FAILURE ANALYSIS IN ENGINEERING APPLICATIONS
CONTENTS 1 INTRODUCTION TO SUCCESSFUL ROOT CAUSE FAILURE ANALYSIS (RCFA) 1 1 TROUBLESHOOTING VS FAILURE ANALYSIS 1 2 DEFINING FAILURE – 4 LEVELS OF FAILURE 1 3 RELIABILITY & RCFA 1 4 PREDICTING FAILURE 1 5 MAINTENANCE & RCFA 2 5 RIGHTS OF SUCCESSFUL RCFA 2 1 THE RIGHT SYSTEMS 2 1 1 RCFA PROCESS INFRASTRUCTURE 2 1 2 TYPE OF RCFA PROCESS 2 1 2 1 KEPNER TREGOE 2 1 2 2 THE 5 WHYS 2 1 2 3 FAILURE MODE BASED 2 2 RIGHT RESOURCES 2 2 1 PEOPLE 2 2 2 BUDGET 2 2 3 TOOLS 2 3 RIGHT EVIDENCE 2 3 1 EVENT INVESTIGATION 2 3 2 FAILURE SCENE 2 3 3 FAILURE TYPE 2 4 RIGHT ANALYSIS 2 4 1 FAILURE MODE 2 4 2 POSSIBLE CAUSES 2 4 3 PHYSICS OF FAILURE 2 4 4 FAILURE PATTERNS 2 4 5 ENDING ANALYSIS 2 5 RIGHT CORRECTIVE ACTIONS 2 5 1 TYPE OF ACTION ITEMS 2 5 2 EXECUTION OF ACTION ITEMS 2 5 3 CLOSING THE LOOP 3 KEY FACTORS IN FATIGUE FAILURE 3 1 FUNDAMENTALS OF FATIGUE FAILURE 3 2 CASE STUDY 1 – CHAIN FATIGUE FAILURE 3 3 CASE STUDY 2 – CONVEYOR SHAFT FAILURE 4 KEY FACTORS IN BEARING FAILURE 4 1 FUNDAMENTALS OF BEARING FAILURE 4 2 CASE STUDY 1 – COMBUSTION FAN BEARING FAILURE 4 3 CASE STUDY 2 – SUCTION ROLL BEARING FRACTURE 4 4 CASE STUDY 3 – PULPER MOTOR BEARING FAILURE 4 5 CASE STUDY 4 – VACUUM PUMP BEARING FAILURE 4 6 CASE STUDY 5 – SUCTION PRESS ROLL INTERNAL BEARING FAILURE 4 7 CASE STUDY 6 – EXHAUST FAN BEARING FAILURE 5 KEY FACTORS IN PUMP SYSTEM FAILURE 5 1 FUNDAMENTALS OF PUMP FAILURE 5 2 CASE STUDY 1 – WHITE WATER PUMP FAILURE 5 3 CASE STUDY 2 – STOCK DILUTION PUMP FAILURE 5 4 CASE STUDY 3 – LOOP 1 DILUTION PUMP FAILURE 5 5 CASE STUDY 4 – REJECTS PUMP SYSTEM FAILURE 5 6 CASE STUDY 5 – SCREEN FEED PUMP FAILURE 6 KEY FACTORS IN MECHANICAL POWER TRANSMISSION FAILURE 6 1 FUNDAMENTALS OF MECHANICAL POWER TRANSMISSION FAILURE 6 2 CASE STUDY 1 – AGITATOR BELT DRIVE FAILURE 6 3 CASE STUDY 2 – SCREEN BELT DRIVE SHEAVE FAILURE 6 4 CASE STUDY 3 – PAPER ROLL GEARBOX FAILURE 6 5 CASE STUDY 4 – COATING ROLL GEARBOX FAILURE 6 6 CASE STUDY 5 – PRESS ROLL GEARBOX FAILURE 7 KEY FACTORS IN BOLTED JOINT FAILURE 7 1 FUNDAMENTALS OF BOLT FAILURE 7 2 CASE STUDY – DRYER JOURNAL BOLT FAILURES