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A practical and accessible approach to machinery troubleshooting
Unique Methods for Analyzing Failures and Catastrophic Events is designed to assist practicing engineers address design and fabrication problems in manufacturing equipment to support safe process operation. Throughout the book, a wealth of real-world case studies and easy-to-understand illustrated examples demonstrate how to use simplified failure analysis methods to produce insights for a wide range of engineering problems.
Dr. Anthony Sofronas draws from his five decades of industry experience to help engineers better understand the science behind a particular problem, evaluate the failure analysis of an outside consultant, and recommend the best path forward to management. The author distills sophisticated engineering analysis approaches into compact, user-friendly methodologies that can be easily applied to the readers' own situations to avoid costly failures. Each chapter includes a thorough summary of the topic, relatable technical examples, and a concluding section with key takeaways and expert tips and advice. This invaluable guide:
* Helps readers make better decisions while solving complex engineering problems
* Provides numerous illustrated examples from engineering and science that can be used to develop real-world solutions
* Features detailed descriptions of both basic and advanced engineering analysis techniques
* Covers essential technical subjects that facilitate safe facility design and effective troubleshooting
Unique Methods for Analyzing Failures and Catastrophic Events: An Illustrated Guide for Engineers is a must-have for chemical, petroleum, and mechanical engineers, reliability managers and technicians, design contractors, and maintenance workers working in process industries.
List of contents
About the Author xvii
Preface xix
Acknowledgments xxi
1 Engineering Suggestions Based on Experience 1
1.1 What Should We Learn from This Book? 1
1.1.1 Summary 3
Reference 3
1.2 We All Contribute to Each Other's Success 3
1.2.1 Summary 5
Reference 5
1.3 Why Performing Calculations is Important to an Engineer's Career 5
1.3.1 Summary 7
Reference 8
1.4 How an Engineering Consultant Can Help Your Company 8
1.4.1 Summary 10
1.5 The Benefit of Keeping Complex Problems Simple 10
1.5.1 Summary 14
1.6 Taking Risks and Making High-Level Presentations 15
1.6.1 Summary 16
1.7 Searching the Literature for Data 16
1.7.1 Equations 17
1.7.2 Facts 17
1.7.3 Credibility 17
1.7.4 Accuracy of the Data 17
1.7.5 Sources to Search 18
1.7.6 Summary 18
References 19
1.8 Cautions to New to Industry Technical Personnel 19
1.8.1 The Wrong Frequency 19
1.8.2 Using the Incorrect Measuring Technique 20
1.8.3 Never Under-Estimate the Value of Experienced People 20
1.8.4 Check and Double Check Your Design 20
1.8.5 Some Understand the Equipment Much Better Than You 21
1.8.6 Summary 22
1.9 A Method for Analyzing Catastrophic Type Failures 22
References 24
2 Evaluating Failures and Designs 25
2.1 Twenty Rules to Remember 25
2.1.1 Summary 28
2.2 How to Avoid Being Overwhelmed in a Failure Situation 29
2.2.1 Summary 31
2.3 Catastrophic Failures and the Human Factor 31
2.3.1 Summary 35
References 35
2.4 The Importance of Alliances and Networking 35
2.4.1 Summary 36
2.5 Personal Checklists are Important 37
2.6 Checklist for Vibration Analysis 37
2.6.1 Summary 39
Reference 40
2.7 Checklist for New Piping System Installations 40
2.8 Checklists for Pumps and Compressors 40
2.9 Understanding What the Failure Data Is Telling You 41
2.9.1 Gear Damage 41
2.9.2 Shaft Failures 42
2.9.3 Weld Failures 43
2.9.4 Bolt Failures 43
2.9.5 Brittle Fracture Failures 45
2.9.6 Anti-Friction Bearing Failures 46
2.9.7 Spring Failures 46
2.9.8 Drilled Holes 47
2.9.9 Summary 48
2.10 Phantom Failures and Their Dilemma 49
2.10.1 Summary 50
2.11 Various Types of Equipment and Their Failure Loads 50
2.11.1 Summary 52
3 Mechanical Failures 53
3.1 Preventing Crankshaft Failures in Large Reciprocating Engines 53
3.1.1 Summary 57
3.2 Structural Collapse of a Reinforced Concrete Bridge 57
3.2.1 Summary 61
Reference 61
3.3 Failure Analysis Computations Differ from Design 61
3.3.1 Summary 64
3.4 Crack Growth and the Bending Failures of a Hollow Shaft 64
3.4.1 An In-Service Failure Example 66
3.4.2 The Assumptions and Comparisons 67
3.4.3 Summary 68
Reference 68
3.5 Why Did a Small Piece of Foam Cause the Shuttle Columbia to Crash? 68
3.5.1 Summary 71
Reference 71
3.6 Can the Aircraft Cowling Contain a Broken Turbine Blade? 71
3.6.1 Summary 72
References 72
3.7 Why Did My Car Windshield Break from a Very Small Stone? 73
3.7.1 Summary 73
3.8 Momentum or Why a Car Is Harder to Push and Then Easie
About the author
A. Sofronas, DEng, PE, is the former Worldwide Lead Mechanical Engineer for ExxonMobil. He was involved with machinery troubleshooting for 50 years with more than 130 publications and numerous presentations at industry seminars worldwide. Dr. Sofronas is a contributing editor for
Hydrocarbon Processing and the author of
Analytical Troubleshooting of Process Machinery and Pressure Vessels, Case Histories in Vibration Analysis and Metal Fatigue, and
Survival Techniques for the Practicing Engineer.
