Details
Taking a detailed and systematic approach, Practical Plant Failure Analysis: A Guide to Understanding Machinery Deterioration and Improving Equipment Reliability thoroughly explains the four major failure mechanisms-wear, corrosion, overload, and fatigue-as well as how to identify them. The author clearly identifies how these mechanisms appear in various components and supplies convenient charts that demonstrate how to identify the specific causes of failure.
Plus:
Presents practical guidance on failure mechanisms, what leads to these failures, and how to avoid them in the future
Integrates aspects of mechanics, corrosion, materials science, and tribology into a clear and concise approach
Provides easy-to-follow charts that help you logically diagnose a failure and take appropriate corrective action
Supplies more than 300 photographs and illustrations that help build confidence and competence in visual diagnosis
Contains a clear and detailed explanation of the differences between through- and case-hardened gear teeth
Author: Neville W. Sachs
Published: 2007
Format: Hardback
Pages: 266
Excerpt: As every reliability professional has seen, another area where the value of failure analysis commonly isn't utilized involves the practice of routinely scheduled outages. Should maintenance be scheduled based on the position of the sun or the moon and end up with monthly or annual outages? What is the real difference between a scheduled outage and a breakdown? The need for maintenance has to be recognized but in many cases the time between these "scheduled failures" can be greatly lengthened by analysis of the need for the various phases of the outage. We have never seen a situation where, after a competent and detailed analysis, the time between outages hasn't been increased by at least 50%.
Table Of Contents:
AN INTRODUCTION TO FAILURE ANALYSIS
The Causes of Failures
Root Cause Analysis (RCA) and Understanding the Roots
The Human Error Study
Latent Roots
How the Multiple Roots Interact
The Benefits and Savings
Summary
SOME GENERAL CONSIDERATIONS ON FAILURE ANALYSIS
The Failure Mechanisms: How They Occur and Their Appearances
Summary
MATERIALS AND THE SOURCES OF STRESSES
Stress
Elasticity
Plasticity
Modulus of Elasticity (Young's Modulus)
Toughness
Fatigue
Some Basic Metallurgy
Plain Carbon Steel: The Basics
Understanding Steel Terminology and Material Designations
Strengthening Metals
Summary
OVERLOAD FAILURES
Introduction
Unusual Conditions
Summary
FATIGUE FAILURES (PART 1): THE BASICS
Fatigue Failure Categories
FATIGUE (PART 2): TORSIONAL, LOW-CYCLE, AND VERY-LOW-CYCLE FAILURE INFLUENCES AND FATIGUE INTERPRETATIONS
Torsional Fatigue Loads
River Marks and Fatigue Crack Growth
Plate and Rectangular Failures
Fatigue Data Reliability and Corrosion Effect on Fatigue Strength
Residual Stress
Combined Fatigue and Steady State Stresses
Base Material Problems
Very-Low-Cycle and Low-Cycle Fatigue
Very-Low-Cycle in Relatively Brittle Materials
VLC in Ductile Materials
Unusual Situations
Failure Examples
UNDERSTANDING AND RECOGNIZING CORROSION
Corrosion Rates
pH Effects
Effect of Available Oxygen
Exposure Time and Flow Effects
Temperature Effects
The Eight Types of Corrosion
LUBRICATION AND WEAR
Three Types of Lubricated Contacts
Manufacturing a Lubricant
Greases
Lubricant Applications
Summary
Defining Wear Mechanisms
Summary Comments on Wear Failures
BELT DRIVES
Belt Design
Belt Operation and Failure Causes
Drive Efficiencies
Belt Drive Failure Analysis Techniques
BALL AND ROLLER BEARINGS
Bearing Materials
Parts of a Bearing
Cages
Bearing Ratings and Equipment Design
A Detailed Rolling Element Bearing Failure Analysis Procedure
Roller and Tapered Roller Bearing Mounting Surfaces
Summary
GEARS
Gear Terminology
Types of Gears
Tooth Action
Load and Stress Fluctuations
Gear Materials
Tooth Contact Patterns
Backlash
Design Life and Deterioration Mechanisms
Through-Hardened Gear Deterioration Mechanisms
Case-Hardened Gear Deterioration Mechanisms
Analyzing Gear Failures
Failure Examples
Summary
FASTENER AND BOLTED JOINT FAILURES
How Bolts Work
Fastener Failures
Failure Examples
MISCELLANEOUS MACHINE ELEMENT FAILURES
Chains
Lip Seals
Flexible Couplings
BIBLIOGRAPHY FOR PRACTICAL PLANT FAILURE ANALYSIS
INDEX
Reviews: Providing a clear explanation of the major failure mechanisms and how to identify them, Practical Plant Failure Analysis describes mechanisms, wear, corrosion, overload, and fatigue. Showing how the failure mechanisms appear in components such as shafts, bearings, and gears, it examines many of the critical operating details in an accessible manner. It offers charts that illustrate how to identify specific failure. Additional coverage includes physical failure analysis, basic materials properties, differences between ductile and brittle overload failures, high and low cycle fatigue, lubrication, ball and roller bearings, fastener failures, V-belts, and synchronous belts.
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Custom Variants and Options let you create product customization options and fields quickly and easily. Any product can have custom variants and options – this can be configured in its product configuration. Custom variants and options can be created for products as required or non-required options. They can affect the total price of the product by a fixed amount or percentage.
In other words, custom variants and options allow you to make products that are unique and individualized. Whether it’s a gift with a special message, a sweatshirt with custom embroidered text, or anything in between – possibilities are limitless.