Machinery Failure Analysis & Repair Methods

Course Content

• FAILURE ANALYSIS

  • Rupture phenomena:
  • Ruptures study: material characteristics, influences of metallurgy and surface treatment, design parameters, consequences due to the modification of material behavior.
  • Characteristics of the main kind of ruptures: tensile and compressive stress with necking appearance, influence of the resilience and the transition temperature with regards to the service temperature, mechanical fatigue.
  • Rupture face analysis: mechanisms of rupture, surface morphology.
  • Solutions to avoid rupture: design parameters, limiting stresses, operating conditions and limitations.
  • Wear phenomena:
  • Wear study: friction principle with friction factor and wear rate, tribology.
  • Characteristics of the main kind of wear: adhesive wear depending on the lubrication mode, abrasive wear through particle presence, erosive wear due to flow, mechanical surface fatigue on gears and bearings.
  • Morphology of a worn surface: temperature colors, scratching, scoring, seizure.
  • Solutions to avoid wear: design parameters, limiting friction, operating conditions.
  • Case studies: rupture and wear examinations of machinery parts (bearings, mechanical seals, rotors), analysis of some failures on process centrifugal pumps, reciprocating and centrifugal compressors and gearbox.

• REPAIR & RENOVATION WORK

  • Repair philosophy: integrating all the criteria to choose the best solution: repair or replacement.
  • Different modes of repair: welding, surface treatment, metal striching, deposits (HVOF application).
  • Costs: repair costs, delivery time, on site capabilities.
  • Case studies: description of different approaches used to repair some machines and components.