Machinery failure analysis and troubleshooting:
Gespeichert in:
Hauptverfasser: | , |
---|---|
Format: | Buch |
Sprache: | English |
Veröffentlicht: |
Amsterdam [u.a.]
Butterworth-Heinemann
2012
|
Ausgabe: | 4. ed. |
Schriftenreihe: | Practical machinery management for process plants
2 |
Schlagworte: | |
Online-Zugang: | Inhaltsverzeichnis Klappentext |
Beschreibung: | XV, 743 S. Ill., graph. Darst. |
ISBN: | 9780123860453 |
Internformat
MARC
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245 | 1 | 0 | |a Machinery failure analysis and troubleshooting |c Heinz P. Bloch ; Fred K. Geitner |
250 | |a 4. ed. | ||
264 | 1 | |a Amsterdam [u.a.] |b Butterworth-Heinemann |c 2012 | |
300 | |a XV, 743 S. |b Ill., graph. Darst. | ||
336 | |b txt |2 rdacontent | ||
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490 | 1 | |a Practical machinery management for process plants |v 2 | |
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650 | 7 | |a Usines - Entretien |2 ram | |
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Datensatz im Suchindex
_version_ | 1804149678111981568 |
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adam_text | Contents
Acknowledgments
............................................................................................xiii
Preface
............................................................................................................xv
Chapter
1:
The Failure Analysis and Troubleshooting System
.................................1
Troubleshooting as an Extension of Failure Analysis
.......................................................1
Causes of Machinery Failures
............................................................................................3
Root Causes of Machinery Failure
.....................................................................................7
References
...........................................................................................................................9
Chapter
2:
Metallurgical Failure Analysis
..........................................................7 7
Types of Failures
..............................................................................................................15
Metallurgical Failure Analysis Methodology
..................................................................15
Failure Analysis of Bolted Joints
.....................................................................................21
Shaft Failures
....................................................................................................................28
The Case of the Boiler Fan Turbine
................................................................................46
Analysis of Surface-Change Failures
...............................................................................48
Analyzing Wear Failures
..................................................................................................56
Preventive Action Planning Avoids Corrosion Failure
....................................................65
Case Studies
......................................................................................................................69
Summary
...........................................................................................................................84
References
.........................................................................................................................85
Chapter
3:
Machinery Component Failure Analysis
.............................................87
Bearings in Distress
..........................................................................................................90
Rolling-Element Bearing Failures and Their Causes
......................................................96
Patterns of Load Paths and Their Meaning in Bearing Damage
.....................................98
Troubleshooting Bearings
...............................................................................................131
Journal and Tilt-Pad Thrust Bearings
............................................................................150
Gear Failure Analysis
.....................................................................................................172
Preliminary Considerations
............................................................................................173
Analytical Evaluation of Gear Theoretical Capability
..................................................176
VII
viii Contents
Metallurgical Evaluation
................................................................................................177
General Mechanical Design
...........................................................................................178
Lubrication
......................................................................................................................178
Defects Induced by Other Train Components
...............................................................178
Wear
................................................................................................................................179
Scoring
............................................................................................................................186
Surface Fatigue
...............................................................................................................192
Failures from the Manufacturing Process
......................................................................197
Breakage
.........................................................................................................................202
Lubricated Flexible/Coupling Failure Analysis
.............................................................205
Gear-Coupling Failure Analysis
.....................................................................................206
Gear-Coupling Failure Mechanisms
...............................................................................208
Determining the Cause of Mechanical Seal Distress
....................................................218
Troubleshooting and Seal-Failure Analysis
...................................................................219
Summary of Mechanical Seal Failure Analysis
.............................................................240
Avoiding Common Causes of
О
-ring
Failures
...............................................................241
Failure Without Visible Evidence on Seal
.....................................................................241
Compression Set
.............................................................................................................242
Lubricant Considerations
................................................................................................248
Lubrication Failure Analysis
..........................................................................................248
Why Lube Oil Should Be Purified
.................................................................................250
Six Lube-Oil Analyses Are Required
............................................................................263
Periodic Sampling and Conditioning Routines Implemented
.......................................267
Calculated Benefit-to-Cost Ratio
...................................................................................271
Wear-Particle Analysis
...................................................................................................272
Grease Failure Analysis
..................................................................................................275
Magnetism in Turbomachinery
......................................................................................278
References
.......................................................................................................................292
Chapter
4:
Machinery Troubleshooting
............................................................295
Competing Approaches
..................................................................................................297
The Professional Problem Solver s
(PPS)
Approach
.....................................................301
The Matrix Approach to Machinery Troubleshooting
...................................................304
Troubleshooting Pumps
..................................................................................................312
Making Good Choices
....................................................................................................344
Troubleshooting Centrifugal Compressors, Blowers, and Fans
....................................346
Troubleshooting Reciprocating Compressors
................................................................347
Troubleshooting Engines
................................................................................................361
Troubleshooting Steam Turbines
....................................................................................368
Troubleshooting Gas Turbines
.......................................................................................369
Contents
¡χ
Troubleshooting Electric Motors
....................................................................................373
Electrical Motor Bearing Failures
..................................................................................373
Troubleshooting the Process
...........................................................................................379
Apply Proven Machinery Problem Solving Strategies
..................................................383
References
.......................................................................................................................389
Chapter
5;
Vibration Analysis
........................................................................391
Machine History
.............................................................................................................394
Machine Characteristics
.................................................................................................394
Interpretation of Collected Data
.....................................................................................402
Aerodynamic Row-Induced Vibrations
.........................................................................421
Establishing Safe Operating Limits for Machinery
.......................................................463
Appendix
.........................................................................................................................466
Formulas
.........................................................................................................................475
References
.......................................................................................................................477
Chapter
6:
Generalized Machinery Problem-Solving Sequence
............................479
Situation Analysis
...........................................................................................................480
Cause Analysis
................................................................................................................485
Action Planning and Generation
....................................................................................496
Planning for Change
.......................................................................................................518
References
.......................................................................................................................524
Chapter
7:
Statistical Approaches in Machinery Problem Solving.
.......................525
Machinery Failure Modes and Maintenance Strategies
.................................................526
Machinery Maintenance Strategies
................................................................................542
Method to Identify Bad Repairs from Bad Designs
......................................................549
References
.......................................................................................................................557
Quantifying Reliability Performance to Meet Process Safety Expectations
.................558
How Equipment Reliability has an Impact on Process Safety
......................................558
Case Histories in Responsive Risk Mitigation
..............................................................559
Conservative, but Reasonable?
.......................................................................................562
What Does Good Look Like?
.....................................................................................564
A Standardized Approach to Assessing Pump Failure Risk
.........................................564
Conclusions
.....................................................................................................................575
References
.......................................................................................................................575
Chapter
8:
Formalized Failure Reporting as a Teaching Tool
.............................577
Examining the Sample Reports
......................................................................................579
The Case of the High-Speed, Low-Flow Pump Failure
................................................580
References
.......................................................................................................................614
χ
Contents
Chapter
9:
The Seven Cause Category Approach to Root-Cause
Failure Analysis
............................................................................
Checklists and Failure Statistics Can be Helpful
..........................................................616
Systematic Approaches Always Valuable
......................................................................616
Faulty Design Causes Premature Bearing Failures
........................................................617
Fabrication and Processing Errors Can Prove Costly
....................................................619
Operations Errors Can Cause Pumps to Malfunction
....................................................621
Maintenance Omissions Can Cause Loss of Life
..........................................................622
Awareness of Off-Design and Unintended Service Conditions Needed to Prevent
Failures
........................................................................................................................630
Reduced Life and Catastrophic Failure of Electric Motor Bearings
.............................634
References
.......................................................................................................................635
Chapter
10:
A Principle Based Problem Solving Process
....................................637
Traditional Problem-Solving Strategies
.........................................................................638
Linear Thinking
..............................................................................................................638
Categorization
.................................................................................................................638
Storytelling
......................................................................................................................640
Root Cause Myth
............................................................................................................644
Principles of Causation
...................................................................................................645
Seven Steps to Effective Problem Solving
....................................................................647
RealityCharting
...............................................................................................................648
Continuous Improvement
—
The Essence of Quality
.....................................................648
Additional Resources
......................................................................................................648
References
.......................................................................................................................649
Chapter
11:
Knowledge-Based Systems for Machinery Failure Diagnosis
.............651
Examples of Knowledge-Based Systems
.......................................................................653
Identification and Selection of Knowledge-Based System Applications
......................654
Project Implementation
..................................................................................................659
Expert-System Questionnaire
.........................................................................................662
References
.......................................................................................................................668
Chapter
12:
Training and Organizing for Successful Failure Analysis
and Troubleshooting
....................................................................669
Available Choices and When to Make Them
................................................................670
Why Shared Learning and a Measure of Specialization are Important
........................671
Specific Steps in the Training and Learning Process
....................................................672
Favorable Results Anticipated
........................................................................................674
Contents
χι
Professional
Growth: The Next Step
..............................................................................675
Organizing for Failure Analysis and Troubleshooting
..................................................677
Setting Up a Centrifugal Pump Failure Reduction Program
.........................................677
Definition of Approach and Goals
.................................................................................678
Action Steps Outlined
....................................................................................................679
Development of Checklists and Procedures
...................................................................680
Program Results and Conclusions
..................................................................................688
References
.......................................................................................................................689
Appendix A: Databases, Surveys and mean-time-between-failure expectations
derived from literature and from authors observations
....................691
Appendix B: Probability Plotting of Life Data
...................................................713
Appendix C: Glossary of Problem-Solving and Decision-Making Terms
.................723
Appendix D: Gear Nomenclature
.....................................................................725
Subject Index
.................................................................................................727
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.
Also available from
Elsevier
Lee
et al
·
Metal Fatigue Analysis Handbook: Practical Problem-Solving Techniques for Computer-Aided
Engineering
· 9780123852045
Forsthofier ·
Forsthoffers Best Practice Handbook for Rotating Machinery
· 9780080966762
Smith
·
Reliability. Maintainability and Risk: Practical Methods for Engineers. 8th Edition
· 9780080969022
|
any_adam_object | 1 |
author | Bloch, Heinz P. 1933- Geitner, Fred K. |
author_GND | (DE-588)13710071X |
author_facet | Bloch, Heinz P. 1933- Geitner, Fred K. |
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author_sort | Bloch, Heinz P. 1933- |
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building | Verbundindex |
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dewey-ones | 658 - General management |
dewey-raw | 658.2/7 |
dewey-search | 658.2/7 |
dewey-sort | 3658.2 17 |
dewey-tens | 650 - Management and auxiliary services |
discipline | Technik Wirtschaftswissenschaften |
edition | 4. ed. |
format | Book |
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spelling | Bloch, Heinz P. 1933- Verfasser (DE-588)13710071X aut Machinery failure analysis and troubleshooting Heinz P. Bloch ; Fred K. Geitner 4. ed. Amsterdam [u.a.] Butterworth-Heinemann 2012 XV, 743 S. Ill., graph. Darst. txt rdacontent n rdamedia nc rdacarrier Practical machinery management for process plants 2 Machines - Entretien et réparations ram Usines - Entretien ram Machinery Maintenance and repair Plant maintenance Maschinenschaden (DE-588)4169011-4 gnd rswk-swf Maschine (DE-588)4037786-6 gnd rswk-swf Schadenverhütung (DE-588)4193509-3 gnd rswk-swf Zuverlässigkeit (DE-588)4059245-5 gnd rswk-swf Schadensanalyse (DE-588)4130826-8 gnd rswk-swf Maschine (DE-588)4037786-6 s Zuverlässigkeit (DE-588)4059245-5 s DE-604 Maschinenschaden (DE-588)4169011-4 s Schadensanalyse (DE-588)4130826-8 s Schadenverhütung (DE-588)4193509-3 s Geitner, Fred K. Verfasser aut Practical machinery management for process plants 2 (DE-604)BV012594325 2 Digitalisierung UB Bayreuth application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025419986&sequence=000003&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA Inhaltsverzeichnis Digitalisierung UB Bayreuth application/pdf http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025419986&sequence=000004&line_number=0002&func_code=DB_RECORDS&service_type=MEDIA Klappentext |
spellingShingle | Bloch, Heinz P. 1933- Geitner, Fred K. Machinery failure analysis and troubleshooting Practical machinery management for process plants Machines - Entretien et réparations ram Usines - Entretien ram Machinery Maintenance and repair Plant maintenance Maschinenschaden (DE-588)4169011-4 gnd Maschine (DE-588)4037786-6 gnd Schadenverhütung (DE-588)4193509-3 gnd Zuverlässigkeit (DE-588)4059245-5 gnd Schadensanalyse (DE-588)4130826-8 gnd |
subject_GND | (DE-588)4169011-4 (DE-588)4037786-6 (DE-588)4193509-3 (DE-588)4059245-5 (DE-588)4130826-8 |
title | Machinery failure analysis and troubleshooting |
title_auth | Machinery failure analysis and troubleshooting |
title_exact_search | Machinery failure analysis and troubleshooting |
title_full | Machinery failure analysis and troubleshooting Heinz P. Bloch ; Fred K. Geitner |
title_fullStr | Machinery failure analysis and troubleshooting Heinz P. Bloch ; Fred K. Geitner |
title_full_unstemmed | Machinery failure analysis and troubleshooting Heinz P. Bloch ; Fred K. Geitner |
title_short | Machinery failure analysis and troubleshooting |
title_sort | machinery failure analysis and troubleshooting |
topic | Machines - Entretien et réparations ram Usines - Entretien ram Machinery Maintenance and repair Plant maintenance Maschinenschaden (DE-588)4169011-4 gnd Maschine (DE-588)4037786-6 gnd Schadenverhütung (DE-588)4193509-3 gnd Zuverlässigkeit (DE-588)4059245-5 gnd Schadensanalyse (DE-588)4130826-8 gnd |
topic_facet | Machines - Entretien et réparations Usines - Entretien Machinery Maintenance and repair Plant maintenance Maschinenschaden Maschine Schadenverhütung Zuverlässigkeit Schadensanalyse |
url | http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025419986&sequence=000003&line_number=0001&func_code=DB_RECORDS&service_type=MEDIA http://bvbr.bib-bvb.de:8991/F?func=service&doc_library=BVB01&local_base=BVB01&doc_number=025419986&sequence=000004&line_number=0002&func_code=DB_RECORDS&service_type=MEDIA |
volume_link | (DE-604)BV012594325 |
work_keys_str_mv | AT blochheinzp machineryfailureanalysisandtroubleshooting AT geitnerfredk machineryfailureanalysisandtroubleshooting |