Reliability Engineering Snapshot TM

Updated November 13, 2011

• Failure Case Studies
  • Corrosion
  • Bearing Isolation
    • Case No. 6: Compressor Screw Bearing Ball Corrosive Gas Attack
    • Case No. 12: Bearing Ball Improper Storage Outside
    • Case No. 18: Bearing Ball Corrosion from Steam
  • Carbonic Acid Attack Carbon Steel
    • Case No. 23: Condensate Line Carbonic Acid Attack
  • Chloride Stress Corrosion Cracking 316L
    • Case No. 31: Furnace Dome 316L S/S CSCC Chloride Stress Corrosion Cracking
  • Chromium Carbide Precipitation 316L
    • Case No. 27: Furnace Dome 316L S/S Chromium Carbide Precipitation
  • Crevice 316L
    • Case No. 98: Furnace Dome 316L Crevice Corrosion
  • Galvanic 316L
    • Case No. 124: Gasket Spiral Wound 316L Galvanic Corrosion
  • Leaking Corrosive Damage Examples
    • Case No. 94: Consequences of Leaking Corrosive Media
  • Oxidation 309L
    • Case No. 41: Furnace Dome 309L S/S Oxidation
  • Pitting Corrosion Fatigue 316L
    • Case No. 73: Pipe Pitting 316L Corrosion Fatigue
  • Sensitization 309L
    • Case No. 44: Furnace Dome Support 309L S/S CSCC Sensitization
  • Sodium Chlorate 316L
    • Case No. 103: 316L Exposure to Sodium Chlorate
  • Weld Attack 316L
    • Case No. 1: Furnace Dome 316 S/S Weld Attack
  • Weld Coupon Testing 316L
    • Case No. 115: 316L Weld Coupon Testing
  • Lubrication
  • Auto Lubrication Cartridges
    • Case No. 28: Failure of Automatic Grease Dispenser
  • Boundary
    • Case No. 7: Boundary Lubrication in a Bearing
  • Contamination
    • Case No. 13: Blown Pump Packing Ruins Oil
  • Corrosive Oil
    • Case No. 2: Corrosive Oil
  • Couplings
    • Case No. 24: Grid Flex Coupling Lack of Grease
  • Film Temperature (Actual)
    • Case No. 95: Bearings - Determine Actual Film Operating Temperature
  • Gas Entrainment
    • Case No. 125: Process Gas Entrainment in Compressor
  • Grease Channel Misalignment
    • Case No. 19: Grease Passageway Misalignment Starves Bearing
  • Greasing
    • Case No. 57: Incompatible Polyurea and Lithium Motor Greases
    • Case No. 99: Properly Greased Roller Bearing
    • Case No. 136: The Science and Art of Greasing
  • In-house Oil Analysis
    • Case No. 32: Evaluation and Findings of In-house Oil Analysis
  • Oil Film Instability
    • Case No. 80: Thrust Plate - Incorrectly Installed
  • Open Gear
    • Case No. 45: Oil Contamination
    • Case No. 110: Poor Housekeeping Ruins Open Gear
  • Overloading
    • Case No 113: Overloading a Bearing Mistaken for Lack of Lubrication
  • Pressure Lubricated Systems
    • Case No. 69: Removing Pressure Lubricated Systems and High Heat
  • Ring Oilers
    • Case No. 76: Depending on Ring-oiled Sleeve Bearings as a Backup
  • Seal Misapplication
    • Case No. 106: Labyrinth Seal - Misapplication
  • Temper Loss
    • Case No. 119: Overheats Losing Temper and Softening
  • Trunnion and Tire (Kiln)
    • Case No. 137: Poor Graphite Block Alignment Ruins Tire
  • Worm Gear and Wheel
    • Case No 123: Lubrication Demands are Severe
  • Machine Design [MD] and Material Properties [MP]
  • Bearings
    • Case No. 42: Taper Lock Loose Fit
    • Case No. 61: Roller Thrust Overload
    • Case No. 70: Split Design Loose Fit
    • Case No. 74: Ball Corrosion from Bad Packing
    • Case No. 93: Spherical Thrust Overload
    • Case No. 138: Pillow Block Loose Fit
    • Case No. 117: Ball Loss of Temper from Hi Heat
  • Dye Penetrant
    • Case No. 29: Benefits of Using Liquid Dye Penetrant
  • Casting Crack
    • Case No. 47: Crusher Hammer Casting Crack
  • Electrostatic Discharge
    • Case No. 131: Turbine Sleeve Bearing Electrostatic Discharge
    • Case No. 133: Turbine Excess Magnetic Field - Degaussing
  • Embrittlement of C276
    • Case No. 104: Furnace Burner Tip Hi Temp Embrittlement Mu Phase
  • Expansion Joints
    • Metal Bellows
      • Case No. 96: Expansion Joint Metal Bellows Bad Design
  • Finite Element Analysis [FEA]
    • Case No. 25: Using FEA in Failure Analysis and Redesign
  • Gaskets
    • Spiral Wound
      • Case No. 124: Gasket Spiral Wound 316L Galvanic Corrosion
      • Case No. 8: Gaskets Spiral Wound Color Coding
  • Inspection Access
    • Case No. 100: Inspection Access Screw Conveyors
  • Keyways
    • Case No. 62: Stress Concentration
    • Case No. 63: Shaft Rotary Torsion Versus Rotary Bending
  • Pump Packing
    • Case No. 20: Pump Packing - Thirteen Ways to Ruin
  • Rotary Kiln (Fired Counterflow)
    • Leaf Seals
      • Case No. 90: Leaf Seal Bad Design
    • Lifters
      • Case No. 33: Lifter Weld Stress Concentration
      • Case No. 54: Lifter Stress Concentration
      • Case No. 58: Lifter Thermal Stress
      • Case No. 51: Rotary Kiln Lifters Stress Concentration
      • Case No. 55: Rotary Kiln Cracks from Impact or Thermal Stress
      • Case No. 59: Rotary Kiln Lifters Welding Lack of Fusion & Penetration
      • Case No. 121: Rotary Kiln Lifter Residual Thermal Stress
    • Ring Gear
      • Case No. 25: Ring Gear Leafmount
      • Case No. 46: Ring Gear Cold Flow Overload
      • Case No. 135: Ring Gear Excessive Load
    • Shell
      • Case No. 50: Shell Buckle from Overload
      • Case No. 87: Shell Reinforcement Wrapper Bad Design
      • Case No. 107: Shell Ovality
      • Case No. 126: Shell-Lifter Thermal Stress
      • Case No. 3: Rotary Kiln Shell IG Cracking
    • Stiffening Rings
      • Case No. 29: Stiffening Ring
      • Case No. 111: Stiffening Rings Weld Procedure
      • Case No. 116: Stiffening Weld Toes
  • Shafts
    • Case No. 127: Mine Hoist Shaft Flange
    • Case No. 63: Shaft Rotary Torsion Versus Rotary Bending
    • Case No. 77: Shaft Torsion Fatigue
    • Case No. 85: Shaft Fillet Radius Stress Concentration
    • Case No. 128: Mine Hoist Shaft Fillet Stress Concentration
  • Stress Concentrations
    • Case No. 97: Fillet Radius - Filter Body Bracket
    • Case No. 140: Fillet Radius - Ring Gear
    • Case No. 127: Fillet Radius - Shaft Flange [MD]
    • Case No. 128: Fillet Radius - Shaft Flange [MP]
    • Case No. 85: Fillet Radius - Shaft
    • Case No. 62: Keyway
    • Case No. 33: Lifter Weld - Rotary Kiln
    • Case No. 54: Lifters - Rotary Kiln [MD]
    • Case No. 51: Lifters - Rotary Kiln [MP]
    • Case No. 65: Ring Support - Furnace
  • Stud Bolts

    • Case No. 14: Cut Threads Versus Rolled Threads

      Case No. 9: Fatigue Versus Overload

  • Thermal Stress
    • Case No. 58: Rotary Kiln Lifter Thermal Stress
    • Case No. 55: Rotary Kiln Cracks from Impact or Thermal Stress
    • Case No. 121: Rotary Kiln Lifter Residual Thermal Stress
  • Vibration Induced Cracks
    • Case No. 81: Tank Baffle Steam Lance
    • Case No. 120: Compressor Axial Flow Induced
    • Case No. 130: Tank Baffle Weld Bad Design
  • Welding
    • Arc Strike
      • COR0900 Furnace Wall Weld Arc Strike 316L S/S
      • MP1298 Rotary Kiln Stiffening Ring Weld Arc Strike
    • Crack Gouging
      • MP0199 Rotary Kiln Stiffening Ring No Crack Gouging
    • Distortion from Thermal Stress
      • MP1201 Excessive Distortion
    • Holidays
      • MD0699 Furnace Stack Weld Holiday
    • Interpass Temperature
      • MP1001 Excessive Interpass Temperature
    • Lack of Fusion and Penetration
      • MP0400 Rotary Kiln Lifters Welding Lack of Fusion and Penetration
    • Porosity from Starts and Stops
      • MP0201 Rotary Kiln Stiffening Ring Weld Porosity Starts and Stops
      • MP0703 Pipe Flange Weld Porosity from Start Stop
    • Profile
      • Case No. 116: Weld Toe Stress Concentration
      • Case No. 33: Weld Toe Stress Concentration
      • Case No. 84: Weld Optimization Rotary Kiln Stiffening Ring
      • Case No. 66: Weld Toe Stress Concentration
    • Testing: Bend and Tensile
      • MP0301 Weld Bend & Tensile Testing
    • Weld Procedure Specification WPS
      • MD1001 Rotary Kiln Stiffening Rings Weld Procedure
  • Vibration
  • Axial Screw Compressor
    • Case No.17: Cracked Case
  • Hammer Impacts
    • Case No. 53: Evaluating Field of Influence
  • Loose Bearing Fit
    • Case No. 22: 800 HP Motor Loose Bearing Fit
  • Looseness, Overload, Cross-talk
    • Case No. 75: Differentiating Between Them
  • Split Roller Bearings
    • Case No. 72: Diagnosing
  • Triple Reduction Gearbox
    • Case No. 49: 25 HP Agitator Loose High Speed Shaft
    • Case No. 64: 75 HP Loose Bearings High-Speed Shaft
  • People
  • Communication Limitations
    • Case No. 10: API Standard for Spiral Wound Gaskets
  • Case No. 4: Words of Wisdom Learned the Hard Way
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