Unique Methods for Analyzing Failures and Catastrophic Events: A Practical Guide for Engineers

ISBN-13: 9781119748250 / Angielski / Twarda / 2022 / 336 str.

Anthony Sofronas

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About the Author xviiPreface xixAcknowledgments xxi1 Engineering Suggestions Based on Experience 11.1 What Should We Learn from This Book? 11.1.1 Summary 3Reference 31.2 We All Contribute to Each Other's Success 31.2.1 Summary 5Reference 51.3 Why Performing Calculations is Important to an Engineer's Career 51.3.1 Summary 7Reference 81.4 How an Engineering Consultant Can Help Your Company 81.4.1 Summary 101.5 The Benefit of Keeping Complex Problems Simple 101.5.1 Summary 141.6 Taking Risks and Making High-Level Presentations 151.6.1 Summary 161.7 Searching the Literature for Data 161.7.1 Equations 171.7.2 Facts 171.7.3 Credibility 171.7.4 Accuracy of the Data 171.7.5 Sources to Search 181.7.6 Summary 18References 191.8 Cautions to New to Industry Technical Personnel 191.8.1 The Wrong Frequency 191.8.2 Using the Incorrect Measuring Technique 201.8.3 Never Under-Estimate the Value of Experienced People 201.8.4 Check and Double Check Your Design 201.8.5 Some Understand the Equipment Much Better Than You 211.8.6 Summary 221.9 A Method for Analyzing Catastrophic Type Failures 22References 242 Evaluating Failures and Designs 252.1 Twenty Rules to Remember 252.1.1 Summary 282.2 How to Avoid Being Overwhelmed in a Failure Situation 292.2.1 Summary 312.3 Catastrophic Failures and the Human Factor 312.3.1 Summary 35References 352.4 The Importance of Alliances and Networking 352.4.1 Summary 362.5 Personal Checklists are Important 372.6 Checklist for Vibration Analysis 372.6.1 Summary 39Reference 402.7 Checklist for New Piping System Installations 402.8 Checklists for Pumps and Compressors 402.9 Understanding What the Failure Data Is Telling You 412.9.1 Gear Damage 412.9.2 Shaft Failures 422.9.3 Weld Failures 432.9.4 Bolt Failures 432.9.5 Brittle Fracture Failures 452.9.6 Anti-Friction Bearing Failures 462.9.7 Spring Failures 462.9.8 Drilled Holes 472.9.9 Summary 482.10 Phantom Failures and Their Dilemma 492.10.1 Summary 502.11 Various Types of Equipment and Their Failure Loads 502.11.1 Summary 523 Mechanical Failures 533.1 Preventing Crankshaft Failures in Large Reciprocating Engines 533.1.1 Summary 573.2 Structural Collapse of a Reinforced Concrete Bridge 573.2.1 Summary 61Reference 613.3 Failure Analysis Computations Differ from Design 613.3.1 Summary 643.4 Crack Growth and the Bending Failures of a Hollow Shaft 643.4.1 An In-Service Failure Example 663.4.2 The Assumptions and Comparisons 673.4.3 Summary 68Reference 683.5 Why Did a Small Piece of Foam Cause the Shuttle Columbia to Crash? 683.5.1 Summary 71Reference 713.6 Can the Aircraft Cowling Contain a Broken Turbine Blade? 713.6.1 Summary 72References 723.7 Why Did My Car Windshield Break from a Very Small Stone? 733.7.1 Summary 733.8 Momentum or Why a Car Is Harder to Push and Then Easier When Rolling 733.8.1 Summary 753.9 Bearing Failure Due To Design Error 753.9.1 Summary 763.10 What Is the Shortest Stopping Distance for My Car? 763.10.1 Summary 763.11 How Hot Do Brake Disks Get in a Panic Stop? 773.11.1 Summary 783.12 Will the Turbocharger Disk Go Through its Housing? 783.12.1 Summary 803.13 Failure of an Agitator Gearbox 803.13.1 Summary 823.14 Failure of an Extruder Screw 823.14.1 Summary 83Reference 833.15 Failure of a Steam Turbine Blade 843.15.1 Summary 873.16 How Long Will It Last? 873.16.1 Summary 90Reference 903.17 Gear Life With a Load 903.17.1 Summary 923.18 Analyzing the Life of a Gear 933.18.1 Summary 943.19 Predicting the Cause of a Gear Tooth Crack Growth Past and Future 94References 963.20 Nonlinear and Linear Impact Problems 973.20.1 Summary 1003.21 Phantom Failure of an Expander-Dryer 1003.21.1 Summary 1033.22 Cracking of a Rail Hopper Car Due to Couple-Up 103Reference 1063.23 Loss of Oil Supply and Gear Set Destruction 106References 1093.24 Analyzing the Total Collapse of a Multi-Story Building 110References 1154 Fluid Flow and Heat Transfer Examples 1164.1 Addressing Heat Exchanger Tube Leaks 1164.1.1 Summary 1184.2 Explaining Flow Through Piping Using the Poiseuille Equation 1194.2.1 Summary 1204.3 A Local Flooding Event at a Plant Site 1204.3.1 Summary 122Reference 1224.4 Examining Fan System Pulsations 1224.4.1 Summary 125References 1264.5 The Dynamics of How an Aircraft Flies 1264.5.1 Summary 1294.6 How Much Wind Does It Take to Blow Over a Motor Coach? 1294.6.1 Summary 1314.7 How Much Wind Force to Buckle an Aircraft Hanger Door? 1314.7.1 Summary 1324.8 How Much Water on a Road to Float a Car? 1324.8.1 Summary 1334.9 How Fast Does an Object Hit the Ground? 1334.9.1 Summary 1354.10 Collapse of a Bubble and the Excitation Force on a Structure 1354.10.1 Summary 1394.11 Failure of a Cooling Tower Pump Due to Water Hammer 1394.11.1 Summary 142References 1424.12 Braking Resistor Burn-Out on a Locomotive 1424.12.1 Summary 1444.13 Will a Small Ice Air Conditioner Work? 1444.13.1 Summary 148References 1484.14 Prototype of Smallest Air Ice Cooler 1484.14.1 Summary 1495 Sports Examples 1515.1 Why Does a Baseball Curve? 1515.1.1 Summary 1535.2 How Far Does a Baseball Go When Hit with Drag? 1535.2.1 Summary 1545.3 What Is the Force of a Batted Baseball? 1545.3.1 Summary 1555.4 Why Doesn't a Baseball Catcher's Arm Break with a 100-mph Fastball? 1555.4.1 Some Data 1565.4.2 Summary 1575.5 Dynamics of a Billiard Ball 1575.5.1 Summary 1585.6 How Far Can a Golf Ball Go? 1585.6.1 Summary 1595.7 What Causes an Ice Skater to Spin so Fast? 1595.7.1 Summary 1605.8 Why Don't High Divers Get Injured? 1605.8.1 Summary 162References 1625.9 How Hard Is a Boxers Punch? 1635.9.1 Summary 1646 Gas Explosion Events 1656.1 Energy in Steam Boiler Explosions 1656.1.1 Summary 167References 1676.2 Delayed Fireball-Type Explosions 1676.2.1 Summary 171References 1716.3 Method for Investigating Hydrocarbon Explosions 1716.3.1 Summary 178References 1786.4 Pipeline Explosion Critical Zone 1796.4.1 Summary 1796.5 Pneumatic Explosion Debris Range 1806.5.1 Summary 1816.6 How Are the Effect of Massive Energy Releases Compared? 1826.6.1 Summary 1836.7 Engine Air Intake Manifold Explosion 1836.7.1 Summary 185Reference 1857 Vibration and Impact: The Cause of Failures 1867.1 Investigating a Possible Cause for a Coupling Failure in a Centrifugal Compressor 1867.1.1 Summary 192References 1927.2 Sudden Power Interruption to a System 1937.2.1 Summary 1957.3 Effect of Liquid Slug in a Centrifugal Compressor 1957.3.1 Summary 198Reference 1987.4 Weld Failures in Vibrating Equipment 1987.4.1 Summary 201References 2017.5 Effect of Gear Chatter on Pinion Teeth Impact 2027.5.1 Summary 2027.6 Holzer Method for Calculating Torsional Multi-mass Systems 2037.6.1 Summary 2047.7 What to do When the Vibration Levels Increase on Large Gearboxes 2047.7.1 Summary 209Reference 2097.8 How Vibratory Torque Relates to Bearing Cap Vibration in a Gearbox 2097.8.1 Summary 211Reference 2117.9 Vibration of a Polymer Extruder Gearbox 2117.9.1 Summary 212References 2137.10 Processing and Wear Load Increase in a Polymer Extruder 2137.10.1 Summary 214Reference 2147.11 Vibration Charts Can Give Faulty Information 2147.11.1 Summary 2157.12 Have Torsional Vibrations Caused the Gearbox Pinion to Fail? 2167.12.1 Summary 2188 Examining the Human Body 2198.1 What Causes Football Brain Injuries? 2198.1.1 Summary 223References 2238.2 Life Assessment Diagrams 2238.2.1 Summary 2248.3 Assessing the Cumulative Damage Done by Head Impacts 2248.3.1 Summary 228References 2288.4 What Happens When I Hit My Head and See Stars? 2298.4.1 Summary 2308.5 How Does the Body Keep Cool? 2308.5.1 Summary 2328.6 How Do Our Muscles Work? 2328.6.1 Summary 2348.7 Why Do People Die from Heatstroke in a 75 °F Car? 2348.7.1 Summary 2358.8 What Damage Can a Safety Airbag Do to a Human? 2368.8.1 Summary 2368.9 How Is Blood Pressure Measured? 2368.9.1 Summary 2378.10 How Does the Heart Work? 2378.10.1 Summary 2418.11 Restricting the Spread of a Virus 2418.11.1 Summary 244Reference 2458.12 Why Do Some Survive a Freefall Out of an Aircraft? 2468.12.1 Summary 2469 Other Curious Catastrophic Failures Related to Earth 2479.1 Can an Asteroid Be Deflected from Hitting Earth? 2479.1.1 Summary 2499.2 What Size Crater Does a Large Asteroid Make When It Hits Earth? 2509.2.1 Summary 2539.3 What Is an Earthquake? 2539.3.1 Summary 2559.4 Earthquakes Are so Strong Why Don't They Do More Damage? 2569.4.1 Summary 2589.5 Concerns on the Super-Volcano Under Yellowstone National Park 2589.5.1 Summary 260References 2619.6 What Is a Tsunami and How Do They Form? 2619.6.1 Summary 262Reference 2629.7 What Is a Tornado? 2629.7.1 Summary 264Reference 2649.8 Can a Tornado Really Lift a House? 2649.8.1 Summary 2659.9 Can Straw Penetrate a Tree in a Tornado? 2659.9.1 Summary 266Reference 2669.10 What Is a Hurricane? 2669.10.1 Summary 26710 Strange Occurrences and Other Interesting Items 26810.1 What in the Force of a Ship Hitting a Whale? 26810.1.1 Summary 269Reference 27010.2 How Much Wind to Blow Over a Tree 27010.2.1 Summary 27210.3 Why Do Objects Appear Smaller Than They Are? 27310.3.1 Summary 27410.4 Do We Feel a Force When Near Large Objects? 27410.4.1 Summary 27510.5 Why Does the Moon Sometimes Appear So Big on the Horizon? 27510.5.1 Summary 27610.6 How Does an Air Conditioner Operate? 27610.6.1 Summary 277Reference 27710.7 How Fast to Heat Up a Room? 27810.7.1 Summary 27810.8 How Do I Size an Air Conditioner for a Garage? 27810.8.1 Summary 27910.9 At What Speed Does a Locomotive Become De-railed? 27910.9.1 Summary 28010.10 Are Those Huge Cruise Ships Stable? 28010.10.1 Summary 28110.11 Why Are Arches Used? 28110.11.1 Summary 28510.12 Why Don't Bighorn Sheep Die When Banging Their Heads? 28510.12.1 Summary 28610.13 Why Can't We Walk on Water? 28610.13.1 Summary 288Reference 28810.14 How to Predict the Outcome of the Stock Market 28810.14.1 Summary 29210.15 Things Aren't as Random as They May Appear 293Reference 29410.15.1 Summary 29510.16 Why Do Certain Events Seem to Happen Quite Often? 29510.16.1 Summary 29510.17 Occurrences on Machines and Structures 29510.17.1 Summary 29810.18 How Long Does It Take to Thaw a Frozen Turkey and to Cook It? 29810.18.1 Summary 30011 Magic Tricks Using Engineering Principles 30111.1 Surface Tension and Floating Metal 30111.1.1 Summary 30411.2 Acceleration of Gravity and the Money Challenge 30411.2.1 Summary 30511.3 The Jumping Coin 30511.3.1 Summary 30611.4 The Belt Balancing Act 30611.4.1 Summary 30711.5 How Can It Be Held Up by Threads? 30811.5.1 Summary 30911.6 Pulling the Tablecloth 31011.6.1 Summary 31112 Useful Forms of the Equations Used in this Book 31212.1 The Equations of Motion 31212.2 Newton's First Law of Force 31212.3 Newton's Second Law of Force 31312.4 Newton's Third Law of Force 31312.5 Newton's Gravitation Theory 31312.6 Static Equilibrium 31412.7 Momentum and Impulse 31412.8 Kinetic Energy 31412.9 Potential Energy 31512.10 Conservation of Energy 31512.11 Bernoulli's Equation 31512.12 Specific Heat Equation 31612.13 Conduction Equation 31612.14 Convection Equation 31612.15 Radiation Equation 31712.16 Theories of Material Failure 31712.17 Archimedes Principle 31712.18 Centrifugal Force 31812.19 What Is Enthalpy? 31813 A Little About Some Famous Scientists Mentioned in This Book 31913.1 Isaac Newton (1642-1726 AD) 31913.2 Daniel Bernoulli (1700-1782 AD) 32013.3 Archimedes of Syracuse (287-212 BC) 32013.4 William Rankine (1820-1872 AD) 32113.5 Leonardo da Vinci (1452-1519 AD) 32113.6 Heinrich Holzer 32113.7 Stephan Timoshenko (1878-1972) 322Reference 32213.8 Jacob P. Den Hartog (1901-1989) 322References 32213.9 Wilson, Ker, William 322Index 325

O autorze

A. Sofronas, DEng, PE, is the former Worldwide Lead Mechanical Engineer for ExxonMobil. He was involved with machinery troubleshooting for 50 years with more than 130 publications and numerous presentations at industry seminars worldwide. Dr. Sofronas is a contributing editor for Hydrocarbon Processing and the author of Analytical Troubleshooting of Process Machinery and Pressure Vessels, Case Histories in Vibration Analysis and Metal Fatigue, and Survival Techniques for the Practicing Engineer.