The Importance of Alignment Alignment Tolerances [2] Alternative Alignment Guidelines Alignment Calculation Example Rotor Balance Static Unbalance Dynamic Unbalance Balancing Common Causes of Rotor Unbalance [3] Balancing Grades The Importance of Fit, Clearance & Tolerance Fits, Clearances and Tolerances [5] Tolerance Clearance Coupling Hub Fits Keyed Interference Fits [6] Keyless Interference Fits Closing Thoughts References 11 Procedures + Precision = Reliability 12 The Top 10 Behaviors of Precision-Maintenance Technicians 13 Optimizing Machinery Life Cycle Costs through Precision and Proactive Maintenance Precision Maintenance 101 Life-Extension Equations Worked Example Life Cycle Costs Justifying Precision Maintenance 14 Optimum Reference States for Precision Maintenance Conclusion 15 Writing Effective Machinery Work Order Requests
10 Part IV: ANALYZING FAILURES 16 Improving Machinery Reliability by Using Root Cause Failure Analysis Methods Introduction What Is a Root Cause Failure Analysis? Root Cause Failure Analysis Example #1: Ill-Advised Bearing Replacement Root Cause Failure Analysis Example #2: Reciprocating Compressor Rod Failure [1] RCFA Steps Closing Thoughts Appendix A No Magic Allowed Appendix B Analyzing Component Failure Mechanisms Common Mechanical Failure Modes Rolling Element Bearing Failure Characteristics [6] Tips for Analyzing Mechanical Seal Failures [7] Appendix C Common Machinery Failure Modes [8] References 17 Investigation and Resolution of Repetitive Fractionator Bottom Pump Failures Introduction List of Additional Failure Inherent Causes to Be Rectified Key Shop and Field Pump Measurements Conclusion [1] Actual Findings Effect of Improvements on Pump Radial Shaft Vibration Reference 18 Reliability Improvements Made to 6000 KW Water Injection Pumps Experiencing Wear Ring Failures Summary Sequence of Events New Design Proposal of Eliminating Grub Screws or Flash Butt Welding Upgrade Options Detailed Analysis of Problem & Solution Related to All Pump Wear Rings Discussion on Reliability Improvements Added to Achieve High Reliability Manufacturing Errors: None Found User Maintenance Errors: None Found
13 Index
List of Illustrations
1 Chapter 1Figure 1.1 Managing the risk associated with a site’s process machinery is a key...Figure 1.2 Machinery failure modes distributions.Figure 1.3 Machinery failure modes can be broken down into those that are readil...Figure 1.4 Centrifugal compressor