Machinery Failure Analysis Handbook

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