Handbook of Technical Diagnostics: Fundamentals and Application to Structures and Systems PDF
Preview Handbook of Technical Diagnostics: Fundamentals and Application to Structures and Systems
Handbook of Technical Diagnostics Horst Czichos Editor Handbook of Technical Diagnostics Fundamentals and Application to Structures and Systems 1 3 Editor Horst Czichos Beuth HochschulefürTechnik Berlin Germany ISBN 9783642258497 ISBN 9783642258503 (eBook) DOI 10.1007/9783642258503 SpringerHeidelbergNewYorkDordrechtLondon LibraryofCongressControlNumber:2012955407 (cid:2)SpringerVerlagBerlinHeidelberg2013 Thisworkissubjecttocopyright.AllrightsarereservedbythePublisher,whetherthewholeor part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway, andtransmissionorinformationstorageandretrieval,electronicadaptation,computersoftware, orbysimilarordissimilarmethodologynowknownorhereafterdeveloped.Exemptedfromthis legalreservationarebriefexcerptsinconnectionwithreviewsorscholarlyanalysisormaterial suppliedspecificallyforthepurposeofbeingenteredandexecutedonacomputersystem,for exclusiveusebythepurchaserofthework.Duplicationofthispublicationorpartsthereofis permitted only under the provisions of the Copyright Law of the Publisher’s location, in its currentversion,andpermissionforusemustalwaysbeobtainedfromSpringer.Permissionsfor use may be obtained through RightsLink at the Copyright Clearance Center. Violations are liabletoprosecutionundertherespectiveCopyrightLaw. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthis publicationdoesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesare exemptfromtherelevantprotectivelawsandregulationsandthereforefreeforgeneraluse. Whiletheadviceandinformationinthisbookarebelievedtobetrueandaccurateatthedateof publication, neither the authors nor the editors nor the publisher can accept any legal responsibilityforanyerrorsoromissionsthatmaybemade.Thepublishermakesnowarranty, expressorimplied,withrespecttothematerialcontainedherein. Printedonacidfreepaper SpringerispartofSpringerScience+BusinessMedia(www.springer.com) Preface Functionality,quality,reliability,andsafetyareindispensableattributes of all technologies. This handbook presents concepts, methods, and techniques to examine symptoms of fault and failure of structures, systems, and components to monitor functional performance and structural integrity. The book is organized in five parts: • Part I introduces the scope and application of technical diagnostics and gives a comprehensive overview of the physics offailure. • Part II presents all relevant methods and techniques for diagnostics andmonitoring:fromstress,strain,vibrationanalysis,nondestructive evaluation, thermography and industrial radiology to computed tomography and subsurface microstructural analysis. • PartIIIcorestheprinciplesandconceptsoftechnicalfailureanalysis, illustrates case studies, and outlines machinery diagnostics with an emphasis on tribological systems. • Part IV describes the application of structural health monitoring and performancecontroltoplantsandtechnicalinfrastructures,including buildings, bridges, pipelines, electric power stations, offshore wind structures, and railway systems. • Part V is an excursion on diagnostics in arts and culture. IthankDr.WernerDaumandDr.WolfgangHabelandtheteamof scientists and engineers of BAM (German Federal Institute for Mate- rials Research and Testing) who helped to create the concept of this handbook and who authored chapters in all parts of it. The book integrates knowledge of basic sciences and engineering disciplines with contributions from research institutions, academe, and industry,writtenbyinternationallyknownexpertsfromvariouspartsof the world, including Europe, Canada, India, Japan, and the US. I am very grateful to all colleagues for their excellent contributions, and Springerforpublishingthisinternationalinterdisciplinarywork—which may help to make the world safer. Berlin, July 2012 Horst Czichos v Contents Part I Introduction 1 Scope of Technical Diagnostics . . . . . . . . . . . . . . . . . . . . . 3 Horst Czichos 2 Application of Technical Diagnostics. . . . . . . . . . . . . . . . . 11 Horst Czichos 3 Physics of Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Horst Czichos Part II Methods and Techniques for Diagnostics and Monitoring 4 Overview of Diagnostics and Monitoring Methods and Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Baldev Raj and B. Venkatraman 5 Stress and Strain Determination. . . . . . . . . . . . . . . . . . . . 69 Thomas Kannengiesser and Klaus-Peter Gründer 6 Modal Analysis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Werner Rücker 7 Vibration Analysis: Methods and Applications . . . . . . . . . 121 J. Lyle Bagley 8 Acoustic Emission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Jürgen Bohse 9 Non-destructive Evaluation. . . . . . . . . . . . . . . . . . . . . . . . 161 Anton Erhard 10 Infrared Thermography . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Clemente Ibarra-Castanedo and Xavier P. V. Maldague vii viii Contents 11 Industrial Radiology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 Uwe Ewert, Gerd-Rüdiger Jaenisch, Uwe Zscherpel, Kurt Osterloh and Bernhard Redmer 12 Computed Tomography . . . . . . . . . . . . . . . . . . . . . . . . . . 249 Jürgen Goebbels 13 Embedded Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259 Werner Daum 14 Micro-Diagnostics: X-ray and Synchrotron Techniques . . . 287 B. R. Müller and M. P. Hentschel 15 Surface Chemical Analysis at the Micro- and NanoScale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 Wolfgang E. S. Unger and Vasile-Dan Hodoroaba 16 Sub-Surface Microstructural Analysis. . . . . . . . . . . . . . . . 323 Werner Österle Part III Technical Diagnostics of Machines and Plants 17 Principles and Concepts of Technical Failure Analysis. . . . 341 Thomas Boellinghaus 18 Failure Analysis: Case Studies . . . . . . . . . . . . . . . . . . . . . 355 Christian Klinger 19 Machinery Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 387 Richard S. Cowan and Ward O. Winer Part IV Structural Health Monitoring and Performance Control 20 Principles, Concepts and Assessment of Structural Health Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413 Werner Daum 21 Buildings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425 Akira Mita 22 Bridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429 Helmut Wenzel 23 Pipelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453 Daniele Inaudi Contents ix 24 Electric Power Stations and Transmission Networks . . . . . 471 Wolfgang Habel and Gerd Heidmann 25 Offshore Wind Structures. . . . . . . . . . . . . . . . . . . . . . . . . 505 Claus Kupferschmidt, Mareike Strach, Holger Huhn and Fabian Vorpahl 26 Railway Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519 L. Quiroga and E. Schnieder 27 Guidelines for Structural Health Monitoring. . . . . . . . . . . 539 Werner Daum Part V Excursion 28 Diagnostics in Arts and Culture . . . . . . . . . . . . . . . . . . . . 545 Oliver Hahn Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 557 Part I Introduction 1 Scope of Technical Diagnostics Horst Czichos Fault (FR Panne, DE Fehlzustand): the condi- 1.1 Meaning and Impact tion of an item that occurs when one of its of Diagnostics components or assemblies degrades or exhibits abnormal behavior. The word diagnostics originates from the med- Failure (FR Defaillance, DE Ausfall): the ter- ical field and refers to the identification of the mination of the ability of an item to perform nature of a health problem and its classification a required function. (Failure is an event as by examination and evaluation. The term diag- distinguished from fault, which is a state.). nostic criteria designates the combination of The failure mode is the phenomenon by signs, symptoms, and test results to be used in which a failure is observed. After a failure, attempts to determine the problem. Diagnosis is the systematic examination of an item in the result of a diagnostics process (Fig. 1.1). order to identify the failure mode and deter- TECHNICAL DIAGNOSTICS is the examination of mine the failure mechanism and its basic symptoms and syndromes to determine the nat- cause is called root cause failure analysis. ure offaults or failures of technical objects [1]. The identification of faults and failures are • Asymptomisaperception,madebymeansof important tasks of technical diagnostics. This humanobservationsandmeasurements,which can be illustrated by examples of failure char- may indicate the presence of an abnormal acteristics, defined in international standards condition with a certain probability. from various technology areas and industrial • A syndrome is a group of symptoms that branches [2]. A failure, to be detected by tech- collectively indicate or characterize an nical diagnostics, can be: abnormal condition. • Termination of the ability of a structure to The terms fault and failure are defined as perform its required function when one or follows [1]: moreofthecomponentsofastructureareina defective condition, either at a service or ultimate limit state. Mechanical vibration and shock (ISO ThisintroductorychapteroftheHandbookoutlinesthe 16587). meaningandimpactofdiagnostics,definesitsbasic • Loss ofthe abilityofabuildingor itsparts to termsandgivesanoverviewofconcepts,methodsand perform a specified function. techniques. Buildings and constructed assets (ISO H.Czichos(&) 15686). BeuthHochschulefürTechnik, • Premature malfunction or breakdown of a LuxemburgerStraße20a,13353Berlin,Germany function ora component or the whole engine. email:[email protected] H.Czichos(ed.),HandbookofTechnicalDiagnostics, 3 DOI:10.1007/9783642258503 1,(cid:2)SpringerVerlagBerlinHeidelberg2013 4 H.Czichos Fig.1.1 Theobjectofmedicaldiagnosticsandexamplesofobjectsoftechnicaldiagnostics Internal combustion engines (ISO 2710). • Anyleakageorjointseparation,unlessotherwise • Sudden and unexpected ending of the ability determinedtobeduetoapipeorfittingdefect. of a component or equipment to fulfill its Ships and marine technology (ISO 15837). function. • Termination of the ability of an item to per- Gas turbines (ISO 3977). form a required function. • Actual condition of an item which does not Space systems (ISO 14620). perform its specified function under the • Systemstatewhichresultsinnon-performance specified condition. orimpairedperformanceasaresultofahard- Earth-moving machinery (ISO 8927). wareorsoftwaremalfunction. • Event causing the loss or reduction of the Road vehicles (ISO 17287). nominal serviceability. • Insufficient load-bearing capacity or inade- Cranes (ISO 11994). quateserviceabilityofastructureorstructural • Loss of structural integrity and/or transmis- element. sion offluid through the wall of a component Reliability for structures (ISO 2394). or a joint. These examples from the different techno- Petroleum and natural gas industries (ISO logical areas and industrial sectors show that 14692). various faults and failures may detrimentally • State at which a component reaches the influence technical items. Damage identification threshold level or terminates its ability to by technical diagnostics has to consider gener- perform a required function. ally four basic aspects: Hydraulic fluid power (ISO/TR 19972). • the existence of damage, • Occurrence of bursting, leaking, weeping or • damage location, pressure loss. • damage type, Plastics piping systems (ISO 7509). • damage severity.
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