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El. knyga: Practical Root Cause Failure Analysis: Key Elements, Case Studies, and Common Equipment Failures

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Root Cause Failure Analysis (RCFA) is a method used by maintenance and reliability industry professionals as one of the key tools to drive improvement. This book offers a quick guide to the applications involved in performing a successful RCFA by providing a foundational view of maintenance and reliability strategies. It also highlights the practical applications of RCFA and identifies how to achieve a successful RCFA, as well as discussing common equipment failures and how to solve them. Case studies on topics including pump system failure analysis and vibration analysis are included.





Suggests examples on how to solve common failure on many types of equipment, including fatigue, pumps, bearings, and mechanical power transmission





Highlights practical applications of RCFA





Identifies key elements for how to achieve a successful RCFA





Presents case studies on topics including pump system failure analysis and vibration analysis

The book is a must-read for any reliability engineer, particularly mechanical reliability professionals.

Recenzijos

"This is the most complete, concise and usable reference I have ever read on the subject of reliability"

Phil Hendrix, President and Founder, Hendrix Precision

"This is THE book to guide you through conducting an RCFA. For more than thirty years, Randy has been the go-to engineer for investigating and solving failures. Now hes sharing his experience and success stories to help others. After walking the reader through the basics of the RCFA process, his approach in using that information for application is straight forward and practical, with great examples and case studies. This is a must-have resource for those in maintenance and reliability."

Tom Mauter, Supplier Quality Assurance Manager, International Paper

"This book is a home run for anyone that has the drive to get to root cause! Following the '5 Rights' detailed in this book will improve your teams ability to conduct a successful RCFA and eliminate re-occurring breakdowns forever."

Randy Short, Manufacturing Excellence Director Maintenance & Reliability, Essity

Foreword vii
Preface ix
Author Biography xi
1 Introduction to Successful Root Cause Failure Analysis (RCFA)
1(14)
1.1 Troubleshooting vs Failure Analysis
2(2)
1.2 Defining Failure -- 4 Levels of Failure
4(4)
1.3 Reliability & RCFA
8(1)
1.4 Predicting Failure
9(2)
1.5 Maintenance & RCFA
11(4)
2 5 Rights of Successful RCFA
15(26)
2.1 The Right Systems
16(6)
2.1.1 RCFA Process Infrastructure
17(1)
2.1.2 Type of RCFA Process
18(1)
2.1.2.1 Kepner Tregoe
19(1)
2.1.2.2 The 5 Whys
20(1)
2.1.2.3 Failure Mode Based
21(1)
2.2 Right Resources
22(2)
2.2.1 People
22(1)
2.2.2 Budget
23(1)
2.2.3 Tools
23(1)
2.3 Right Evidence
24(5)
2.3.1 Event Investigation
24(1)
2.3.2 Failure Scene
25(1)
2.3.3 Failure Type
26(3)
2.4 Right Analysis
29(6)
2.4.1 Failure Mode
29(1)
2.4.2 Possible Causes
30(1)
2.4.3 Physics of Failure
31(1)
2.4.4 Failure Patterns
32(1)
2.4.5 Ending Analysis
33(2)
2.5 Right Corrective Actions
35(6)
2.5.1 Type of Action Items
36(2)
2.5.2 Execution of Action Items
38(1)
2.5.3 Closing the Loop
39(2)
3 Key Factors in Fatigue Failure
41(16)
3.1 Fundamentals of Fatigue Failure
41(5)
3.2 Case Study 1 -- Chain Fatigue Failure
46(6)
3.3 Case Study 2 -- Conveyor Shaft Failure
52(5)
4 Key Factors in Bearing Failure
57(30)
4.1 Fundamentals of Bearing Failure
57(4)
4.2 Case Study 1 --- Combustion Fan Bearing Failure
61(4)
4.3 Case Study 2 -- Suction Roll Bearing Fracture
65(4)
4.4 Case Study 3 -- Pulper Motor Bearing Failure
69(3)
4.5 Case Study 4 -- Vacuum Pump Bearing Failure
72(3)
4.6 Case Study 5 -- Suction Press Roll Internal Bearing Failure
75(3)
4.7 Case Study 6 -- Exhaust Fan Bearing Failure
78(9)
5 Key Factors in Pump System Failure
87(30)
5.1 Fundamentals of Pump Failure
87(3)
5.2 Case Study 1 -- White Water Pump Failure
90(8)
5.3 Case Study 2 -- Stock Dilution Pump Failure
98(4)
5.4 Case Study 3 -- Loop 1 Dilution Pump Failure
102(4)
5.5 Case Study 4 -- Rejects Pump System Failure
106(3)
5.6 Case Study 5 -- Screen Feed Pump Failure
109(8)
6 Key Factors in Mechanical Power Transmission Failure
117(24)
6.1 Fundamentals of Mechanical Power Transmission Failure
117(2)
6.2 Case Study 1 -- Agitator Belt Drive Failure
119(4)
6.3 Case Study 2 -- Screen Belt Drive Sheave Failure
123(5)
6.4 Case Study 3 -- Paper Roll Gearbox Failure
128(2)
6.5 Case Study 4 -- Coating Roll Gearbox Failure
130(5)
6.6 Case Study 5 -- Press Roll Gearbox Failure
135(6)
7 Key Factors in Bolted Joint Failure
141(12)
7.1 Fundamentals of Bolt Failure
141(5)
7.2 Case Study -- Dryer Journal Bolt Failures
146(7)
Index 153
A native of Kossuth, MS, Mr. Randy Riddell attended Mississippi State University where he received a Bachelor of Science in Mechanical Engineering. Mr. Riddell has over 30 years of industrial experience with a career focused on maintenance and reliability in the paper industry. His formal certifications include CMRP from SMRP, MLTI from ICML, CLS from STLE, Level 1 Vibration, and Pump System Assessment Professional, PSAP, from the Hydraulic Institute. Mr. Riddell has published many articles around industrial equipment reliability topics. Mr. Riddell has also been a guest speaker at several industry and University engineering settings.
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