Component failures result from a combination of factors involving materials science, mechanics, thermodynamics, corrosion, and tribology. With the right guidance, you don’t have to be an authority in all of these areas to become skilled at diagnosing and preventing failures. Based on the author’s more than thirty years of experience, Practical Plant Failure Analysis: A Guide to Understanding Machinery Deterioration and Improving Equipment Reliability is a down-to-earth guide to improving machinery maintenance and reliability. Illustrated with hundreds of diagrams and photographs, this book examines... · When and how to conduct a physical failure analysis · Basic material properties including heat treating mechanisms, work hardening, and the effects of temperature changes on material properties · The differences in appearance between ductile overload, brittle overload, and fatigue failures · High cycle fatigue and how to differentiate between high stress concentrations and high operating stresses · Low cycle fatigue and unusual fatigue situations · Lubrication and its influence on the three basic bearing designs · Ball and roller bearings, gears, fasteners, V-belts, and synchronous belts Taking a detailed and systematic approach, Practical Plant Failure Analysis 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.

This is a practical guide for those who do the work of maintaining and improving the reliability of mechanical machinery. It is for engineers and skilled trades personnel who want to understand how failures happen and how the physical causes of the great majority can be readily diagnosed in the field. It explains the four major failure mechanisms, wear, corrosion, overload, and fatigue and, using easy-to-read charts, how they can be diagnosed at the site of the failure. Then, knowing the physical failure mechanics involved, the reader can accurately solve the human causes. To improve the reader’s understanding, all the diagrams and most of the tables have been redrawn. The number of actual failure examples has been increased, plus the last chapter on miscellaneous machine elements includes new material on couplings, universal joints, and plain bearings. Features A practical field guide showing how to recognize how failures occur that can be used to solve more than 85% of mechanical machinery failures Incorporates multiple easy-to-follow logic trees to help the reader diagnose the physical causes of the failure without needing detailed laboratory analysis Explains how the mechanics, corrosion, materials science, and tribology of components can fit together to improve machinery reliability Includes more than 150 completely redrawn charts and tables, plus almost 250 actual failure photographs to help guide the reader to an accurate analysis Contains clear and detailed explanations of how lubricants function and the critical roles of corrosion and lubrication play in causing mechanical failures

This is a practical guide for those who do the work of maintaining and improving the reliability of mechanical machinery. It is for engineers and skilled trades personnel who want to understand how failures happen and how the physical causes of the great majority can be readily diagnosed in the field. It explains the four major failure mechanisms, wear, corrosion, overload, and fatigue and, using easy-to-read charts, how they can be diagnosed at the site of the failure. Then, knowing the physical failure mechanics involved, the reader can accurately solve the human causes. To improve the reader’s understanding, all the diagrams and most of the tables have been redrawn. The number of actual failure examples has been increased, plus the last chapter on miscellaneous machine elements includes new material on couplings, universal joints, and plain bearings. Features A practical field guide showing how to recognize how failures occur that can be used to solve more than 85% of mechanical machinery failures Incorporates multiple easy-to-follow logic trees to help the reader diagnose the physical causes of the failure without needing detailed laboratory analysis Explains how the mechanics, corrosion, materials science, and tribology of components can fit together to improve machinery reliability Includes more than 150 completely redrawn charts and tables, plus almost 250 actual failure photographs to help guide the reader to an accurate analysis Contains clear and detailed explanations of how lubricants function and the critical roles of corrosion and lubrication play in causing mechanical failures

Filling a gap in the literature, Practical Engineering Failure Analysis vividly demonstrates the correct methodology to conduct successful failure analyses, as well as offering the background necessary for these investigations. This authoritative reference covers procedures to reduce the occurrence of component failures due to errors in material se

Root Cause Failure Analysis provides the concepts needed to effectively perform industrial troubleshooting investigations. It describes the methodology to perform Root Cause Failure Analysis (RCFA), one of the hottest topics currently in maintenance engineering. It also includes detailed equipment design and troubleshooting guidelines, which are needed to perform RCFA on machinery found in most production facilities. This is the latest book in a new series published by Butterworth-Heinemann in association with PLANT ENGINEERING magazine. PLANT ENGINEERING fills a unique information need for the men and women who operate and maintain industrial plants. It bridges the information gap between engineering education and practical application. As technology advances at increasingly faster rates, this information service is becoming more and more important. Since its first issue in 1947, PLANT ENGINEERING has stood as the leading problem-solving information source for America's industrial plant engineers, and this book series will effectively contribute to that resource and reputation.Provides information essential to industrial troubleshooting investigationsDescribes the methods of root cause failure analysis, a hot topic in maintenance engineeringIncludes detailed equipment-design guidelines

Root Cause Failure Analysis Provides the knowledge and failure analysis skills necessary for preventing and investigating process equipment failures Process equipment and piping systems are essential for plant availability and performance. Regularly exposed to hazardous service conditions and damage mechanisms, these critical plant assets can result in major failures if not effectively monitored and assessed—potentially causing serious injuries and significant business losses. When used proactively, Root Cause Failure Analysis (RCFA) helps reliability engineers inspect the process equipment and piping system before any abnormal conditions occur. RCFA is equally important after a failure happens: it determines the impact of a failure, helps control the resultant damage, and identifies the steps for preventing future problems. Root Cause Failure Analysis: A Guide to Improve Plant Reliability offers readers clear understanding of degradation mechanisms of process equipment and the concepts needed to perform industrial RCFA investigations. This comprehensive resource describes the methodology of RCFA and provides multiple techniques and industry practices for identifying, predicting, and evaluating equipment failures. Divided into two parts, the text first introduces Root Cause Analysis, explains the failure analysis process, and discusses the management of both human and latent error. The second part focuses on failure analysis of various components such as bolted joints, mechanical seals, steam traps, gearboxes, bearings, couplings, pumps, and compressors. This authoritative volume: Illustrates how failures are associated with part integrity, a complete system, or the execution of an engineering process Describes how proper design, operation, and maintenance of the equipment help to enhance their reliability Covers analysis techniques and industry practices including 5-Why RCFA, fault tree analysis, Pareto charts, and Ishikawa diagrams Features a detailed case study of process plant machinery and a chapter on proactive measures for avoiding failures Bridging the gap between engineering education and practical application, Root Cause Failure Analysis: A Guide to Improve Plant Reliability is an important reference and guide for industrial professionals, including process plant engineers, planning managers, operation and maintenance engineers, process designers, chemical engineers, and instrument engineers. It is also a valuable text for researchers, instructors, and students in relevant areas of engineering and science.

This book addresses the failures of structural elements, i.e. those components whose primary mission is to withstand mechanical loads. The book is intended as a self-contained source for those with different technical grades, engineers and scientists but also technicians in the field can benefit from its reading.

Updated and revised, this book presents the application of engineering design and analysis based on the approach of understanding the physical characteristics of a given problem and then modeling the important aspects of the physical system. This third edition provides coverage of new topics including contact stress analysis, singularity functions,