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This newly expanded edition shows plant engineers and maintenance personnel how to systematically analyze and troubleshoot machinery distress and component problems. You will find complete coverage of gears, rolling-element bearings, sliding bearings, bolting, couplings, and mechanical seals, with more on pumps, compressors, electric motors, steam turbines, and similar equipment.
Eliminate just the symptoms, and not the root cause, and you will again face equipment downtime and component failure. This book documents and analyzes actual failure events to give you the know-how to discover not just the problem, but its underlying cause.
A new chapter examines root cause analysis and shows how to pursue the cause-and-effect relationship. Details on the practical aspects of metallurgical failure analysis have been added and the chapter on vibration analysis has been thoroughly updated.
Reliability professionals, process engineers, plant operators, and repair and maintenance personnel will value this new edition as the standard authority on the subject.
| Author: | Heinz P. Bloch and Fred K. Geitner |
|---|---|
| Format: | Hardback |
| Pages: | 668 |
| Excerpt: | "A rather large number of factors influences lubricating oil degradation and, consequently, pump bearing life. If your centrifugal pumps are equipped with rolling element bearings, there is little doubt that medium viscosity turbine oils (ISO Grade 68) will perform better than the lighter oils originally specified by many pump manufacturers. But, by far, the most frequent cause of lube-oil-related failure incidents is water and dirt contamination. With only 20 ppm water in pure mineral oil, bearing surface and rolling element fatigue life is reduced by an incredible 48 percent. Although the fatigue life reduction is less pronounced with inhibited lubricants, there are always compelling reasons to exclude dirt and water from pump bearing housings. Lip seals are a poor choice for centrifugal pump installations demanding high reliability. Face seals represent superior, "hermetic" sealing and should be given serious consideration. "On a related subject, have you explained to your operators and maintenance personnel that a full-bottle oiler is no guarantee of adequate lubrication? The height of the beveled tube determines the level of oil in the bearing housing, and all too often there will be costly misunderstandings. However, there are at least two considerably more elusive problems involving bottle oilers. "The first of these is that bottle oilers may malfunction unless suitably large bearing housing vents are provided. With a relatively viscous oil and close clearance at the bearing housing seal, an oil film may exist between seal bore and shaft surface. Good lube oils have a certain film strength and under certain operating conditions, this sealing film near the bearing end cap may break only if the pressure difference bearing housing interior-to-surrounding atmosphere exceeds 3/8 inch of water column. "If now, the bearing housing is exposed to a temperature increase of a few degrees, the trapped vapors - usually an air-oil mix - floating above the liquid oil level will expand and the pressure may rise 1/4 inch of water column. While this would not be sufficient to rupture the oil film so as to establish equilibrium between atmosphere and bearing housing interior, the pressure buildup is nevertheless sufficient to depress the oil level from its former location near the center of a bearing ball at the 6 o'clock position to a new level now barely touching the extreme bottom of the lowermost bearing rolling element. At that time, the bearing will overheat and the lube oil in contact with it will carbonize. An oil analysis will usually determine that the resulting blackening of the oil is due to this high temperature degradation. "The second of the elusive oil-related problems often causes the contents of bottle oilers to turn grayish color. This one is primarily observed on ring-oil lubricated rolling element bearings. "Suppose you have very precisely aligned the shafts of pump and driver; nevertheless, shims placed under the equipment feet in order to achieve this precise alignment caused the shaft system to slant 0.005" or 0.010" per foot of shaft length. As a consequence, the brass or bronze oil slinger ring will now exhibit a strong tendency to run "downhill." Thus bumping into other pump components thousands of times per day, the slinger ring gradually degrades and sheds numerous tiny specks of the alloy material. The specks of metal cause progressive oil deterioration and, ultimately, bearing distress. "Pump users may wish to pursue one of two time-tested preventive measures. First, use properly vented bearing housings or, better yet, hermetically sealed bearing housings without oiler bottles. The latter are offered by some pump manufacturers and incorporate bull's-eye-type sight glasses to ascertain proper oil levels. "The second preventive measure would take into account the need for radically improved pump and driver leveling during shaft alignment or, even more desirable, apply flinger spools. Of course, oil mist lubrication or direct oil injection into the bearings would represent an altogether more dependable, long- term satisfactory lube application method for centrifugal pumps." |
| Table Of Contents: | The Failure Analysis and Troubleshooting System Metallurgical Failure Analysis Machinery Component Failure Analysis Machinery Troubleshooting Vibration Analysis Generalized Machinery Problem-Solving Sequence Statistical Approaches in Machinery Problem Solving Sneak Analysis Formalized Failure Reporting as a Teaching Tool The "Seven-Cause Category Approach" to Root-Cause Failure Analysis Cause Analysis by Pursuing the Cause-and-Effect Relationship Knowledge-Based Systems for Machinery Training and Organizing for Successful Failure Analysis and Troubleshooting |
| Reviews: | A revised and updated guide (1st ed., 1983) that shows plant engineers and supervisors how to systematically analyze and troubleshoot machinery component distress with field-proven techniques. It covers gears, rolling-element bearings, sliding bearings, bolting, couplings, mechanical seals, etc. on pumps, compressors, electric motors, steam turbines, and similar equipment. New to this edition are descriptions of enhanced methods of metallurgical failure analysis, approaches to coupling distress investigations, and updated procedures for lube-oil management in process plants. Annotation copyright Book News, Inc. Portland, Or. --This review refers to an out of print or unavailable edition of this title. |
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