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Summary of Industrial Plant Maintenance and Plant Engineering PDF
Summary of Industrial Plant Maintenance and Plant Engineering PDF
Industrial Plant
Maintenance and
Plant Engineering
Handbook
For Industrial Plant Maintenance
Managers, Plant Maintenance Engineers
and Maintenance Technicians
Mike Sondalini
www.lifetime-reliability.com
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Industrial Plant Maintenance and Plant
Engineering Handbook
Disclaimer: Because the authors, publisher and resellers do not know the context in
which the information presented in this book is to be used, they accept no responsibility
for the consequences of using the information contained or implied in it.
CONTENTS
Bulk Materials ............................................................................................................................... 7
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Keep Gearboxes Running.......................................................................................................... 92
The Connection Between Nut Torque And Bolt Tension. ........................................................ 94
Preheating Welds....................................................................................................................... 96
Isolation Valves For Different Services .................................................................................... 99
Polyethylene – Its Properties And Uses .................................................................................. 102
Heat Welding Of Plastics ........................................................................................................ 105
Heating Liquids By Steam Sparging ....................................................................................... 111
Separation & Segregation Of Dangerous Goods ..................................................................... 114
Angular Contact Bearing Use ................................................................................................. 117
Shaft Coupling Selection Issues .............................................................................................. 119
Stress In Metals Cause Failure ................................................................................................ 120
Locating Pressure Relief Valves ............................................................................................. 123
Equipment And Plant Layout For Improved Maintenance ..................................................... 125
Spherical Roller Bearings........................................................................................................ 127
Bronze – Use The Right One In The Right Place. .................................................................. 129
Converting From Oiled To Greased Shaft Roller Bearings .................................................... 132
Electric Motor Problems ......................................................................................................... 134
Metal Corrosion Basics ........................................................................................................... 137
Vee-Belt Drives ....................................................................................................................... 144
Vertical Bulk Liquid Storage Tank Construction and Maintenance. ...................................... 147
Metal Fatigue Failure .............................................................................................................. 150
Chain Drives – Some Experiences In-The-Field..................................................................... 154
Cooling Water Towers ............................................................................................................ 156
Static Electricity Basics. .......................................................................................................... 159
O-Ring Design, Operation and Use......................................................................................... 160
What is Life Cycle Costing? ................................................................................................... 162
Steam Trap Operation And Selection...................................................................................... 163
Hazardous Areas For Dusts And Flammables ........................................................................ 166
Sealing Threaded Pipe Connections ........................................................................................ 171
Air Compressor Operation And Care ...................................................................................... 174
Heat Exchanger Design And Use ............................................................................................ 176
Oil – How Clean Does It Have To Be? ................................................................................... 180
Spread Forces Throughout Equipment and Reduce Breakdowns ........................................... 184
Set-up Tank Agitator Gearboxes for Long Life at Low Cost ................................................. 187
Gluing Plastic Pipes so You Can Trust Them. ........................................................................ 190
Non-Destructive Testing Of Welds ......................................................................................... 192
Rolling Bearing Vibration Detection ...................................................................................... 195
Rotating Shafts Under Bending Stress .................................................................................... 197
The Big Bang – Starting And Stopping Equipment Under Load ............................................ 200
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6 Secrets of Trouble-free Lubrication Success ....................................................................... 203
Heat Transfer Basics ............................................................................................................... 205
Fired Packaged Boiler Basics .................................................................................................. 209
Lubrication Cleanliness and Filtration .................................................................................... 212
Membrane And Leaf Filtration Overview ............................................................................... 214
Air Mover and Air Amplifier Problems .................................................................................. 217
Acid Sparge And Acid Sparging ............................................................................................. 219
Cheap Way To High Pumping Circuit Availability ................................................................ 221
The Galvanic Corrosion Trap .................................................................................................. 223
Present A Winning Financially Justification For New And Replacement Equipment ........... 227
The Cost of Maintenance Destroys Your Capital Investment Returns ................................... 232
Some Quality Paradigms are Expensive ................................................................................. 234
A Simple Fault Finding Technique ......................................................................................... 235
Recommended Approach To Fault Finding ............................................................................ 236
Fault Finding Practice ............................................................................................................. 236
The Continuous Improvement Method of Thomas Edison ..................................................... 237
Benchmarking using Replacement Asset Value ..................................................................... 239
Importance Of Fit, Tolerance And Clearance ......................................................................... 242
Can Your Spare Parts Be Made Locally? ................................................................................ 245
Failure Analysis Of A Gearbox, Fan, Bearing and Shaft ........................................................ 247
Maintenance Planning – Make Your Planner Successful! ...................................................... 249
What makes a World-Class Asset Management Organisation? .............................................. 251
Job Types On Work Orders ..................................................................................................... 253
Job Performance Reviews ....................................................................................................... 254
Maintenance Planning and Scheduling ................................................................................... 255
Valuable Secrets In Every Work Order Report. ...................................................................... 256
Agitator Shaft Thrust Bearings ............................................................................................... 257
Job Descriptions Tell Tradesmen What To Do ....................................................................... 259
Equipment Identification Tags Save Time .............................................................................. 260
Confined Space Entry Safety .................................................................................................. 261
Preventative Maintenance Stops Breakdowns ........................................................................ 264
Fibreglass Construction and Repair ........................................................................................ 265
Use Written Work Instructions to Make it Clear .................................................................... 268
Use Words Instead Of Code Numbers On Work Orders ........................................................ 269
Watch Keeping - Added Value From Operators ..................................................................... 270
Components of an Effective Maintenance System ................................................................. 271
Have Good Valve Decontamination Practices ........................................................................ 272
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Predictive Maintenance – What Is It? ..................................................................................... 273
How Accounting Policies Affect Maintenance Costs ............................................................. 274
Safety Shower Installations ..................................................................................................... 275
Job Safety on Hazardous and Dangerous Work ...................................................................... 277
Tools to Focus on Plant Reliability ......................................................................................... 278
Reliability Centered Maintenance - What Is It? ...................................................................... 280
Creative Disassembly .............................................................................................................. 283
Holiday Detection in Above-ground Tank Bottom Lining Inspection ................................... 286
Root Cause Analysis Answers Your Problems ....................................................................... 288
Is Your Wet Scrubbing Tower Working? ............................................................................... 290
Plant Compressed Air Waste Control ..................................................................................... 293
Work Within The Design Limits ............................................................................................. 295
5 Whys Method of Root Cause Analysis ................................................................................ 296
The 5 ‘S’ Method of Operation ............................................................................................... 299
Equipment Criticality .............................................................................................................. 301
The 9 Great Benefits Of A CMMS* ....................................................................................... 303
Budgets – What To Do And How To Use Them .................................................................... 306
When To Use Stainless And Alloy Steel In Place Of Plastic Or Carbon Steel....................... 309
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