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Plant and Machinery Failure Prevention

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Monitoring and predictive maintenance methods are not reliable enough in indicating certain important problems in manufacturing equipment, such as cracking of power transmission components, inadequate lubrication of parts, and excessive cutting edge wear of a tool or die. Plant and Machinery Failure Prevention is based on the premise of "Zero-Failure Performance".

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Author: A. A. Hattangadi Published: 2005 Format: Hardback Pages: 458 Excerpt: In case of ball bearing failures one of the first things to check on is the quality of the grease used. If the bearing has seized, the quality of grease in similar bearings may be checked. Bearings with a service due for grease replacement should be checked. The feel or consistency of the grease removed from the bearings should be compared with that of new grease. If the grease feels harder, drier or less slippery, if oil droplets are seen in bearing overflow vents it is an indication that some of the suspended oil has been churned out and the grease is unsuitable for the application. If the grease is of the approved brands the whole issue of approval of the brand should be reopened and the manufacturer of the grease should be notified. Table Of Contents: 1. Introduction 2. How to Attain Zero Failure Performance 3. General Feature of Failures 4. Investigation of Failures 5. Degradation Processes (Mechanical) 6. Degradation Processes (Electrical) 7. Split Pin and Cotter Failures 8. Threaded Fastener Failures 9. Shaft or Axle Failures 10. Ball and Roller Bearing Failures 11. Sleeve Bearing Failures 12. Failures of White Metal Bearings of Electric Locomotives 13. Flat Belt Failures 14. Vee-belt Failures 15. Pulley Failures 16. Gear Failures 17. Steel Wire Rope Failures 18. Spring Failures 19. Gasket Failures 20. O-ring And U-ring Failures 21. Rubber Hose Pipe Failures 22. Pipes and Tube Failures 23. Compressed Air Valve Failures 24. Failures of Compressed Air Operated Equipment 25. Fluid Filter Failures 26. Compressed Air Motor Failures 27. Air Compressor Failures 28. Vacuum Brake Failures on DC EMUS 29. Fan and Blower Failures 30. Thermal Cracks on Motor Coach Tyres 32. Crimped Socket Failures 33. Wires and Cable Failures 34. Insulated Wire Failures 35. Auxiliary Motor Cable Failures 36. Multicore Coupler Failures 37. Knife Switch Failures 38. Parallel Clamp Failures 39. Terminal Board Failures 40. Capacitor Failures 42. Potentiometer Failures 43. Contact Failures 44. Relays Failures 45. Failures of Fuses and Miniature Circuit Breakers 46. Bus-Bar Failures 47. Failures of Lead Acid Batteries 48. Failures of Incandescent Lamps 49. Insulator Failures 50. Solenoid Failures 51. Failures of Carbon Brushes and Commutators 52. Commutator Connection Failure 53. Commutator Failures 54. Failures of Rotor or Armature Coils in dc Machines 55. Failures of Stator Coils in Rotating Machines 56. Starting Resistor Failures 57. Tapchanger Connection Failures 58. Electrical Machine Failures due to Ventilation Problems 59. Power Transformer Explosions 60. Failures of OHE Regulating Equipment 61. Minimum Oil Circuit-breaker Failures 62. Line Breaker Failures 63. Squirrel Cage Failures in Asynchronous Motors 64. Failures of Mush Wound Stator Windings 65. Pantograph OHE Entanglements 66. Failures and Accidents in Chemical Plant Reviews: Maximize Productivity by Keeping Plant and Equipment Downtime and Unscheduled Maintenance at a Minimum Constant monitoring and preventive maintenance are not the most effective ways of avoiding common problems in manufacturing equipment - engineers need better, more reliable methods. Packed with expert advice, Plant and Machinery Failure Prevention is based on the premise of "zero-failure performance," a method designed to assist maintenance engineers discover and solve problems in mechanical and electrical equipment before they occur. The author presents solid statistical as well as investigative methods for determining failures in mechanical and electrical equipment components - including flat belts, vee belts, pulleys, gears, steel wire ropes, springs, gaskets, and more - at the earliest stage possible. Comprehensive diagnostics on the nature/causes of equipment failures Numerous case studies to emphasize key points and procedures Investigation methods for electrical and mechanical equipment failures

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