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Machinery Lubrication and Reliability First Edition
by Trinath Sahoo Ph.D (Author)

Hardcover: 450 pages
Publisher: Industrial Press, Inc.; First edition (April 1, 2020)
Language: English
ISBN-10: 0831136383
ISBN-13: 978-0831136383

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Machinery Lubrication and Reliability
By: Trinath Sahoo

Publisher:  Industrial Press, Inc.
eText ISBN: 9780831195069, 0831195061
Edition: 1st
Copyright year: 2020
Format: PDF

دانلود کتاب Machinery Lubrication and Reliability

While it is mostly “behind the scenes,” lubrication is used wherever you look—in all types of machines, vehicles, and aircrafts. Its usefulness is everywhere, in every industry, from all types of manufacturing, power, health, petrochemicals, food, paper, and metallurgy to small industries and agriculture. Lubrication is absolutely essential to the world.

There is an undeniable link between maintenance strategy and lubrication reliability. Depending on the industry, maintenance costs can represent between 15-60% of the cost of goods produced. Therefore, the reliability of plant and equipment has a significant impact on the profits of any organization. Unfortunately, most problems related to machinery in plants are lubrication-related. To get maximum benefit from advanced maintenance strategies, an understanding of equipment lubrication is a must. That’s why this work is invaluable.

Machinery Lubrication and Reliability contains everything a maintenance, plant, or industrial professional needs to know about lubrication theory, with vital information on all the critical equipment lubrication requirements. It illustrates how to improve reliability, maximize equipment life, eliminate unscheduled shut downs, and reduce operating costs.

Rounding out this amazing package are questions and answers for those looking to obtain their ICML certifications. An affiliated web site (www.machinerylubricationreliability.com) contains additional questions for exam takers looking for extra practice.

Features The only book that covers all the topics for the ICML certification course.
Includes the industry standard API-614 throughout.
Contains practice questions for the ICML exam at the end of each chapter, along with additional ones on the affiliated website.

دانلود ایبوک کتاب روغن کاری و قابلیت اطمینان ماشین آلات

در حالی که بیشتر “در پشت صحنه” وجود دارد ، روغن کاری در هر کجا که به نظر برسید در همه دستگاه ها ، وسایل نقلیه و هواپیماهای هوایی استفاده می شود. سودمندی آن در همه جا ، در هر صنعت ، از انواع تولید ، نیرو ، بهداشت ، پتروشیمی ، مواد غذایی ، کاغذ و متالورژی گرفته تا صنایع کوچک و کشاورزی وجود دارد. روغن کاری برای جهان کاملاً ضروری است.

بین استراتژی نگهداری و قابلیت اطمینان روغنکاری رابطه غیرقابل انکار وجود دارد. بسته به صنعت ، هزینه های تعمیر و نگهداری می تواند بین 60 تا 60 درصد هزینه کالاهای تولید شده را نشان دهد. بنابراین ، قابلیت اطمینان کارخانه و تجهیزات تأثیر بسزایی در سود هر سازمان دارد. متأسفانه بیشتر مشکلات مربوط به ماشین آلات در گیاهان مربوط به روغن کاری است. برای به دست آوردن حداکثر بهره مندی از استراتژی های پیشرفته تعمیر و نگهداری ، درک روغن کاری تجهیزات ضروری است. به همین دلیل این اثر ارزشمند است.

روغن کاری و قابلیت اطمینان ماشین آلات شامل همه چیزهایی است که یک تعمیر و نگهداری ، کارخانه یا نیازهای حرفه ای صنعتی در مورد تئوری روانکاری با اطلاعات حیاتی در مورد کلیه نیازهای مهم تجهیزات روانکاری برخوردار است. این روش چگونگی بهبود قابلیت اطمینان ، به حداکثر رساندن عمر تجهیزات ، از بین بردن تعطیلات غیر برنامه ریزی شده و کاهش هزینه های عملیاتی را نشان می دهد.

گردآوری این بسته شگفت انگیز سؤالات و پاسخ هایی است که به دنبال دریافت گواهینامه های ICML خود هستند. یک وب سایت وابسته (www.machinerylubricationreliability.com) شامل سوالات اضافی برای متقاضیان امتحان که به دنبال تمرین اضافی هستند.

فهرست مطالب Machinery Lubrication and Reliability

Front Matter
Title Page
Copyright
Contents
Preface
Acknowledgments
Chapter 1
Introduction
Link Between Maintenance Strategy and Lubrication Reliability
Asset Maintenance Strategy
Reactive Maintenance
Preventive Maintenance
Predictive Maintenance
Proactive Maintenance
Reliability-Centered Maintenance
Developing the Right Maintenance Strategy for Your Assets
What Is Lubrication Reliability?
Maintenance Strategy Applicable to Lubrication Reliability
Managing A Successful Lubrication Program
Conclusion
International Conference on Machine Learning (ICML) Questions
Chapter 2
Friction, Wear, and Lubrication
Friction
Laws of Sliding Friction
Rolling Friction
Properties of Rolling Friction
Laws of Rolling Friction
Fluid Friction
Wear
Wear Mechanisms
Adhesion
Corrosive Wear
Abrasive Wear
Surface Fatigue Wear
How to Avoid Wear of Lubricated Contacts
Lubrication
Theory of Oil Film Formation
Lubrication Regimes
Conformal and Nonconformal Surfaces
Modes of Lubrication
Hydrodynamic Lubrication
Elastohydrodynamic Lubrication
Partial/Mixed Lubrication
Boundary Lubrication
Stribeck Curve
Factors That Affect the Effectiveness of the Oil Film
Conclusion
ICML Questions
Chapter 3
Lubricants and Their Properties
Solid Lubricants
Classification of Solid Lubricants
Inorganic Lubricants with Lamellar Structure
Soft Metals
Polymeric Materials
Ceramics and Cermets (Metal-Bonded Ceramic) Coatings
Advantages of Solid Lubricants
Disadvantages of Solid Lubricants
Semisolid Lubricants (Greases)
Types and Characteristics of Greases
Composition
What Does Base Oil Do in Lubricating Greases?
What Does Thickener Do in Lubricating Greases?
Types of Thickeners
What Do Additives Do in Lubricating Greases?
Types and Characteristics of Grease Components
Base Oils
Petroleum Oils
Synthetic Fluids
Vegetable Oils
Thickening Agents
Simple Soaps
Complex Soaps
Nonsoap Thickeners
Additives
Tackiness Additives
Extreme Pressure (EP) Additives
Classification of Greases: NLGI Grease Grade Numbers
Properties of Greases
Consistency and Penetration
Bleeding
Bleeding (ASTM D 1742)
Dropping Point
Grease Selection
Temperature
Speed
Pressure
Viscosity, Speed, and Pressure
Conditions, Environment, and Contamination
Incompatibility of Greases
Oil Versus Grease
Liquid Lubricants
Classification of Liquid Lubricants
Vegetable Oils
Mineral Oils
Paraffinic Components
Disadvantages of Mineral Oils
Synthetic Lubricants
Gaseous Lubricants
Liquid Lubricant Selection
Operating Speed
Load
Temperature
Method of Lubrication
Operating Environment
Physical Properties of Lubricating Oils
Density
Lubricity
Demulsibility
Foaming
Filterability
Total Base Number
Detergency and Dispersancy
Low-Temperature Properties
Cloud Point
Pour Point
High-Temperature Properties
Volatility
Flash Point and Fire Point
Chemical Properties
Corrosivity
Oxidation Stability
Lubricant Additives
Surface-Protective Additives
Lubricity Additives
Antiwear Additives
Extreme Pressure Additives
Tackiness Additives
Corrosion- and Rust-Inhibiting Additives
Detergent and Dispersant Additives
Detergents
Dispersants
Friction-Modifying Additives
Performance-Enhancing Additives
Viscosity Index Improvers
Pour Point Depressants
Demulsifiers
Lubricant-Protective Additives
Oxidation Inhibitors
Foam Inhibitors
Additive Depletion
Conclusion
ICML Questions
Chapter 4
Pump Lubrication
Lubrication Selection Guidelines
Lubrication Application Methods
Oil Sump
Benefits of an Oil Sump
Application
Flinger Ring
Slinger Disk
Factors That Affect Oil Sump Lubrication
Quantity
Oil Starvation
Excessive Lubrication
Quality
Poor Oil Sump Lubrication—Causes
Water Contamination
Particle Contamination
Heat
Air Entrainment
Oil Degradation
Prevention Measures to Improve Lubrication
Preventing Improper Quantity
Preventing Contamination
Prevention of Degradation
Preventing Operating Temperature Problems
How to Stop the Contamination
Sealing of Bearing Housings
Oilers
Conclusion
ICML Questions
Chapter 5
Lubrication of Reciprocating Compressors
Bearing Lubrication
Splash Lubrication
Pressure Circulation Lubrication
Frame Lubrication System
Components
Oil Strainer
Oil Pump
Oil Cooler
Oil Temperature Control Valve
Oil Filters
Compressor Prelube Pump/Auxiliary Oil Pump
Oil Heaters
Lube Oil Analysis Sampling Point
Frame Lubrication Operating Conditions
Compressor Frame Lubricant
Synthetic Compressor Lubricants
Oil Viscosity
Oil Temperature
Oil Maintenance
Oil Sampling
Oil System Cleanliness
Selecting Lubricants
Factors That Affect Crankcase Lubrication
Problems with Crankcase Oil
Frequency of Oil Changes
Cylinder and Packing Lubrication
Force-Feed Lubrication Systems
Common Oil Supply
Independent Force-Feed Lubricator Systems
Independent Oil Supply
Injection Oil Inlet Filter
Oil Dilution
Cylinder Oil Lubrication
Under/Overlubrication
Inadequate
Excessive
Inadequate Lubrication Symptoms
Lubricator Cycle Time
Force-Feed Lubrication System Monitoring
Minimum Requirements
Devices
Choosing a Lube System Monitor
Break-in Rate
Factors Affecting Cylinder Lubrication
Rate of Oil Feed
Excessive Oil Feed
Cylinder Oil Feed
Contamination Concerns
Purging Oil Lines and Components
Conclusion
ICML Questions
Chapter 6
Lubrication of Screw Compressors
Basic Operating Principles
Selection of Lubricating Oil
Viscosity and Gas Solubility
Selection of Oil
Problems with Residues, Deposits, and Sludge in the Oil
High Oil Consumption and High Oil Carryover to the Gas Stream
Conclusion
ICML Questions
Chapter 7
Lubrication Systems for Turbo Machinery
Circulating Lube Oil System Components
Console/Skid
Vessel and Piping
Oil Pumps
Filter Subsystem
Cooling Subsystem
Overhead Oil Tank
Instrumentation/Alarms
Lube Oil Pressure Control Valves
Seal Oil System
Reservoir
Purpose
Capacity
Normal Flow
Design Considerations
Material
Capacity and Residence Time
Layout
Manway
Pump Suction Lines
Return Lines
Vent
Baffles
Reservoir Fill Cap
Additional Items Required for a Reliable Design
Armored Sight Glass
Oil Purification Connections
Potential Reservoir Problem Areas
Electric Heater Short Circuits
Carbonizing Electric Heaters
Damage to the Reservoir Internal Coating
Addition of Overhead Rundown Tanks
Oil Contamination
Pumps
Design Considerations
Positive-Displacement Pumps
Characteristics of Positive-Displacement Pumps
Centrifugal Pumps
Potential Pump Problem Areas
Priming of Positive-Displacement Pumps with Nonflooded Suctions
Maximum Oil Temperature in Positive-Displacement Pumps During Flush
Slow-Rolling Turbine Drive Auxiliary Oil Pumps
Pump Misalignment During Console Shipment
Main Pump to Standby Pump Transients
Transient Dampers
Regulating and Control Valves
Relief Valves
Design Considerations
API 614 Specification Requirements
Potential Relief-Valve Problem Areas
Oil Coolers
Design Considerations
API 614 Specification Requirements
Potential Oil Cooler Problem Areas
Cooler Thermal Cycling
Drop in Cooler Efficiency After Cleaning
Excessive Tube Failures
Oil Filters
Design Considerations
Types
Pleated Paper
Pleated Fiberglass/Polyester
Wound Cartridge Filters
Ratings
Sizing
Potential Oil Filter Problem Areas
High Filter Pressure Differential
Cartridge Separation or Unwinding
Cartridge Life
Cartridge Ratings
Cartridge Swelling
Instrumentation
Design Considerations
API 614 Specification Requirements
Switches
Pressure Gauges
Thermometers
Sight Flow Indicators
Liquid Level Indicators
Potential Switch Problem Areas
Motor-Driven Auxiliary Oil Pump
Hand-Off Auto Switches
Unit Trips Before Alarm
Switch Failure
Interconnecting Piping
Layout
Material
Pipe Size
Pump Piping
Potential Piping Problem Areas
Drain Pipe
Piping
Insulation and Heat Tracing
Conclusion
ICML Questions
Chapter 8
Gear Lubrication
Gear Teeth Lubrication
Frictional Force Between the Gear Teeth and the Impact of Speed
Gear Design Dictates Lube Design
Spur Gears
Bevel Gears
Hypoid Gears
Worm Gears
Double Helical Gears
Consider Gear Speed
Determine Type of Load
Identify Viscosity Recommendation
Know Gearbox Construction and Capacity
Minimize Effects of the Operating Environment
Ensure Fluid Durability for Extended Drains
Properties of Gear Oils
Operating Temperature
Viscosity
Aging Behavior
Low-Temperature Behavior
Anticorrosion Properties
Corrosion Protection on Steel
Corrosion Protection on Copper (Compatibility with Nonferrous Metals)
Compatibility with Interior Coatings
Foaming Behavior
Elastomer Compatibility
Wear Protection
Protection of Gear Teeth
Scuffing.
Micropitting
Type of Gear Oil
Rust and Oxidation (R&O)–Inhibiting Oils
Extreme Pressure (EP) Oils
Compounded Gear Oils
Synthetics
Avoiding Common Gearbox Lubrication Problems
Gearbox Contamination Control
Contamination During Oil Change
Gearbox Maintainability
Conclusion
ICML Questions
Chapter 9
Storage and Handling of Lubricants
New Lubricant Quality Control
Proper Unloading And Handling
Proper Storage Environment
Proper Storage Management
Indoor Storage
Outdoor Storage
What Happens with Vertical Storage?
Lubricant Degradation During Storage
Thermal Degradation of Lubricants
Accurate Labeling
Health and Safety Precautions
Preparation for Worst-Case-Scenario Spills
Fire Precautions
Contamination Control
Proper Long-Term Storage
Handling of Lubricating Oil
Transferring Large Volumes of Oil
Prefiltering of Lubricants
Use of Sealable, Cleanable Top-Up Containers
Precautions During Top-Up Activities
Are the Lubricants Ready for Dispensing?
Appropriate Stock Rotation
Conclusion
ICML Questions
Chapter 10
Oil Sampling
Data Density And Data Disturbance
Sampling Frequency
Strategic Sampling Considerations
Locations for Sampling
Sampling Port Location
Primary Sampling Ports
Secondary Sampling Ports
Sampling of Circulating Systems
Turbulence
Ingression Points
Filtration
Drain Lines
Sampling Wet Sumps
Sampling Noncirculating Systems
Oil Sampling Tools
Sampling Valves/Ports
Pitot Sampling Tubes/Probes
Liquid Level Gauge Sampling Ports
Vacuum Pump
Sampling Bottles and Hardware
Conclusion
ICML Questions
Chapter 11
Understanding Oil Analysis: How It Can Improve Reliability
Oil Analysis Tests and Their Significance
Physical Analysis
Viscosity
Neutralization Number
Acid Number
Base Number
Water Contamination
Significance
Applications
Particle Count
Particle Count Reporting and ISO Regulations
Ferrous Wear Concentration
Ferrography
DR Ferrography
Analytical Ferrography
Elemental Spectroscopy
Significance
Taking Action with Oil Analysis
Determining If Oil Analysis Is Warranted
Oil Analysis Intervals
Required Information for Proper Analysis
Analysis Results and Interpretation
Trending
Advantages of Oil Analysis
Reduce Unneeded Maintenance and Oil Waste
Increase Equipment Reliability
Normalize Equipment Operation with Trending Data
Enhance Equipment Resale Value by Exhibiting Component Integrity
Avoid Oil Mix-Up
Contamination Control
Failure Analysis
Conclusion
ICML Questions
Chapter 12
Creating an Effective Lubrication Program
Lubrication Program Management
Right Type
Right Quality
Right Amount
Right Place
Right Time
Right Lubrication Procedures
How to Achieve the Six R’s
Lubrication Program Development Phase
Develop an Equipment List
Conduct a Lubrication Survey
Questions Relating to Lubricant Quality, Quantity, and Type
Questions Relating to Storage and Handling
Questions Relating to Sampling
Questions Relating to In-Service Lubricant Health/Condition
Questions Relating to Lubricant Contamination
Questions Relating to Training Needs
Selecting the Right Lubricant
Consolidation of Lubricants (If Applicable)
Lubrication Manual Development
Organization and Planning
Leading the Program
Role of Lubrication Subject-Matter Experts
Role of Planning Department
Role of Maintenance Department (Customer)
Role of Staff Performing Lubrication Functions
Building the Lubrication Preventive Maintenance (PM) Program
Set Lubrication (PM) Frequency
Logistics and Supply Chain
Necessary Lubrication Equipment Procurement
Implementing the Lubrication Program
Lubricant Storage and Handling
Lubricant Dispensers and Grease Gun Storage
Contamination and Condition Control
Standard Operating Procedures (SOPs)
Improving Your Lubrication Program
Performance Measurements
Continuous Improvement
Training and Education
Conclusion
ICML Questions
Index