Machinery Failure Analysis Handbook

Machinery Failure Analysis Handbook

Sustain Your Operations and Maximize Uptime

1st Edition - November 1, 2006

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  • Author: Luiz Octavio Amaral Affonso
  • Hardcover ISBN: 9781933762081
  • eBook ISBN: 9780127999821

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Description

Understanding why and how failures occur is critical to failure prevention, as even the slightest breakdown can lead to catastrophic loss of life and asset as well as widespread pollution. This book helps anyone involved with machinery reliability, whether in the design of new plants or the maintenance and operation of existing ones, to understand why process equipment fails and thereby prevent similar failures.

Table of Contents


  • Preface

    Part I Introduction to Failure Analysis

    1 Fundamental Causes of Failures

    1.1 Design Failures

    1.2 Material Selection Deficiencies

    1.3 Material Imperfections

    1.4 Manufacturing Defects

    1.5 Assembly and Installation Errors

    1.6 Maintenance and Operation Errors

    Conclusion

    2 Failure Analysis Practice

    2.1 Failure Analysis Objectives

    2.2 How Far Should We Go?

    2.3 Main Steps

    2.4 Reports and Databases

    3 Failure Prevention Efforts

    3.1 Types of Failure

    3.2 Prevention of Failures

    3.3 Machinery Monitoring and Anticipatory Action

    3.4 Operator’s Role in Machinery Reliability

    Part II Failure Modes

    4 Ductile and Brittle Fractures

    4.1 Ductile Fracture Morphology

    4.2 Ductile Fracture Mechanism

    4.3 Brittle Fracture

    4.4 Brittle Fracture Morphology

    4.5 Brittle Fracture Mechanism

    5 Fatigue Fractures

    5.1 Fatigue Fracture Mechanism

    5.2 Fatigue Fracture Surface Morphology

    5.3 Factors That Influence Fatigue Strength

    6 Wear

    6.1 Sliding Wear

    6.2 Hard Particle Wear

    6.3 Liquid Impingement Wear

    6.4 Cavitation

    7 Corrosion

    7.1 Electrochemical Corrosion Mechanism

    7.2 Uniform Corrosion

    7.3 Corrosion Fatigue

    7.4 Pitting Corrosion

    7.5 Galvanic Corrosion

    7.6 Corrosion Erosion

    7.7 Stress Corrosion Cracking

    8 Incrustation

    8.1 Coke Deposition

    8.2 Salt Deposition

    8.3 Biological Incrustation

    9 Electric Discharge Damage

    Part III Machinery Component Failures

    10 Shafts

    10.1 Stresses Acting on a Shaft

    10.2 Fatigue Failures

    10.3 Shaft Wear

    10.4 Shaft Distortion

    11 Hydrodynamic Bearings

    11.1 Operation of a Hydrodynamic Bearing

    11.2 Hydrodynamic Bearing Construction

    11.3 Hydrodynamic Bearing Failure Analysis

    11.4 Fatigue Failures

    11.5 Bearing Metal Wear

    11.6 Corrosion

    11.7 Effect of Hard Particles on Bearings

    11.8 Effect of Lubrication

    11.9 Effect of Temperature

    11.10 Effect of Overloads

    11.11 Assembly Deficiencies

    11.12 Electrical Discharge Damage

    11.13 Fabrication-related Failures

    11.14 Design-related Failures

    12 Antifriction Bearings

    12.1 Antifriction Bearing Lubrication

    12.2 Antifriction Bearing Design Life

    12.3 Contact Patterns on Bearing Races

    12.4 Antifriction Bearing Failure Analysis

    12.5 Types of Failure

    13 Mechanical Seals

    13.1 How a Mechanical Seal Works

    13.2 Seal Mechanical Design

    13.3 Seal Hydrodynamic Design

    13.4 P × V

    13.5 Sealing System

    13.6 Mechanical Seal Failure Analysis

    13.7 Face Contact Patterns

    13.8 Failure Mechanisms and Causes

    13.9 Corrosion of Seal Components

    13.10 Mechanical Damage

    13.11 Thermal Damage

    13.12 Design and Manufacturing Defects

    14 Bolts

    14.1 How a Bolt Works

    14.2 Application of the Preload

    14.3 Reusing Bolts

    14.4 Bolt Failure

    15 Gears

    15.1 Gear Tooth Contact and Lubrication

    15.2 Loads Acting on the Gear Teeth

    15.3 Gear Failure

    16 Reciprocating Compressor Valves

    16.1 How a Compressor Valve Works

    16.2 Valve Failure

    17 Belt Transmissions

    17.1 “V” Belts

    17.2 Synchronized Belts

    18 Couplings

    18.1 Disc Coupling Couplings

    18.2 Grid Couplings

    18.3 Gear Couplings

    18.4 Coupling Standardization

    19 Turbomachinery Blades

    19.1 How a Turbomachinery Blade Works

    19.2 Blade Failure Analysis

    Part IV Case Studies

    20 Failure Analysis Examples

    20.1 A Pump Failure Caused by Turbine Driver Overspeed

    20.2 Hydrogen Compressor Seal Failure

    20.3 Vibration-induced Fatigue Failures of Identical Reciprocating Compressors

    20.4 A Gearbox Failure from the Electrical Discharge Damage of a Bearing

    Bibliography

    Index

Product details

  • No. of pages: 308
  • Language: English
  • Copyright: © Gulf Publishing Company 2006
  • Published: November 1, 2006
  • Imprint: Gulf Publishing Company
  • Hardcover ISBN: 9781933762081
  • eBook ISBN: 9780127999821

About the Author

Luiz Octavio Amaral Affonso

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  • vinodkallianpur Thu Jun 14 2018

    Very well written.

    Very well written.