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