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Article
Publication date: 1 April 1988

Balbir S. Dhillon and Subramanyam N. Rayapati

A newly developed model for performing reliability and availability analysis of mechanical devices subject to multiple failure modes is presented. Using this model…

Abstract

A newly developed model for performing reliability and availability analysis of mechanical devices subject to multiple failure modes is presented. Using this model, reliability analyses of mechanical devices such as brakes, bearings, engines, fans, gears, generators, heat exchangers and pumps are developed. Real life failure rate data for these devices are obtained from various sources and are used in their reliability analyses. Principal failure modes of these devices are identified and expressions for reliability, state probabilities, mean time to failure and variance of time to failure are developed. For known field failure data reliability and state probability plots are shown.

Details

International Journal of Quality & Reliability Management, vol. 5 no. 4
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 1 April 1995

Bill Wilson

Summarizes briefly the dramatic advances made in the reliability of mechanical seals for rotating shafts in the process chemical and petrochemical industries over the last…

Abstract

Summarizes briefly the dramatic advances made in the reliability of mechanical seals for rotating shafts in the process chemical and petrochemical industries over the last 30 years. Shows that expected mean time before failure has improved from tens of days to years over that time.

Details

Industrial Lubrication and Tribology, vol. 47 no. 2
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 2 May 2008

B. Sharma and O.P. Gandhi

Most of the mechanical systems consist of common tribo components such as gear, bearing, seal, pump, etc. During operation, the failure of such a component may lead to…

Abstract

Purpose

Most of the mechanical systems consist of common tribo components such as gear, bearing, seal, pump, etc. During operation, the failure of such a component may lead to failure of the system or any other components depending on the system structure or its connections. The transformation of functional quantities or parameters within and various components make these vulnerable to failures and breakdowns. The main purpose of this paper is to evaluate the reliability of a tribo‐pair during operation based on the operational parameters which takes into account the deviation in functional objective and considers the component structure explicitly.

Design/methodology/approach

Failure representation using digraph models have mainly been limited to chemical systems and processes but have been applied to a limited extent to mechanical systems. Researchers have considered the operating parameters such as pressure, temperature; feed rate, flow, etc. as the input/output operational parameter for failure cause identification of tribo mechanical system. However, these are not true in case of components like gear, bearing, etc. Therefore, this methodology has been refined in this paper, and is extended to a tribo‐pair by considering its functions along with operating parameters for reliability assessment. The tribo‐pair considered for the development of model is a gear pair, which is a common and important example of mechanical components.

Findings

Understanding of the failure modes helps the designer in identifying the root cause of failure and the operational parameters whose increase/decrease affects the functional objective. Consideration of the input and output parameters and their interrelations are used to develop input‐output model of a gear pair called gear pair model. This requires consideration of the input and output parameters, which are based on the gear pair functionality. These parameters have been identified. Four input parameters; five output parameters and one condition monitoring parameter are considered to model the gear pair. In addition to input and output parameters condition monitoring parameters are also considered to develop the gear pair model.

Originality/value

Reliability assessment of a tribo‐pair during operation will help the practicing engineers to take corrective action and minimize the occurrence of undesired failure symptom during operation. The decrease in possibility of undesired failure symptom will enhance the reliability of mechanical system.

Details

Industrial Lubrication and Tribology, vol. 60 no. 3
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 3 August 2010

Abhijit Ghosh and S.K. Majumdar

The purpose of this paper is to model the occurrences of successive failure types and times to failure of the two repairable machine systems.

Abstract

Purpose

The purpose of this paper is to model the occurrences of successive failure types and times to failure of the two repairable machine systems.

Design/methodology/approach

Historical data on failure types and time to failures of the given machine systems (4 nos) were gainfully used. Second order time homogeneous Markov Chain models were used to characterize the occurrences of the two broad failure type, namely, mechanical and electrical, after having found that the occurrences of failure types were dependent. Second order time homogeneous Markov Chain with Bivariate Distribution function (M2BVD) was used to model the times between successive failures {Tn, n≥1} for each machine system.

Findings

It is possible to apply the theoretical framework of Markov chain models to the accumulated data on failure types and failure times of any repairable system, which provide a wealth of information on the systems and are often left unused.

Research limitations/implications

The framework used in the study can be improved to accommodate multiple failure types and failure times of any repairable system to the extent that a more accurate prediction of these two variables and a better estimate of the system reliability are available.

Originality/value

The models for failure types and failure times of the given machine systems would be of immense use to the maintenance crew for predicting the future failure types and failure times of any given system and subsequently organizing and fine‐tuning their state of preparedness.

Details

International Journal of Quality & Reliability Management, vol. 27 no. 7
Type: Research Article
ISSN: 0265-671X

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Article
Publication date: 2 August 2017

Zahid Hussain Hulio and Wei Jiang

The purpose of this paper is to analyze wind climate parameters and performance functions, on the basis of two years of data, and reliability of Pakistan’s first wind farm…

Abstract

Purpose

The purpose of this paper is to analyze wind climate parameters and performance functions, on the basis of two years of data, and reliability of Pakistan’s first wind farm located at Jhimpir, Sindh.

Design/methodology/approach

The methodology covers assessment of wind climate parameters including wind variation at different hub heights, wind shear and diurnal wind shear. In addition, a performance assessment of a wind farm on the basis of technical and real availability, capacity factor and failure rate of mechanical and electrical components has been conducted. The Weibull method has been used for reliability analysis. The maintenance model is proposed for improving the performance. Last is about annual energy volume lost and of financial constraints’ assessment.

Findings

The monthly mean wind variation at heights of 80, 60 and 30 m was found to be 8, 6.9 and 5.9 m/s, respectively. The monthly mean wind shear coefficient was found to be 0.2419. The performance assessment of the wind farm includes technical and real availability, and the capacity factor was found to be 97, 90 and 35.5 per cent, respectively. The failure rate found in the first and second year was 8 and 14 per cent, respectively. Reliability decreased from the first year to the second year, i.e. 0.89 to 0.71 per cent. The components’ failure frequency rose to 57.2 per cent in the second year. The lost energy production due to electrical and mechanical failures was 27.241 GWh in two years that cost Pakistani Rs. 329.8m.

Originality/value

The results of the assessment show that a wind farm needs drastic maintenance strategies to maximize the its performance.

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Article
Publication date: 20 May 2020

Zahid Hussain Hulio and Wei Jiang

The rapid rising of renewable energy sources particularly wind energy cannot be ignored. The numerical increase in wind energy farms throughout the world is the best…

Abstract

Purpose

The rapid rising of renewable energy sources particularly wind energy cannot be ignored. The numerical increase in wind energy farms throughout the world is the best example. The purpose of this paper is to assess the basic question of whether wind characteristics affect the performance and cost of energy. The importance of this question cannot be ruled out while comparing renewable energy to a conventional form of energy more specifically especially for the developing country where the cost of energy is very high.

Design/methodology/approach

The research design of this paper is consists of an assessment of local wind characteristics of the wind farm site using Weibull k and c parameters. The performance model is used to assess the performance of the wind turbine (WT) corresponding to local wind characteristics. The wind correlation with WT in terms of changing wind speed has been assessed to quantify the effects of wind speed on the WT behavior and failure of WT components. Similarly, the power curve of WT is assessed and compared with the International Electrotechnical Commission standards 61400-12-2. The WT power coefficient and tip speed ratio corresponding to wind speed is also investigated. The energy volume and cost of energy lost model is used to determine the cost and volume loss of energy/kWh of the wind farm.

Findings

The findings of practical wind farms showed that the wind conditions of the site are showing a strong tendency that can be determined from the results of Weibull k and c parameters. The k and c parameters are observed to be 3.44 and 9.16 m/s, respectively, for a period of a year. The standard deviation is observed to be 2.56 for a period of a year. WT shows the efficient behavior can be obtained from the power coefficient and tip speed of WT at different wind speeds. Also, wind farm observation showed that to be some increasing wind speed cause of based WT component failures. The results of energy volume and cost/kWh assessment showed that the major portion of energy volume and cost of energy is lost owing to network, voltage dip and frequency surge, electrical and mechanical components failures.

Originality/value

Generally, it can be concluded that the WTs are now able to cope with variable wind speeds. However, the results of this paper are showing that WT performance and availability decreased due to increased wind speeds. It can also be a reason to decreased volume and increase the cost of energy/kWh.

Details

International Journal of Energy Sector Management, vol. 14 no. 5
Type: Research Article
ISSN: 1750-6220

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Article
Publication date: 16 June 2020

Jiawei Wang, Jinliang Liu, Guanhua Zhang and Jigang Han

Considering the “size effect” and the properties degradation of building materials on the strengthened engineering, in this paper, the technology of pasting steel plate…

Abstract

Purpose

Considering the “size effect” and the properties degradation of building materials on the strengthened engineering, in this paper, the technology of pasting steel plate was adopted to shear strengthen a 16 m prestressed concrete hollow slab, which had serviced 20 years in cold regions. The shear properties of shear strengthen beams are analyzed.

Design/methodology/approach

Shear loading test of the shear strengthened beam and the contrast beam was conducted. Then the mechanical characteristics, failure mechanism, the mechanical response and shear capacity of shear strengthened beam and contrast beam had been discussed.

Findings

The failure mode of shear strengthened beam and contrast beam was shear compression failure, and the bond failure between concrete and prestressed reinforcement happened in both of test beams. The shear strengthening method of pasting steel plate can effectively improve the mechanical response for the shear strengthened beam. Compared with the contrast beam, the cracking load and failure shear capacity for the shear strengthened beam can be effectively increased by 12.2 and 27.6%, respectively.

Originality/value

The research results can be a reference for the detection and evaluation of shear strengthened bridges, which are strengthened by pasting steel plate. Engineers can refer to the shear strengthening method in this paper to strengthen the existing bridge, which can guarantee the safety of shear strengthened bridges.

Details

International Journal of Structural Integrity, vol. 12 no. 3
Type: Research Article
ISSN: 1757-9864

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Article
Publication date: 1 February 2006

Rajiv Kumar Sharma, Dinesh Kumar and Pradeep Kumar

To examine the need to develop, practice and implement such maintenance practices, which not only reduce sudden sporadic failures in semi‐automated cells but also reduce…

Abstract

Purpose

To examine the need to develop, practice and implement such maintenance practices, which not only reduce sudden sporadic failures in semi‐automated cells but also reduce both operation and maintenance (O&M) costs.

Design/methodology/approach

A case‐based approach in conjunction with standard tools, techniques and practices is used to discuss various issues related with TPM implementation in a semi‐automated cell.

Findings

The findings indicate that TPM not only leads to increase in efficiency and effectiveness of manufacturing systems, measured in terms of OEE index, by reducing the wastages but also prepares the plant to meet the challenges put forward by globally competing economies to achieve world class manufacturing (WCM) status.

Originality/value

The paper presents an interesting investigation of TPM implementation issues which may help the managers/practitioners to prepare their plants/units to meet the challenges of competitive manufacturing in twenty‐first century by adopting and implementing TPM.

Details

Industrial Management & Data Systems, vol. 106 no. 2
Type: Research Article
ISSN: 0263-5577

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Article
Publication date: 1 April 1983

IN THE past, many chemical process plant operators have expressed concern about the inconsistencies experienced in mechanical seal reliability. Late in 1981 a paper from…

Abstract

IN THE past, many chemical process plant operators have expressed concern about the inconsistencies experienced in mechanical seal reliability. Late in 1981 a paper from Exxon, published by the American Society of Lubrication stated that a population of 14,000 centrifugal pumps cost in excess of $15 million per year to maintain, and that 70% of this cost was attributable to mechanical seal failure. In addition to the strong economic incentive to cut failure rates, health and safety considerations also require a better knowledge of mechanical seal operation and behaviour.

Details

Industrial Lubrication and Tribology, vol. 35 no. 4
Type: Research Article
ISSN: 0036-8792

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Article
Publication date: 18 September 2009

Tao Bo, Yin Zhouping, Ding Han and Wu Yiping

The purpose of this paper is to present a novel reflow profile optimization method using mechanical reliability estimation of micro‐ball grid array (μBGA) solder joints…

Abstract

Purpose

The purpose of this paper is to present a novel reflow profile optimization method using mechanical reliability estimation of micro‐ball grid array (μBGA) solder joints, based on the heating factor, Qη is introduced, where the coupling effect of reflow temperature and time on the mechanical reliability of μBGA joints is considered.

Design/methodology/approach

The method presented is actualized through vibration fatigue tests. First, a two‐parameter Weibull distribution is used to model the collected data of vibration fatigue lifetime for different Qη. After that, two explicit functions are deduced in a unified mathematic expression form, which give an intuitionistic description of the mean time to failure and reliability of solder joints against induced variable Qη, thus revealing definitely the effect of Qη on the mechanical fatigue lifetime of solder joints suffering from cyclic vibration loading. Finally, for a specified reliability goal, how to choose proper Qη values, based an improved Golden Section Search arithmetic, is discussed.

Findings

Numerical analysis and calculation are performed. The results show that the solder joints made at Qη near 510 have higher mechanical reliability, and those reflowed farther away this optimal value have less reliability.

Originality/value

This paper presents a useful and applicable solution to achieve reflow profile optimization and process control for a quantitative mechanical reliability estimation of μBGA solder joints.

Details

Soldering & Surface Mount Technology, vol. 21 no. 4
Type: Research Article
ISSN: 0954-0911

Keywords

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