25 Objectives 25 2-1 Hand Tools 26 2-2 Measuring Devices 40 2-3. Power Tools 4B Summary 47 Review Questions 48 3. Fasteners 49 Objectives 49 3-1. Threads 50 3-2. Taps and Dies 4 3-3. Fastener Types 7 3-4 Fastener Grades 58 3-5. Torque Specifications 59 3-6 Retaining Ring Fasteners 62 Summary 64 Review Questions 65 Industrial Print Reading 67 Objectives 67 4-1 Mechanical Drawings 68 4-2. Piping Symbols and Drawings 70 4-3. Hydraulic/Pneumatic Symbols and Drawings 72 4-4 Electrical Symbols and Drawings 76 4-5. Welding Symbols and Drawings 85 Summary 88 Review Questions 89 Rigging and Mecha Installations 91 Objectives 1 5-1 Formulae and Weight Estimations 92 5-2 Load Balancing 99 5-3. Synthetic Slings 101 5-4 Fiber Rope and Securing 108 5-5 Wire Rope and Wire Rope Stings 114 5-6 Chain and Chain Slings 121 5-7 Prelift Planning 126 Summary 127 Review Questions 127 nnn Bn enn pry eb ed NEvil Contents SECTION 2 MECHANICAL KNOWLEDGE 129 6. 10. Mechanical Power Transmission Objectives 6-1 Belts and Sheaves 6-2 Chainsand Sprockets 6-3 Gears and Gearboxes 6-4 Speed Calculations Summary Review Questions Bearings Objectives 74 Bearing Loads 7-2 Bearing Construction 73 Seties of Bearings 7-4 Bearing Types 7-5. Bearing Installation and Removal 76 Bearing Failures Summary Review Questions Coupled Shaft Alignment Objectives 81 Shaft Alignment 8.2 Dial Indicator Method 8-3 Reverse Dial Indicator Method 8-4 Fecler Gauge Method 8.5 Laser Shaft Aligament Summary Review Questions Lubrication Objectives 9-1 General Terms 9-2 Types of Lubricants 9.3. Methods of Application 9-4 Lubrication Schedules Summary Review Questions Seals and Packing Objectives 10-1. Packing Seals 10.2. Mechanical Secls 131 131 132 142 144 149 193 134 155 155 156 156 157 158 162 165 166 166 167 167 168 175 180 131 135 186 187 189 189 190 190 191 194 195 195 197 197 10-3 Radial Lip Seals Suromery Review Questions 11. Pumps and Compressors Objectives 11-1 Hydraulic Pumps 11-2 Pump Specifications 11-3 Pump Troubleshooting 11-4. Air Compression 11-5. Compressor Types 116 Compressor Troubleshooting Suramary Review Questions 12. Fluid Power Objectives 12-1 Fluid Power Fundamentals 122 123 Hydraulics Pneumatics 124 Valves 12.5. Linear Actuators Summary Review Questions 13. Piping Systems Objectives 13-1 Piping Tools 13-2. Piping Systems 133. Fittings 1344. Fitting Allowances 13-5 Pipe Connection Methods Surmmary Review Questions 202 203 204 205 205 206 212 214 21s 217 219 219 221 223 223 224 224 228 231 240 249 250 251 251 252 254 256 258 262 266 267 Sao) ELECTRICAL KNOWLEDGE 14, Electrical Fundamentals Objectives 141 14-2 143 144 145 ‘Atomic Structure Current Voltage Resistance Resistor Wattage Ratings and Power 269 271 271 272 274 274 276 28015. 16. 17, 18. 146 a7 Scientific Notation Engineering Notation 148 Ohm's Law 14-9, Power Law 14-10 Magnetism Summary Review Questions Test Equipment Objectives 15-1 Digital Multimeter 15-2. Clamp-On Ammater 15-3. Megahmmeter 15-4 Oscilloscope Summary Review Questions Basic Resistive Electrical Circuits Objectives 16-1. Series Circuits 16-2. Parallel Circuits 16-3 Combination Circuits Summary Review Questions Reactive Circuits and Power Factor Objectives 17-1 Inductance and Rel Circuits 17-2 Capacitance and R-C Circuits 17-3. ReL-C Series and Parallel Circuits 17-4. Power Factor Correction 17-5. Three-Phase Circuits 17-6 Three-Phase Power Factor Correction Summary Review Questions Wiring Methods Objectives 181 Conductor Selection and Sizing 18-2 Conductor Color Code 183. Raceway Selection 18-4 Raceway Sizing summary Review Questions 282 282 283 286 290 290 290 291 291 292 296 297 300 309 309 31 311 312 317 323 335 335 337 337 338 348, 360 369 373 374 377 378 379 379 380 383 385 19. 20. 21. 22. Contents Transformers Objectives 19-1. Basic Transformers 19-2. Autotransformers 19-3. Current Transformers 19-4 ‘Three-Phase Transformers 19-5. Primary Distribution Systems 19-6 Consumer Distribution System 19-7, Grounding System Summary Review Questions Electrical Machinery Objectives 20-1 DC Generators 20-2. DC Motors 20-3 20-4 Alternators Three-Phase Motors 20-5. Single-Phase Motors 20-6 Motor Maintenance Summary Review Questions Control and Controlled Devices Objectives 21-1. Pushbuttons 21-2. Rotary Switches 21-3. Limit Switches 21-4 2-5 21-6 2-7 21-8 Proximity Switches Photoelectric Switches Relays Motor Starters ‘Annunciators Summary Review Questions Motor Control Circuits Objectives 22-1 22.2 223 22-4 22.5 22-6 22.7 Two-Wire Controls Three-Wire Controls Multiple Start/Stop Controls Forward/Reverse Controls Speed Control Jog Control Miscellaneous Control 391 391 392 401 405 406 424 425 425 428 428 431 431 432 436 441 4a 446 452 454 454 455 455 456 458 460 460 462 468 47 472 474 474 475 475 476 476 478 481 484 486 487x Contents 22-8 Multiple Motor Starter Control 488 RRTSTTeyW 22.9 Sequential Starting Control 489 22-10 Various Starting Methods 492 WELDING KNOWLEDGE 643 22-11 Braking 498 27, Gas Welding 645 Suen, 500 Objectives 645 Review Questions: 501 27-1 Gas Welding Safety 646 23. Basic Industrial Electronics 503 27-2. Setup Procedures 648 Objectives 503 27-3. Shutdown Procedures 649 23-1. Diodes soa 27-4 Types of Flames 649 23-2. Transistors su 275 Pudeling and Running a Bead 650 23-3. Thyristors 519 274 Types of Welds 650 23-4. 555 Timer 525 27-7 Types of Joints 651 23-5 Operational Amplifiers 530 27-8. Welding Positions 652 23.6 Digital Logic 536 Summary 653 23-7 Replacing Solid-State Devices 543 Review Questions 654 summary 544 Review Questions 544 28. Arc Welding 655 24, Electronic Variable-Speed agian o aoe se 1. Are Welding safely 656 28.2 Arc Welding Components 657 Obpectives ata 28-3. Striking the Arc 658 261 (DG Drvse ad 284 Running a Bead 659 242. Troubleshooting DC Drives. 571 268 Ways eo 24-3. AC (Inverter) Drives 578 286 "peat loins teh 24-4 Troubleshooting Inverter Drives 599 Sapte Rnct wees Summary oi of Arc Welding 661 Review Questions on summary 662 Fay Riigteniatalel bale Review Questions 663 Controllers 613 Objectives 613 25-1 PLC Components 614 25-2 WOWiring 616 PREVENTIVE MAINTENANCE 665 25-3. Programming 618 ; Suniel 630 29. Preventive Maintenance— Review Questions 631 Developing and Implementing 667 26. Lighting 633 Objectives 667 Objectives 633 2041 History 668 26-1. Types of Lamps 634 29-2 Planning and Coordinating 668 26-2 Luminaires 637 29.3 Hazardous and Confined 26-3. Ballasts 638 Locations oro 26-4 Relamping 638 294. Executing the PAM 671 Summary 641 Suromary 672 Review Questions 641 Review Questions 67330, Mechanical PM 675 Objectives 675 30-1 Bearings 676 30-2 Gearboxes 676 30-3 Seals 676 304 Belts 677 30:5. Chains and Sprockets 678 30-6 Couplings 678 summary 679 Review Questions 680 681 681 31-1 General Requirements 682 31-2. Inspection Records 682 31.3 Four Rules of Electrical Maintenance 683 31-4 Maintenance Resporsibility 684 Summary 684 Review Questions 684 Appendix A 685 NEC Tables 310.15(6)(16), 310.1 5(6)(17), 310.1 5(B)(18), and 310.15(B)(19) 686 Appendix B 691 NEC Table 310.15(8)(2)(b) 692 Appendix € 695 NEC Tables C1 through C12 696 Appendix D 743 NEC Table 5 744 Contents xi Appendix E 747 NEC Table 8 748 The following appendices F through K can be found on the student campanion website at wow.cengagebrain.com. Follow the instructions in the Supplements section of the Preface for access information. Appendix F NEC Table 4 Appendix G Weights & Measures Conversion Tables Appendix H Weight Estimation Tables Appendix | Web Sling ~ Load Capacity Tables Appendix J Wire Rope Sling - Load Capacities and Sately Factors Appendix K Chain Property Tables, Chain Sling ~ Load Capacities, & Temperature Derating Factors GLOSSARY 749 INDEX 773aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.il) gape can tan tleWith a combined total of over 25 years experience in the field and more than 40 years of teaching experience in the subject area, the authors share their knovledge and. firsthand experiences with the learner, MICHAEL E. BRUMBACH Mike is the Industrial Maintenance Department Chair as well as an instructor in the Industrial Maintenance program at York Technical College in Rock Kill, SC. He has been employed by York ‘Technical College since 1986, having spent the previous 11 years workingin industry. Mike possesses an AS degree. You maye-mail Mike at mbrumbach@comporium.net JEFFREY (JC) CLADE IC isan instructor in the Industrial Maintenance program. He has been employed by York Technical College since 1997, havingspent the previous 15 years serving with the U.S. Air Force and working in industry. JC possesses an AS degree and is a member of the International Association of Electrical Inspectors (IAEI) and the National Fire Protection Association (NEPA), You may e-mail JC atjelade@comporium.net \ hip ai Me nk fn ee net in me re tin iail) gape can tan tleaa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.GENERAL KNOWLEDGE Safety Tools Fasteners Industrial Print Reading A TYPICAL DAY IN MAINTENANCE Check It Out 7:00 au, and your shift has begun. You have had your breakfast and coffee, and itis time to eam your pay. Your supervisor hands you a work order for the number 3 press. The press operator reports that the press was making a loud vibration, then the operator smelled a “funny” odor, and now the press will not run. You mentally run through several possible causes of the problem. You gather the relevant prints, personal protective equipment (PPE), hand tools, and test equip- ment and proceed onto the plant floor to press number 3. It is now 7:20 Aw. Work It Out 1. What might be the cause of the problem with the press? 2. What types of drawings or prints would be helpful? 3. What PPE do you need? Which hand tools would you consider taking slong? ve What test equipment would be of benefit?nnd aac a4 Hn Be pene en heen A a Rae pe fn sn net cn te a a Pi apathy NAOT ON MRT NEY =Safety This text will delve into the field of industrial maintenance, but before we can do that, we must begin with safety. Without safety, maintenance would be a deadly occupation because equipment and machinery are dangerous by nature. A wise man once said, “An accident is nothing more than an unsafe condition and an unsafe act that have been combined. If the unsafe condition had been removed, there would have been no accident. If the unsafe act had been removed, once again there would have been no accident.” The maintenance mechanic needs to be safety oriented to avoid unnecessary accidents and bodily harm when working around equipment and machinery. It takes only one accident, and a very small moment in time, to lose a life. OBJECTIVES After studying this chapter, the student should be able to Understand the importance of personal protective equipment. Demonstrate the proper procedure for lifting. Use lockout and/or tagout when needed. Discuss the proper use of safety belts, scaffolds, and ladders. . . . © List several general electrical safety practices. ® ‘= Identify all the organizations that govern the safety of hazardous material . List the classifications of fire and the proper method of extinguishing a fire.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.aa You have either reached a page that is unavailable for viewing or reached your viewing limit for this book.image not availableuse a Class © fire extinguisher, Most industrial machines have a main disconnect. ‘Ihis is the point at which the machine can be totallyremoved from its electrical energy source, ILisimportant to remember, if a Class C fre does exist, to pull the main disconnect handie to the off position. Keep in mind, however, that there may be some remain: ing stored electrical energy in some elecirical equipment as you fight the fire. For this reason, it is always important to consider all electrical equipment energized. As with the others, there is a pictograph that represents a Class € five, which ran he seen in Figure 1-16. A blue circle with a capital letter C in it may also represent a Class C classification A Class D fire is fire that burns combustible metals, such as magnesium, potassium, powdered aluminum, zine, sodium,or titanium. Because most combustible metals are highly volatile to water in a high-heat environment, @ special dry-powder extinguishing agent or a foam extinguisher is used on this class of fie, Extinguisher Use Here isa proposed list of the procedures that should be followed in the event ofa fire, & Locate and activate the nearest fire alarm. If no fire alarm is in the immediate area, then yell the word firees loudlyas possible to get the attention ofa coworker or a supervisor. © Make certain thata callto 911 is placed. It ismost important to notily the local fire department of the fire © Make sure that the facility's emergency response or first responder team is notified, © Getall nonessential personnel out of harm’s way. 1 Deenergize all electrical sources that are in the immediate vicinity of the fie, if possible © Quickly identify the class of the fire and retrieve the appropriate extinguisher. © Always make sure thatyou have an escape route as you are trying to extingulsh the fire, © Use the extinguisher properly « achieve the maximum firefighting capability of the extin. guisher. Try touse the BA.S.S, method, + Pull the pin. + Aim at the base ofthe fire. + Squeeze the handle or trigger. (Be prepared; some extinguishers are extremely loud when the extinguishing agentis released.) CHAPTER 1 Safety + sweep the extinguisher from side to side as 1¢ isused, & Continue to fight the fire as long as possible, pre- venting any spreading until the local firefighters. If you extinguish the fire, keep a watchful eye unt the fire department arrives to ensure that it oes not flare up again. @ IF a fire becomes too large and gets to a point where it is out of control before the fire depart. ment’s arrival, evacuate the facility and stand as, far away from the hire as possible. Remember, a Joss of life due to a fire isnot acceptable, Remember, the safety of all personnel is what is important. These OSHA standards and NFPA standards are for our safety. Ifa salety violation is noticed, report it as soon as possible to avoid any unnecessary injury. Safety is everyone's job! Take it seriously WEB LADDERS AND SCAFFOLDS Ladders OSHA Standard 1926.1051 (General Requirements) states thata stairway or ladder shall be provided at all personnel points of access where there isa break inelevation of 19 in. (48cm) or more, and no ramp, runway, sloped embankment, or personnel hoist is provided, OSHA Standard. 1926.1053 lists the requirements for the manufacturing or constrac- tion of a ladder, OSHA Standard 1928. portable wooden ladders; 1926.26 covers portable metal ladders; 1926.27 covers fixed ladders; and 1926.103 struction industry, Regarding ANSI ratings, difler- ent safety codes apply, depending on the type of material and type of ladder. the ANSI Codes are as follows: covers ladders that are used in the con WoodLadders ANSI Metalladders — ANSTA42 Fixed ladders ANSIAL43 Fiberglassladders ANSTA4.5 Steel ladders ANSIALAT Rollingsesffold _ ANSI.A10.3, 2011 edition, (covered laterin this section) Duty ratings have also. been established by ANSI. Ihese ratingsidentify the ladder’sload capac- ity and its intended use, Allladders must have a rat ing label. 19