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IPT's Rotating Equipment Handbook: Machinery Reliability & Condition Monitoring

IPT’s Rotating Equipment Handbook and Training Manual
Informative and Thorough

As an on-the-job reference or a primary resource for a complete training program, IPT’s Rotating Equipment books are North America’s number one source for machinery reliability and condition monitoring information. Millwrights, industrial mechanics, heavy-duty mechanics and rotating equipment technicians find both the handbook and manual invaluable assets.

Comprehensive Machinery Reliability and Condition Monitoring Information

Featuring 500 pages, 300 illustrations and 30 tables and charts, IPT’s Rotating Equipment Handbook and Training Manual discuss proven diagnostics, corrective methods and procedures for determining the condition of machinery. They can also help in the prediction of mechanical problems and contain essential vibration analysis, bearing failure analysis, performance monitoring, and safe lockout and tagout procedures.

 

SECTION ONE - MAINTENANCE AND RELIABILITY
Rotating Maintenance Problems p 2-4 Maintenance Planning p 14-19
MIRP Program p 4-6 Long Range Planning p 14
Maintenance Methods p 6-9 Short - Mid Range Planning p 15
Preventive Maintenance p 6,7 Intermediate Planning p 15
Predictive Maintenance p 7-8 Critical Path Method (CPM) p 15-19
Breakdown Maintenance p 8 Program Evaluation (PERT) p 19
Predictive Program Methods p 9 Predictive Maintenance Concerns p 19-21
Machine Monitoring p 9-13 Predictive Maintenance Applications p 21-27
Temperature p 10 Vibration and Noise p 22,23
Vibration p 11 Non-Destructive Testing p 23,25
Listening p 12 Fluid Analysis p 25,26
Sight p 13 Machinery Measurement/Evaluation p 26,27
Corrective Maintenance p 14  
SECTION TWO - VIBRATION ANALYSIS
Introduction p 30 Sound Measurement p 67,68
What is Vibration p 30 Sound Pressure Levels p 68-70
Vibration Amplitude p 31,41 Sound Fields p 71,72
Vibration Facts p 31,32 Directional Noise p 72
Machine Properties p 32,33 Noise & Machinery Condition p 72,73
Excitation Forces p 33,34 Noise Level Facts p 73,74
Vibration Causes p 34,35 Vibration & Noise Measurement p 74-79
Vibration Characteristics p 35-44 Vibration Meters p 74,75
Vibration Frequency p 36,37 Vibration Monitor p 76
Vibration Displacement p 37,38 Vibration Analyzer p 76-79
Vibration Velocity p 38,39 Transducers p 80-92
Vibration Acceleration p 39-41 Transducer Proximity Probes p 80-83
Vibration Phase p 42-44 Velocity Transducers p 83-86
Frequency and RPM p 44,45 Hand Held Transducer p 86,87
Resonance p 45-47 Magnetic Pick-up Holder p 87,88
Resonance and Damping p 47 Shaft Stick p 88-90
Critical Speed p 47,48 Accelerometer Transducers p 90-92
Measuring Amplitude p 49,50 Microphones p 93,94
Selecting Vibration Indicator p 50-54 Vibration Pick-up Positions p 94,95
Numerous Frequencies p 54-58 Amplitude vs Frequency p 95-99
Absolute Tolerances p 58-61 "X-Y" Plotter p 100,101
Sound p 61,62 FFT Recording p 100-104
Sound Sources p 62,63 Spectrum Analysis p 104,105
Sound Causes p 63 Vibration Data Interpretation p 105-116
Sound Characteristics p 64-67  
Vibration Causes Introduction p 118 Oil Whip p 156,157
Unbalance Vibration p 118-124 Mechanical Looseness Vibration p 157-160
Causes of Unbalance p 119-124 Electrical Problem Vibration p 160-167
Deposit and Build-Up p 119 Slip Frequency p 162
Corrosion and Wear p 119,120 Torque Pulsations p 162,163
Eccentricity p 120 Armature Problems p 163-165
Keys and Keyways p 120-122 Stator Problems p 165-167
Clearance Tolerance p 122 Belt Drive Vibration p 167-174
Distorsion p 122,123 Determining Belt Frequency p 169-170
Casting Imperfections p 123,124 Belt Tension p 170,171
Misalignment Vibration p 124-131 Belt Slippage p 171,172
Types of Misalignment p 124-130 Defective Belts p 172,173
Parallel Offset p 124,125 Balancing Belt Pulleys p 173,174
Angular p 124,125 Damaged Gear Vibration p 174-177
Parallel Offset & Angular p 124,125 Resonance Vibration p 178,179
Misalignment Sources p 131 Aerodynamic & Hydraulic Vibration p 179-195
Eccentric Forces Vibration p 131-135 Cavitation p 181-187
Bent Shaft Vibration p 135-137 Recirculation p 187-189
Resonant Whirl p 136,137 Discharge Recirculation p 189,190
Anti-Friction Bearing Vibration p 137-146 Suction Recirculation p 190,191
Frequency Analysis p 137,142 Flow Turbulence p 191-194
Bearing Loads p 142,143 Random Vibration p 195
Causes of Bearing Failure p 143-146 Reciprocating Forces Vibration p 195-198
Vibration from Journal Bearings p 146-157 Rubbing Vibration p 198,199
Excessive Bearing Clearance p 148,149 Rotor Flex Vibration p 199-201
Detecting Faulty Bearing p 149,150 Beat or Pulsation Vibration p 201-203
Oil Whirl p 150-156 Hydraulic System Vibration p 203-206
SECTION FOUR - EQUIPMENT BALANCING
Introduction p 208, 209 Balancing Methods p 234-251
In-Place Balancing p 209 Single Plane Balancing p 235-246
Balancing Machine p 210,211 Static Balancing p 235,236
Unbalance p 212-214 Vector Method p 236-240
Types of Unbalance p 214-218 Balancing in One Run p 241-243
Static Unbalance p 214-217 Four Run Method p 243-246
Couple Unbalance p 217 Two Plane-Cross Effect p 247,248
Quasi-Static Unbalance p 217,218 Single Plane Solutions p 248,249
Dynamic Unbalance p 218 Two Plane Vectors p 249
Natural Frequency p 219,220 Two Plane Overhung Rotors p 250,251
Critical Speeds p 221-223 Multi-Plane Balancing p 252
Rigid or Flexible Rotors p 223 Weight Changes p 252,253
Balancing Tools p 224 Changing Weight Radius p 253,254
Trial Weights p 224-227 Dividing a Balance Weight p 254-257
How Much Trial Weight p 225-227 Combining Balance Weights p 257,258
Attaching Trial Weights p 227 Balancing Tolerances p 259-261
Phase Angle Measurement p 228-232 Residual Unbalance Tolerances p 261-266
Trial Weight p 228,232 ISO Tolerances p 264-266
Before Balancing p 233,234 Conclusion p 266
SECTION FIVE - LUBRICATION
Introduction p 268 Greasing Intervals p 305,306
Lubrication Functions p 268,269 Oil Lubrication p 306
Lubrication Selection p 269 Oil Classifications p 306-319
Friction p 269-272 Industrial Classifications p 306-309
Lubrication Principles p 272-278 Gear Oil Classifications p 310,311
Viscosity p 272,273 Engine Oil Classifications p 311-316
Consistency p 273 Automotive Gear Oils p 317-319
Lubrication Film p 274 Lubricating Oil Types p 320-322
Boundary Layer p 274 Mineral Oils p 320
Hydrodynamic (Full Film) p 274,275 Animal & Vegetable Oils p 321
Partial Hydrodynamic p 275 Synthetic Oils p 321,322
Surface Finish p 276-278 Common Oil Additives p 322-325
Grease Lubrication p 276-279 Oxidation Inhibitors p 323
Grease Ingredients p 279,280 Pour Point Depressant p 323
Grease Types p 280-282 Rust Inhibitors p 323
Calcium Soap p 280 Anti-Wear Additives p 324
Sodium Soap p 280 Foam Depressants p 324
Lithium Soap p 281 Detergent-Dispersant p 325
Complex Soap p 281 Viscosity Index p 325,326
Mixed Soap p 281 Load Carrying Tests p 326
Inorganic Thickener p 281 Flash & Fire Points p 326,327
Synthetic Greases p 282 Oil Analysis p 327-350
Grease Additives p 282,283 Oil Analysis Program p 327-330
Grease Properties p 283-294 Oil Sample Slip p 330-332
Consistency p 284,285 Oil Analysis Tests p 333
Temperature and Load p 285-289 Spectrographic Analysis p 333-339
Dropping Point p 287,290 TBN and TAN p 339-342
Miscibility p 290,291 Allowable Soot Test p 343,344
Mechanical Stability & Wear p 291 Viscosity Test p 343-346
Sealing Properties p 292-294 Wear Metal - Iron p 345-347
Grease Selection Factors p 294 Allowable Oxidation p 345
Bearing Greasing p 294-303 Oil Sampling Procedures p 348-350
Correct Mounting p 295 Conclusion & Decision p 349,351
Correct Time p 295,296 Changing Lubricant p 351,352
Correct Quantity p 296 Oil Lubrication Systems p 352-354
Correct Methods p 296-301 Oil & Grease Storage p 355-357
Replacing Grease (anti-friction) p 301-303 Lubrication Scheduling p 357
Correct Amount p 303,304 Lubrication Department p 358-360
Application Methods p 304,305    
SECTION SIX - NON-DESTRUCTIVE TESTING
NDT Purpose p 362,363 Inspection and Interpretation p 376
Direct Visual Inspection p 363 Ultrasonic Testing p 376-385
Remote Visual Inspection p 364-368 Types of Sound Waves p 377
Videoimagescope p 364-368 Ultrasonic Requirements p 377-379
Fiberscope p 364-368 Surface Preparation p 379
Borescope p 364-368 Ultrasonic Testing Methods p 379-385
Liquid Penetrant Testing p 368-371 Resonant Frequency p 379,380
Preparation and Application p 369,370 Transit Time Method p 380
Developing and Inspection p 370,371 Intensity Method p 380-385
Magnetic Particle Testing p 371-376 Intensity & Transit Time p 380-385
Magnetizing the Part p 373-375 Eddy Current Testing p 386
Particle Application p 375,376 Radiography Testing p 387-389
SECTION SEVEN - BEARING FAILURE ANALYSIS
Bearing Problems p 392 Electric Current Passage p 409,410
Anti-friction Bearing Life p 392,393 Journal Bearing Failure p 410-418
Load Path Patterns p 393-398 Unsuitable Design p 410,411
Premature Anti-friction Failure p 398-399 Unsuitable Operating Environment p 411-413
Lubrication Failure p 399-401 Lubrication Problems p 414,415
Lubrication Contamination p 401-403 Misalignment p 415-417
Incorrect Tolerances p 403-405 Ove
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