Machinery Failure Analysis and Troubleshooting

4th Edition

Practical Machinery Management for Process Plants

Authors: Heinz P. Bloch Fred K. Geitner
Hardcover ISBN: 9780123860453
eBook ISBN: 9780123860460
Imprint: Butterworth-Heinemann
Published Date: 27th August 2012
Page Count: 760
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Solve the machinery failure problems costing you time and money with this classic, comprehensive guide to analysis and troubleshooting

  •  Provides detailed, complete and accurate information on anticipating risk of component failure and avoiding equipment downtime
  • Includes numerous photographs of failed parts to ensure you are familiar with the visual evidence you need to recognize
  • Covers proven approaches to failure definition and offers failure identification and analysis methods that can be applied to virtually all problem situations
  • Demonstrates with examples how the progress and results of failure analysis and troubleshooting efforts can be documented and monitored

Failures of machinery in a plant setting can have wide-ranging consequences and in order to stay competitive, corporations across all industries must optimize the efficiency and reliability of their machinery.

Machinery Failure Analysis and Troubleshooting is a trusted, established reference in the field, authored by two well-known authorities on failure and reliability. Structured to teach failure identification and analysis methods that can be applied to almost all problem situations, this eagerly awaited update takes in the wealth of technological advances and changes in approach seen since the last edition published more than a decade ago.

Covering both the engineering detail and management theory, Machinery Failure Analysis and Troubleshooting provides a robust go-to reference and training resource for all engineers and managers working in manufacturing and process plants.

Key Features

  • Provides detailed, complete and accurate information on anticipating risk of component failure and avoiding equipment downtime
  • Presents documented failure case studies and analyzes the procedures employed to define events that led to component or systems failure
  • Includes numerous photographs of failed parts to ensure readers are familiar with the visual evidence they need to recognize


Engineers involved with the design, maintenance, and reliability of production machinery. Equipment Engineers, Reliability Engineers and Mechanical Engineers who have responsibility for improving equipment performance.

Table of Contents




Chapter 1. The Failure Analysis and Troubleshooting System

Troubleshooting as an Extension of Failure Analysis

Causes of Machinery Failures

Root Causes of Machinery Failure


Chapter 2. Metallurgical Failure Analysis

Types of Failures

Metallurgical Failure Analysis Methodology

Failure Analysis of Bolted Joints

Shaft Failures

The Case of the Boiler Fan Turbine

Analysis of Surface-Change Failures

Analyzing Wear Failures∗

Preventive Action Planning Avoids Corrosion Failure∗

Case Studies



Chapter 3. Machinery Component Failure Analysis

Bearings in Distress

Rolling-Element Bearing Failures and Their Causes∗

Patterns of Load Paths and Their Meaning in Bearing Damage

Troubleshooting Bearings

Journal and Tilt-Pad Thrust Bearings∗

Gear Failure Analysis

Preliminary Considerations∗

Analytical Evaluation of Gear Theoretical Capability

Metallurgical Evaluation

General Mechanical Design


Defects Induced by Other Train Components



Surface Fatigue

Failures from the Manufacturing Process


Lubricated Flexible/Coupling Failure Analysis

Gear-Coupling Failure Analysis

Gear-Coupling Failure Mechanisms

Determining the Cause of Mechanical Seal Distress

Troubleshooting and Seal-Failure Analysis

Summary of Mechanical Seal Failure Analysis

Avoiding Common Causes of O-ring Failures∗

Failure Without Visible Evidence on Seal

Compression Set

Lubricant Considerations

Lubrication Failure Analysis

Why Lube Oil Should Be Purified

Six Lube-Oil Analyses Are Required



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About the Author

Heinz P. Bloch

A consulting engineer residing in Montgomery, texas, Heinz. P. Bloch has held machinery-oriented staff and line positions with Exxon affiliates in the United States, Italy, Spain, England, The Netherlands, and Japan. His career spanned several decades prior to his 1986 retirement as Exxon Chemical's regional machinery specialist for the USA. Since his retirement from Exxon, he has been in demand throughout the world as a consultant and trainer in the areas of failure avoidance, root cause failure identification, and reliability improvement. Mr. Bloch is the author/co-author of thirteen books and over 200 other publications on subjects related to machinery reliability and failure avoidance. He is the Reliability and Equipment Editor of Hydrocarbon Processing magazine and has served as chair of the annual conference program for Hydrocarbon Processing's Process Plant Reliability Conference for a number of years.

Affiliations and Expertise

Consulting Engineer, Montgomery, TX, USA

Fred K. Geitner

Fred K. Geitner is a registered Professional Engineer in the Province of Ontario, Canada, engaged in process machinery consulting. He retired from Imperial Oil with 20 years of service as an engineer.

Affiliations and Expertise

Professional Engineer, Ontario, Canada.