Root Cause Failure Analysis. Trinath Sahoo

Conclusion

      25  Index

      26  End User License Agreement

      List of Tables

      1 Chapter 4Table 4.1 Industrial accidents caused by human error.

      2 Chapter 9Table 9.1 Max DN value of bearing.

      3 Chapter 14Table 14.1 Percentage failure due to separate compressor components.and proce...

      List of Illustrations

      1 Chapter 2Figure 2.1 Events leading to compressor failure.

      2 Chapter 4Figure 4.1 Contributing factors to human error.

      3 Chapter 5Figure 5.1 Stress–strain diagram of a medium‐carbon structural steel.Figure 5.2 Stress–strain curve of brittle and ductile material.Figure 5.3 Ductile vs brittle fracture. (a) Very ductile, soft metals (e.g.,...Figure 5.4 Different stages before ductile fracture. (a) Necking (b) formati...Figure 5.5 Cup and cone fracture in Al.Figure 5.6 Brittle fracture in a mild steel.Figure 5.7 Ductile failure: ‐one piece ‐large deformation (after some amount...Figure 5.8 Brittle failure: ‐many pieces ‐small deformation, (even when the ...Figure 5.9 Schematic representation of the fatigue crack (three stage) pheno...Figure 5.10 Stress concentration at corners.Figure 5.11 Stress corrosion on a bar.Figure 5.12 Stress corrosion cracking.

      4 Chapter 7Figure 7.1 Forces acting on a gasket.Figure 7.2 Tensile stress strain diagram of fastener.Figure 7.3 Use of sleeve around bolt.Figure 7.4 Use of conical washer around bolt.Figure 7.5 Gap in flange.Figure 7.6 Flange cocked.Figure 7.7 Mis‐aligned flange.Figure 7.8 Out of parallel flange.Figure 7.9 Wrong surface finish of flange.Figure 7.10 Bolting sequence of flange.

      5 Chapter 8Figure 8.1 Flanged rigid coupling.Figure 8.2 Cutaway view (DBC‐ Bolt circle dia.)Figure 8.3 Ribbed rigid coupling.Figure 8.4 Sleeve rigid coupling.Figure 8.5 Quill shaft rigid coupling.Figure 8.6 Gear coupling.Figure 8.7 Grid coupling.Figure 8.8 Disc coupling.Figure 8.9 Pin bush type coupling.Figure 8.10 Jaw coupling.Figure 8.11 Corded tire couplings.Figure 8.12 Disc couplings.Figure 8.13 Diaphragm type couplings.Figure 8.14 Hydraulic hub installation tool.Figure 8.15 Couplings tire failure.Figure 8.16 Improperly fitted key.Figure 8.17 Gear teeth worn from excessive misalignment.Figure 8.18 Disc pack coupling.Figure 8.19 Disc pack failure.Figure 8.20 Bolt damage.Figure 8.21 Excessive angular misalignment and axial movement diaphragm fail...

      6 Chapter 9Figure 9.1 Type of antifriction bearings.Figure 9.2 Bearing internal clearance.Figure 9.3 Mounting force applied to the wrong ring.Figure 9.4 Advanced spalling due to subsurface initiated fatigue of the mate...Figure 9.5 Spalling (surface distress) caused by ineffective lubrication.Figure 9.6 Moisture acids in a spherical roller bearing – Moisture corrosion...Figure 9.7 Water in bearing.Figure 9.8 False brinelling.Figure 9.9 Fatigue fracture of the outer ring flange in a double row full co...Figure 9.10 Typical plain journal bearing.Figure 9.11 Pressure profile in a journal bearing.Figure 9.12 Stribeck curve relating friction factor to viscosity, speed, and...Figure 9.13 Sleeve journal bearing.Figure 9.14 Two‐lobe lemon‐shaped sleeve bearing with pressure‐dam.Figure 9.15 Tilting pad journal bearings.Figure 9.16 Bearing melting.Figure 9.17 Bearing damage due to abnormal load.Figure 9.18 Regions of babbitt material creep in a hot‐running region of a c...Figure 9.19 Severe wiping on a thrust shoe (circumferential scratching, narr...

      7 Chapter 10Figure 10.1 Cross section view of centrifugal pump.Figure 10.2 Cross section view of Mechanical seal.Figure 10.3 Leakage path in seal.Figure 10.4 Components of Mechanical seal.Figure 10.5 Pusher seal.Figure 10.6 Cross section view of pusher seal.Figure 10.7 High‐speed stationary welded metal bellow seal schematic.Figure 10.8 API seal Plan 11 (Recirculation from the pump discharge through ...Figure 10.9 H–Q curve of a centrifugal pump.Figure 10.10 Balance pressure mechanical seal schematic drawing.Figure 10.11 Operating envelope for a contacting seal.Figure 10.12 Radial force and total dynamic head vs. capacity.Figure 10.13 Shaft length – L3/D4.Figure 10.14 Critical pump dimensions.Figure 10.15 Critical pump features.Figure 10.16 Concentric runout.Figure 10.17 Perpendicular runout.Figure 10.18 Shaft end float.

      8 Chapter 11Figure 11.1 Cross section view of centrifugal pump.Figure 11.2 Pump failure causes.Figure 11.3 Centrifugal pump component damage and causes as a function of op...Figure 11.4 Recirculation flow pattern in impeller at low flows.Figure 11.5 The pressure profile across a typical pump at a fixed flow condi...Figure 11.6 Vortex breaker in cooling tower pump inlet.Figure 11.7 Bearing cross section view.Figure 11.8 Oil bath lubrication showing a typical oil level.

      9 Chapter 12Figure 12.1 Schematic view of reciprocating pump.Figure 12.2 Schematic view of reciprocating pump parts.Figure 12.3 The five wave forms with the five pressure variations.Figure 12.4 Cross‐sectional view of a dampener.Figure 12.5 Correct piping design.Figure 12.6 Reciprocating pump stuffing box (nonlubricated) showing pressure...Figure 12.7 Reciprocating pump disk valve.Figure 12.8 The structure and wear pattern of the valve is an important piec...

      10 Chapter 13Figure 13.1 Process diagram for compressor.Figure 13.2 Parts of centrifugal compressor.Figure 13.3 Parts of compressor rotor.Figure 13.4 Impeller.Figure 13.5 Cross section view of horizontal split compressor.Figure 13.6 Barrel type casing.Figure 13.7 Compressor surge diagram.Figure 13.8 Change of speed affect surge.Figure 13.9 Process schematic diagram – power turbine/gas compressor lubrica...

      11 Chapter 14Figure 14.1 Compressor components.Figure 14.2 Schematic view of piston rod packing.Figure 14.3 Typical compressor rod packing system positioning in the compres...Figure 14.4 Forces acting on a compressor piston.Figure 14.5 Rod load diagram of a reciprocating compressor.Figure 14.6 Poppet valve.(take drawings to below as marked)Figure 14.7 Ring valve.(take drawings to below as marked)Figure 14.8 Plate valve.(take drawings to below as marked)Figure 14.9 Cut‐away view of packing case.Figure 14.10 Cross section view of packing over piston rod.Figure 14.11 Piston ring and Rider ring mounted in the piston.Figure 14.12 Web deflection measurement.Figure 14.13 Rod drop measurement.Figure 14.14 P–V diagram of a reciprocating compressor.Figure 14.15 P–V diagram.Figure 14.16 Plot of compression efficiency versus compression ratio.Figure 14.17 (a)–(c) are P–V diagrams showing the changes that result ...Figure 14.18 Plot of power versus suction pressure with constant discharge p...Figure 14.19 Plot of capacity versus suction pressure with constant discharg...

      12 Chapter 15Figure 15.1 Moisture in oil its detection and its effect.Figure 15.2 Oil life varies with base oil type and temperature.Figure 15.3 Sampling port locations on a lube oil system that feeds three se...Figure 15.4 Dispensing equipments for lubricants.Figure 15.5 Lubricant pre filtration pump.Figure 15.6 Sealable and cleanable oil‐handling containers with colour codin...

      13 Chapter 16Figure 16.1 Thermodynamic trap.Figure 16.2 Float steam trap.Figure 16.3 Inverted bucket trap.Figure 16.4 Metallic‐expansion trap.Figure 16.5 Balanced‐pressure thermostatic trap.Figure 16.6 Bimetallic steam trap.

      14 Chapter