1 INTRODUCTION Reliability engineering and predictive maintenance have two major objectives: pre- venting catastrophic failures of critical plant production systems and avoiding devia- tions from acceptable performance levels that result in personal injury, environmental impact, capacity loss, or poor product quality. Unfortunately, these events will occur no matter how effective the reliability program. Therefore, a viable program also must include a process for fully understanding and correcting the root causes that lead to events having an impact on plant performance. This book provides a logical approach to problem resolution. The method can be used to accurately define deviations from acceptable performance levels, isolate the root causes of equipment failures, and develop cost-effective corrective actions that pre- ‘vent recurrence. This three-part set is a practical, step-by-step guide for evaluating ‘most recurring and serious incidents that may occur in a chemical plant. Part One, Introduction to Root Cause Failure Analysis, presents analysis techniques used 10 investigate and resolve reliability-related problems. It provides the basic methodology for conducting a root cause failure analysis (RCFA). The procedures defined in this section should be followed for all investigations. Part Two provides specific design, installation, and operating parameters for particu- lar types of plant equipment. This information is mandatory for all equipment-related problems, and it is extremely useful for other events as well. Since many of the chronic problems that occur in process plants are directly or indirec:ly influenced by the operating dynamics of machinery and systems, this part provides invaluable ‘guidelines for each type of analysis. Part Three is a troubleshooting guide for most of the machine types found in a chemi- cal plant. This part includes quick-reference tables that define the cemmon failure or