Machinery Failure Analysis Handbook

<br>Preface</br><br>Part I Introduction to Failure Analysis</br><br> 1 Fundamental Causes of Failures</br><br> 1.1 Design Failures</br><br> 1.2 Material Selection Deficiencies</br><br> 1.3 Material Imperfections</br><br> 1.4 Manufacturing Defects</br><br> 1.5 Assembly and Installation Errors</br><br> 1.6 Maintenance and Operation Errors</br><br> Conclusion</br><br> 2 Failure Analysis Practice</br><br> 2.1 Failure Analysis Objectives</br><br> 2.2 How Far Should We Go?</br><br> 2.3 Main Steps</br><br> 2.4 Reports and Databases</br><br> 3 Failure Prevention Efforts</br><br> 3.1 Types of Failure</br><br> 3.2 Prevention of Failures</br><br> 3.3 Machinery Monitoring and Anticipatory Action</br><br> 3.4 Operator’s Role in Machinery Reliability</br><br>Part II Failure Modes</br><br> 4 Ductile and Brittle Fractures</br><br> 4.1 Ductile Fracture Morphology</br><br> 4.2 Ductile Fracture Mechanism</br><br> 4.3 Brittle Fracture</br><br> 4.4 Brittle Fracture Morphology </br><br> 4.5 Brittle Fracture Mechanism</br><br> 5 Fatigue Fractures</br><br> 5.1 Fatigue Fracture Mechanism</br><br> 5.2 Fatigue Fracture Surface Morphology</br><br> 5.3 Factors That Influence Fatigue Strength</br><br> 6 Wear</br><br> 6.1 Sliding Wear</br><br> 6.2 Hard Particle Wear</br><br> 6.3 Liquid Impingement Wear</br><br> 6.4 Cavitation</br><br> 7 Corrosion</br><br> 7.1 Electrochemical Corrosion Mechanism</br><br> 7.2 Uniform Corrosion</br><br> 7.3 Corrosion Fatigue</br><br> 7.4 Pitting Corrosion</br><br> 7.5 Galvanic Corrosion</br><br> 7.6 Corrosion Erosion</br><br> 7.7 Stress Corrosion Cracking</br><br> 8 Incrustation</br><br> 8.1 Coke Deposition </br><br> 8.2 Salt Deposition </br><br> 8.3 Biological Incrustation</br><br> 9 Electric Discharge Damage</br><br>Part III Machinery Component Failures</br><br> 10 Shafts</br><br> 10.1 Stresses Acting on a Shaft</br><br> 10.2 Fatigue Failures</br><br> 10.3 Shaft Wear</br><br> 10.4 Shaft Distortion</br><br> 11 Hydrodynamic Bearings </br><br> 11.1 Operation of a Hydrodynamic Bearing</br><br> 11.2 Hydrodynamic Bearing Construction</br><br> 11.3 Hydrodynamic Bearing Failure Analysis</br><br> 11.4 Fatigue Failures</br><br> 11.5 Bearing Metal Wear</br><br> 11.6 Corrosion</br><br> 11.7 Effect of Hard Particles on Bearings</br><br> 11.8 Effect of Lubrication</br><br> 11.9 Effect of Temperature</br><br> 11.10 Effect of Overloads</br><br> 11.11 Assembly Deficiencies </br><br> 11.12 Electrical Discharge Damage</br><br> 11.13 Fabrication-related Failures</br><br> 11.14 Design-related Failures</br><br> 12 Antifriction Bearings</br><br> 12.1 Antifriction Bearing Lubrication</br><br> 12.2 Antifriction Bearing Design Life</br><br> 12.3 Contact Patterns on Bearing Races</br><br> 12.4 Antifriction Bearing Failure Analysis</br><br> 12.5 Types of Failure</br><br> 13 Mechanical Seals</br><br> 13.1 How a Mechanical Seal Works</br><br> 13.2 Seal Mechanical Design</br><br> 13.3 Seal Hydrodynamic Design</br><br> 13.4 P × V</br><br> 13.5 Sealing System</br><br> 13.6 Mechanical Seal Failure Analysis</br><br> 13.7 Face Contact Patterns</br><br> 13.8 Failure Mechanisms and Causes</br><br> 13.9 Corrosion of Seal Components </br><br> 13.10 Mechanical Damage</br><br> 13.11 Thermal Damage</br><br> 13.12 Design and Manufacturing Defects</br><br> 14 Bolts</br><br> 14.1 How a Bolt Works</br><br> 14.2 Application of the Preload</br><br> 14.3 Reusing Bolts</br><br> 14.4 Bolt Failure</br><br> 15 Gears</br><br> 15.1 Gear Tooth Contact and Lubrication</br><br> 15.2 Loads Acting on the Gear Teeth</br><br> 15.3 Gear Failure </br><br> 16 Reciprocating Compressor Valves</br><br> 16.1 How a Compressor Valve Works</br><br> 16.2 Valve Failure</br><br> 17 Belt Transmissions </br><br> 17.1 “V” Belts</br><br> 17.2 Synchronized Belts</br><br> 18 Couplings</br><br> 18.1 Disc Coupling Couplings</br><br> 18.2 Grid Couplings </br><br> 18.3 Gear Couplings</br><br> 18.4 Coupling Standardization </br><br> 19 Turbomachinery Blades </br><br> 19.1 How a Turbomachinery Blade Works </br><br> 19.2 Blade Failure Analysis</br><br>Part IV Case Studies</br><br> 20 Failure Analysis Examples</br><br> 20.1 A Pump Failure Caused by Turbine Driver Overspeed</br><br> 20.2 Hydrogen Compressor Seal Failure</br><br> 20.3 Vibration-induced Fatigue Failures of Identical Reciprocating Compressors</br><br> 20.4 A Gearbox Failure from the Electrical Discharge Damage of a Bearing</br><br>Bibliography</br><br>Index</br>