Applying FMEA & RCFA to Asset Management in the 21st Century
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Transcript of Applying FMEA & RCFA to Asset Management in the 21st Century
Applying FMEA & RCFA to Asset Management in the 21st
CenturyUnderstanding the Tools and Techniques Needed to Reduce, Eliminate, or Accept Asset and Facility Risk
Michael B. CowleyPresidentCE Maintenance Solutions, LLC
PRESENTERS:
Steven D. SchneiderAsset Reliability ManagerNE Ohio Regional Sewer District
Scott A. McBrayer, PEProject EngineerDonahue IDEAS, LLC
Course Outline
Understand Basic Risk Management
Become Familiar with Risk Management Tools
What is Root Cause Failure Analysis (RCFA)?
RCFA Tools and Examples
What is Failure Mode and Effect Analysis (FMEA)?
FMEA Tools and Processes
FMEA Examples and Exercises
2
NEORSD Asset Initiative
NEORSD Asset Management – Phase 2Asset codes analysis and facilitation
WAM database analysis for Renewable Energy Facility (REF) assets
Failure Modes and Effects Analysis (FMEA)Facilitating 6 Pilot Projects (4 O&M FMEAs and 2 Design FMEAs)
Root Cause Failure Analysis (RCFA)Facilitating 4 Pilot Projects
Equipment Condition Assessments• As-Needed at District discretion
3
Why Do You Need Risk Management?
What Keeps You Awake at Night?
Three (3) Risk Management Priorities1. Safety – Keeping Employees and Customers Safe
2. Ensuring You Don’t Go to Jail
3. Making Sure You Sleep All Night
4
What is Risk Management ?
Unacceptable RiskRisk assessment is the determination of quantitative or qualitative value of risk related to a concrete situation and a recognized hazard.
Quantitative risk assessment requires calculations of two components of risk: the magnitude of the potential loss, and the probability the loss will occur.
5
What is Risk Management ?
Acceptable RiskIs a risk that is understood and tolerated usually because the cost or difficulty of implementing an effective countermeasure for the associated vulnerability exceeds the expectation of loss.
6
What Does it Take to Develop a Risk Management Program?
Management Culture of Continuous Improvement
Leading Class Equipment and Asset Management System
Complete and Detailed Understanding of Your Operating System and Process
Mature Maintenance Management System and Process
7
Risk Management
8
Risk Types
UncertaintyAssociated with unknown and unexpected events, generally catastrophic
TraitsUnknown or difficult to quantify
Catastrophic or disastrous
Can be costly
Outside the organization’s sphere of control
Examples Include:Building damage by flash flooding, arson or sabotage
Hurricanes, tornados or blizzards
9
Source: Facility Management Association of Australia, Ltd, Facility Management Guidelines to Managing Risk 2004
Risk Types
HazardAssociated with a source of potential harm or a situation with the potential to cause harm
TraitsUsually known
Readily quantifiable, tangible
Impact predominantly on safety
Examples Include:Catastrophic Equipment Failure
Management and use of hazardous chemicals
Confined space entries
10
Source: Facility Management Association of Australia, Ltd, Facility Management Guidelines to Managing Risk 2004
RCFA –What is it?
Root Cause Failure Analysis (RCFA)Problem solving method
Reactive process
Eliminates recurring problems
Manages the consequences of failure
Not a tool but a process
RCFA is a Reactive Process Initiated After the Failure has Occurred
11
What is the Objective of a RCFA ?
Analysis is Performed in Order to Identify:What behaviors
Actions
Inactions
Conditions
Led to a failure
Success is defined as the near certain prevention of recurrence
12
RCFA – Failure Classifications
ChronicEvents that have happened in the past, but may have significant cumulative losses over time
Events that happen more than once should be classified as chronic
SporadicOnetime events that involve significant, unexpected and severe consequences
13
What is a Root Cause?
The Root Cause is the Most Basic Reason for the Problem Occurring
There are three types of root causes:
Physical,
Human, and
Latent
A failure results from one or more root causes
14
What is a Root Cause?
PhysicalA component or material failed (such as a shaft breaking)
HumanActions or decisions lead to failure (an operator made a mistake)
LatentReasons causing human decisions to be made incorrectly
15
RCFA Problem Solving Steps
1. Define the Problem
2. Define the Team
3. Contain the Symptoms
4. Root Cause Analysis
5. Corrective Actions
6. Preventive Actions
7. Evidence of Effectiveness
8. Team Sign-Off
16
17
Asset # Southerly ID Fan Pillow Block Bearing Work Order #
Why did the bearings fail? The bearings failed because of lack of grease.
Name: Paul Crum / RCFA team
Date: 2/27/2015
Upper maintenance management.
Why did the maintenance employee not know
which hole was the proper one for the
connection?
The maintenance employee didn't investigate / study
how to properly install the grease line.
Step 3: Corrective Actions (What should be done to f ix the problem?)
Re-pipe all grease lines to the proper grease port in the bearing housing.
Step 4: Preventive Actions (What should be done to prevent the problem from happening again?)
1. Use color indicators around the correct grease port. 2. Any time the pillow block is replaced, visually
inspect the bearing to ensure proper grease line installation. 3. Make sure all employees are trained to
review installation diagrams prior to installation.
Why was it the grease line hooked to the
wrong location?
There were multiple holes available for the connection.
(Only one hole is shown on the diagram.) The
mechanical maintenance employee did not know which
hole was the proper one.
Why????? Because:
Step 5: Communications (Who needs to be informed?) Step 6: Completed By
Why??? Because:
How was the Memo Lube Installed
improperly? (assume at this point the Memo
Lube was installed in-house)
The grease line was hooked to the wrong location.
Why???? Because:
Why? Because:
Because of improper (Memo Lube) manufacturer
installation.
Why?? Because:
Why was there a lack of grease?
Step 2: 5-Why Analysis (Ask w hy the condition occurred until you obtain the root cause)
NEORSD - Root Cause Failure Analysis 5 Why Form
Step 1: Define the Problem (What, Where, How Many?)
Premature failure on the in-board and out-board fan pillow block bearings.
FMEA –What Is It?
Failure Mode and Effect AnalysisFMEA is a systematic method of identifying and preventing product and process problems before they occur
Potential problem analysis
Anticipate problems before they occur
Crystal ball method of maintenance
What if this happens????
18
19
The FMEA process entails asking eight basic questions about the asset or system under review.
1. What is the function and associated performance standards of the overall asset in its present operating context? Why did you buy it and what do you expect from it (e.g. to pump 300 gal/hr.)?
2. In what ways does it fail to fulfill its functions? e.g. Unable to pump at all or unable to pump 300 gal/hr.
3. What causes each functional failure? What are the failure modes, what is the root cause of the failure for the asset, e.g. Pump bearing fatigued.
4. What is the Consequence of Failure?In regards to Safety, Regulatory Compliance and Fiscal Impact, e.g. Failure may violate EPA permit.
19
20
The FMEA process entails asking eight basic questions about the asset or system under review.
5. What happens when each failure occurs? What happens when the failure occurs, e.g. Bearing seizes, alarm notifies operator, etc.
6. What is the likelihood of Occurrence? How likely is that failure to occur?
7. What is currently done to prevent or detect each failure? What Proactive Maintenance Policy or Task is currently being done.
8. What Proactive Maintenance Task can be done to prevent or detect the failure? What action can be taken, including Standard Operating Procedures and Redesigns.
20
3 Key Factors to FMEAs
Risk Rating ScalesRequires the analysis team to use past experience and engineering judgment to rate each potential risk according to three rating scales
Severity (Criticality)The consequence of the failure should it occur
OccurrenceThe probability of frequency of the failure occurring
DetectionThe probability of the failure being detected before the impact of the effect is realized
2121
Risk Priority NumberRPN = Criticality Score x Occurrence Score x Detection Score
RPN Number Will Range From 3 to 225
Highest Numbers Should be Attended to First
Any RPN’s with High Criticality Scores of Between 5 and 9 in Any of the Categories Should be Addressed Regardless of the RPN
Once Remediation has Taken Place the RPN Should be Recalculated (Revised RPN)
Once RPN is Within the Acceptable Range it Should Only be Reviewed if Process, Conditions, Outside Factors Change
22
Severity and Consequence of Failure/Criticality
23
Consequence of Failure/Criticality
Weighing Score Scoring Description
1 Poses no threat
Employee/Public Safety 33% 2Poses some threat/exposes public or employees to potential injury
3Poses significant threat/exposes public or employees to potential serious injury
1No violation likely to result if remedial action undertaken is planned
Regulatory Compliance/Public Impact
33% 2Violation might occur even if remedial action is undertaken as planned and potential media exposure
3 Violation is likely with extensive media exposure likely
1 Remediation can be done at minimal cost < $100K
Fiscal Impact 33% 2 Results in costly remediation $100K< and <$1M
3 Remediation would be a major staff burden or cost >$1M
Occurrence Description
24
Score
Occurrence
Description
5 Very Likely
4 Likely
3 Possible
2 Unlikely
1 Very Unlikely
Detection Description
25
Score Detection Description
5 not detectable
4 requires invasive inspection
3detected through preventive or
predictive inspections or rounds
2detected using human senses
during operator rounds
1automatically detected and
acknowledged
The FMEA Team
Team LeaderBest leader is non expert
Process or Equipment ExpertMust know all aspects and details of equipment and process
4-6 MembersOperators, Mechanics, Electricians
No management presence is preferred
26
10 Keys to Successful FMEA
1. Review the Process or EquipmentReview drawings and process flow diagrams
Tour the location or equipment
Have process or operations expert present
2. Brainstorm Possible Failure ModesBegin the brainstorming process
Each member of team should be responsible for numerous ideas
Remember it’s brainstorming, listen to all thoughts even the unusual
27
10 Keys to Successful FMEA
3. List Potential Effects of Each Failure ModeList all effects of each potential failure mode
Some may have several potential effects
4. Assign Severity Ranking for Each EffectHow severe is the effect if it happens?
What are the consequences of the failure?
The ranking is 1-3 in each category
28
10 Keys to Successful FMEA
5. Assign an Occurrence Ranking for Each FailureUse actual data if available
Obtained from CMMS history or event logs from operators
The ranking is 1-5
6. Assign a Detection Ranking for Each Failure Mode and/or Effect
How likely will you be able to detect the failure?
If difficult or impossible to detect then it warrantsa high score
Detection rankings are 1-529
10 Keys to Successful FMEA
7. Calculate the Risk Priority Number for Each Failure Mode
RPN = Severity X Occurrence X Detection
8. Prioritize the Failure Modes for ActionThe highest RPN possible is 225
Pareto 80/20 rule will tell you that you only need to work on the highest 20%
With experience you will develop a range where anything above that number gets attention
30
10 Keys to Successful FMEA
9. Take Action to Eliminate or Reduce the High-Risk Failure Modes
Take action to eliminate the failure
If not possible, take actions to reduce the RPN to an acceptable level
Always strive to reduce the RPN even further
10. Calculate the Resulting RPN as the Failure Modes are Reduced or Eliminated
Recalculate the RPN
Resulting RPN’s should be significantly lower than the original calculation
31
NEORSD FMEA
NEORSD - Southerly WWTP - ID Fans - Illinois Blower FMEA Key: Safety Score + Regulatory Score + Fiscal Score = Criticality Score
Steve S, Sam S, Josh M, Bob H, Paul C, Fred D, Mike P, Chris D, Rich W, Dan H, John Z, Chris P Criticality Score x Occurrence Score x Detection Score = Risk Priority Number (RPN)
Mike Cowley, CE Maintenance
Operating Context: Functional failure defined as failing to perform the following Function:The primary function of the ID fan (1 of 3 systems) is to remove the products of combustion, pulling them out of the incinerator, through the primary heat exchanger (maintaining a + 5" to -5" water column range),
waste heat boiler, economizer, scrubber and then discharging through the secondary heat exchanger into the atmosphere via the stack.
Worst Case Scenario: Failure off shift, during a holiday; assuming a 30-hour light-up of the back-up unit; also assuming 30 to 40 ft. of inventory.
Scope of Evaluation: Ductwork (leaving the scrubber) through the ID fan to the secondary heat exchanger. Expansion joint to expansion joint.
Assumptions: 1. Maintenance personnel and operators can be around equipment while in operation.
Lin
e Component
Functional FailureFailure Mode
Sa
fety
Re
gu
lato
ry
Fis
ca
l
Cri
tica
lity
Failure Effect
Occu
rre
nce
Current
Controls,
Prevention
Current
Controls,
Detection De
tecti
on
RP
N
Recommended Action Secondary Action
Responsibility
and Target
Completion
Date
Estimated
Cost Sa
fety
Re
gu
lato
ry
Fis
ca
l
Cri
tica
lity
Occu
rre
nce
De
tecti
on
Re
vis
ed
RP
N Final decision / action
to be taken (Based on
review by
management)
1I.D. Fan system fails to
function.
Expansion joint fasteners
are loose.2 1 1 4
Over time, the expansion joint
fasteners loosen up, drop off,
and the expansion joint
connection seperates. The ID fan
speed will vary, and the fan will
use more energy. The feedback
from the pressure transmitter
will send a (true) signal that
5 None Current PMs 3 60Lock-tite and re-torque all fasteners
in the expansion joint.None PUMPs Up to $1,000 2 1 1 4 2 3 24
2I.D. Fan system fails to
function.
The ID fan housing fasteners
loosen.1 1 1 3
Over time, any of the ID housing
fan fasteners loosen up, drop off,
and the joint connection
seperates, potentially vibrating.
The ID fan speed will vary, and
the fan will use more energy. The
feedback from the pressure
transmitter will send a (true)
5 None None 5 75Lock-tite and re-torque all fasteners.
Check on an annual PM.None PUMPs 2 days x 2 PUMPs 1 1 1 3 2 3 18
3I.D. Fan system fails to
function.
Wrong gasket materials (or
size) are used.1 1 1 3
During installation, the wrong
gasket material (or size) is used.
Pre-mature failure allows the
fasteners to loosen, drop off,
and the joint connection
seperates, potentially vibrating.
The ID fan speed will vary, and
the fan will use more energy. The
2 None None 5 30 None None
4I.D. Fan system fails to
function.The gasket deteriorates. 1 1 1 3
Over time, the gasket
deteriorates and weakens,
allowing the fasteners to
become loose, drop off, and the
joint connection seperates,
potentially vibrating. The ID fan
speed will vary, and the fan will
use more energy. The feedback
2 None None 5 30 None None
5I.D. Fan system fails to
function.
Incorrect gasket
installation.1 1 1 3
During installation, the gasket is
installed incorrectly, allowing
the fasteners to become loose,
drop off, and the joint
connection seperates,
potentially vibrating. The ID fan
speed will vary, and the fan will
use more energy. The feedback
2 None None 5 30 None None
6I.D. Fan system fails to
function.
Induction side differential
visual pressure gauge fails.1 1 1 3
No dominant failure mode.
Equipment is not currently used.
1 None None 1 3 None None
7I.D. Fan system fails to
function.
Duct work thermocouple
near expansion joint fails.1 1 1 3
Equipment is used for
observation only.
1 None None 1 3 None None
8I.D. Fan system fails to
function.
The spring-loaded isolation
dampeners (beneath the ID
fan base) fatigue.
1 1 2 4
Over time, the isolation
dampeners (1 of 16) fatigue,
crack and break. Eventually
enough of the dampeners break,
and there is more vibration
between the ID fan base and the
floor. The mortar in the concrete
base will break apart. This could
1 None None 5 20Visually inspect the isolation
dampeners for fatigue.None
Maintenance
Manager to
include in PM
1 1 1 3 1 3 9
Current State Remediation
Process or Equipment:
Team:
Facilitator:
Equipment / Process Function:
FMEA Example
32
NEORSD FMEA
NEORSD - Southerly WWTP - ID Fans - Illinois Blower FMEA Key: Safety Score + Regulatory Score + Fiscal Score = Criticality Score
Steve S, Sam S, Josh M, Bob H, Paul C, Fred D, Mike P, Chris D, Rich W, Dan H, John Z, Chris P Criticality Score x Occurrence Score x Detection Score = Risk Priority Number (RPN)
Mike Cowley, CE Maintenance
Operating Context: Functional failure defined as failing to perform the following Function:The primary function of the ID fan (1 of 3 systems) is to remove the products of combustion, pulling them out of the incinerator, through the primary heat exchanger (maintaining a + 5" to -5" water column range),
waste heat boiler, economizer, scrubber and then discharging through the secondary heat exchanger into the atmosphere via the stack.
Worst Case Scenario: Failure off shift, during a holiday; assuming a 30-hour light-up of the back-up unit; also assuming 30 to 40 ft. of inventory.
Scope of Evaluation: Ductwork (leaving the scrubber) through the ID fan to the secondary heat exchanger. Expansion joint to expansion joint.
Assumptions: 1. Maintenance personnel and operators can be around equipment while in operation.
Lin
e Component
Functional FailureFailure Mode
Sa
fety
Re
gu
lato
ry
Fis
ca
l
Cri
tica
lity
Failure Effect
Occu
rre
nce
Current
Controls,
Prevention
Current
Controls,
Detection De
tecti
on
RP
N
Recommended Action Secondary Action
Responsibility
and Target
Completion
Date
Estimated
Cost Sa
fety
Re
gu
lato
ry
Fis
ca
l
Cri
tica
lity
Occu
rre
nce
De
tecti
on
Re
vis
ed
RP
N Final decision / action
to be taken (Based on
review by
management)
1I.D. Fan system fails to
function.
Expansion joint fasteners
are loose.2 1 1 4
Over time, the expansion joint
fasteners loosen up, drop off,
and the expansion joint
connection seperates. The ID fan
speed will vary, and the fan will
use more energy. The feedback
from the pressure transmitter
will send a (true) signal that
5 None Current PMs 3 60Lock-tite and re-torque all fasteners
in the expansion joint.None PUMPs Up to $1,000 2 1 1 4 2 3 24
2I.D. Fan system fails to
function.
The ID fan housing fasteners
loosen.1 1 1 3
Over time, any of the ID housing
fan fasteners loosen up, drop off,
and the joint connection
seperates, potentially vibrating.
The ID fan speed will vary, and
the fan will use more energy. The
feedback from the pressure
transmitter will send a (true)
5 None None 5 75Lock-tite and re-torque all fasteners.
Check on an annual PM.None PUMPs 2 days x 2 PUMPs 1 1 1 3 2 3 18
3I.D. Fan system fails to
function.
Wrong gasket materials (or
size) are used.1 1 1 3
During installation, the wrong
gasket material (or size) is used.
Pre-mature failure allows the
fasteners to loosen, drop off,
and the joint connection
seperates, potentially vibrating.
The ID fan speed will vary, and
the fan will use more energy. The
2 None None 5 30 None None
4I.D. Fan system fails to
function.The gasket deteriorates. 1 1 1 3
Over time, the gasket
deteriorates and weakens,
allowing the fasteners to
become loose, drop off, and the
joint connection seperates,
potentially vibrating. The ID fan
speed will vary, and the fan will
use more energy. The feedback
2 None None 5 30 None None
5I.D. Fan system fails to
function.
Incorrect gasket
installation.1 1 1 3
During installation, the gasket is
installed incorrectly, allowing
the fasteners to become loose,
drop off, and the joint
connection seperates,
potentially vibrating. The ID fan
speed will vary, and the fan will
use more energy. The feedback
2 None None 5 30 None None
6I.D. Fan system fails to
function.
Induction side differential
visual pressure gauge fails.1 1 1 3
No dominant failure mode.
Equipment is not currently used.
1 None None 1 3 None None
7I.D. Fan system fails to
function.
Duct work thermocouple
near expansion joint fails.1 1 1 3
Equipment is used for
observation only.
1 None None 1 3 None None
8I.D. Fan system fails to
function.
The spring-loaded isolation
dampeners (beneath the ID
fan base) fatigue.
1 1 2 4
Over time, the isolation
dampeners (1 of 16) fatigue,
crack and break. Eventually
enough of the dampeners break,
and there is more vibration
between the ID fan base and the
floor. The mortar in the concrete
base will break apart. This could
1 None None 5 20Visually inspect the isolation
dampeners for fatigue.None
Maintenance
Manager to
include in PM
1 1 1 3 1 3 9
Current State Remediation
Process or Equipment:
Team:
Facilitator:
Equipment / Process Function:
FMEA ExampleCont….
NEORSD FMEA
NEORSD - Southerly WWTP - ID Fans - Illinois Blower FMEA Key: Safety Score + Regulatory Score + Fiscal Score = Criticality Score
Steve S, Sam S, Josh M, Bob H, Paul C, Fred D, Mike P, Chris D, Rich W, Dan H, John Z, Chris P Criticality Score x Occurrence Score x Detection Score = Risk Priority Number (RPN)
Mike Cowley, CE Maintenance
Operating Context: Functional failure defined as failing to perform the following Function:The primary function of the ID fan (1 of 3 systems) is to remove the products of combustion, pulling them out of the incinerator, through the primary heat exchanger (maintaining a + 5" to -5" water column range),
waste heat boiler, economizer, scrubber and then discharging through the secondary heat exchanger into the atmosphere via the stack.
Worst Case Scenario: Failure off shift, during a holiday; assuming a 30-hour light-up of the back-up unit; also assuming 30 to 40 ft. of inventory.
Scope of Evaluation: Ductwork (leaving the scrubber) through the ID fan to the secondary heat exchanger. Expansion joint to expansion joint.
Assumptions: 1. Maintenance personnel and operators can be around equipment while in operation.
Lin
e Component
Functional FailureFailure Mode
Sa
fety
Re
gu
lato
ry
Fis
ca
l
Cri
tica
lity
Failure Effect
Occu
rre
nce
Current
Controls,
Prevention
Current
Controls,
Detection De
tecti
on
RP
N
Recommended Action Secondary Action
Responsibility
and Target
Completion
Date
Estimated
Cost Sa
fety
Re
gu
lato
ry
Fis
ca
l
Cri
tica
lity
Occu
rre
nce
De
tecti
on
Re
vis
ed
RP
N Final decision / action
to be taken (Based on
review by
management)
1I.D. Fan system fails to
function.
Expansion joint fasteners
are loose.2 1 1 4
Over time, the expansion joint
fasteners loosen up, drop off,
and the expansion joint
connection seperates. The ID fan
speed will vary, and the fan will
use more energy. The feedback
from the pressure transmitter
will send a (true) signal that
5 None Current PMs 3 60Lock-tite and re-torque all fasteners
in the expansion joint.None PUMPs Up to $1,000 2 1 1 4 2 3 24
2I.D. Fan system fails to
function.
The ID fan housing fasteners
loosen.1 1 1 3
Over time, any of the ID housing
fan fasteners loosen up, drop off,
and the joint connection
seperates, potentially vibrating.
The ID fan speed will vary, and
the fan will use more energy. The
feedback from the pressure
transmitter will send a (true)
5 None None 5 75Lock-tite and re-torque all fasteners.
Check on an annual PM.None PUMPs 2 days x 2 PUMPs 1 1 1 3 2 3 18
3I.D. Fan system fails to
function.
Wrong gasket materials (or
size) are used.1 1 1 3
During installation, the wrong
gasket material (or size) is used.
Pre-mature failure allows the
fasteners to loosen, drop off,
and the joint connection
seperates, potentially vibrating.
The ID fan speed will vary, and
the fan will use more energy. The
2 None None 5 30 None None
4I.D. Fan system fails to
function.The gasket deteriorates. 1 1 1 3
Over time, the gasket
deteriorates and weakens,
allowing the fasteners to
become loose, drop off, and the
joint connection seperates,
potentially vibrating. The ID fan
speed will vary, and the fan will
use more energy. The feedback
2 None None 5 30 None None
5I.D. Fan system fails to
function.
Incorrect gasket
installation.1 1 1 3
During installation, the gasket is
installed incorrectly, allowing
the fasteners to become loose,
drop off, and the joint
connection seperates,
potentially vibrating. The ID fan
speed will vary, and the fan will
use more energy. The feedback
2 None None 5 30 None None
6I.D. Fan system fails to
function.
Induction side differential
visual pressure gauge fails.1 1 1 3
No dominant failure mode.
Equipment is not currently used.
1 None None 1 3 None None
7I.D. Fan system fails to
function.
Duct work thermocouple
near expansion joint fails.1 1 1 3
Equipment is used for
observation only.
1 None None 1 3 None None
8I.D. Fan system fails to
function.
The spring-loaded isolation
dampeners (beneath the ID
fan base) fatigue.
1 1 2 4
Over time, the isolation
dampeners (1 of 16) fatigue,
crack and break. Eventually
enough of the dampeners break,
and there is more vibration
between the ID fan base and the
floor. The mortar in the concrete
base will break apart. This could
1 None None 5 20Visually inspect the isolation
dampeners for fatigue.None
Maintenance
Manager to
include in PM
1 1 1 3 1 3 9
Current State Remediation
Process or Equipment:
Team:
Facilitator:
Equipment / Process Function:
NEORSD FMEA
NEORSD - Southerly WWTP - ID Fans - Illinois Blower FMEA Key: Safety Score + Regulatory Score + Fiscal Score = Criticality Score
Steve S, Sam S, Josh M, Bob H, Paul C, Fred D, Mike P, Chris D, Rich W, Dan H, John Z, Chris P Criticality Score x Occurrence Score x Detection Score = Risk Priority Number (RPN)
Mike Cowley, CE Maintenance
Operating Context: Functional failure defined as failing to perform the following Function:The primary function of the ID fan (1 of 3 systems) is to remove the products of combustion, pulling them out of the incinerator, through the primary heat exchanger (maintaining a + 5" to -5" water column range),
waste heat boiler, economizer, scrubber and then discharging through the secondary heat exchanger into the atmosphere via the stack.
Worst Case Scenario: Failure off shift, during a holiday; assuming a 30-hour light-up of the back-up unit; also assuming 30 to 40 ft. of inventory.
Scope of Evaluation: Ductwork (leaving the scrubber) through the ID fan to the secondary heat exchanger. Expansion joint to expansion joint.
Assumptions: 1. Maintenance personnel and operators can be around equipment while in operation.
Lin
e Component
Functional FailureFailure Mode
Sa
fety
Re
gu
lato
ry
Fis
ca
l
Cri
tica
lity
Failure EffectO
ccu
rre
nce
Current
Controls,
Prevention
Current
Controls,
Detection De
tecti
on
RP
N
Recommended Action Secondary Action
Responsibility
and Target
Completion
Date
Estimated
Cost Sa
fety
Re
gu
lato
ry
Fis
ca
l
Cri
tica
lity
Occu
rre
nce
De
tecti
on
Re
vis
ed
RP
N Final decision / action
to be taken (Based on
review by
management)
1I.D. Fan system fails to
function.
Expansion joint fasteners
are loose.2 1 1 4
Over time, the expansion joint
fasteners loosen up, drop off,
and the expansion joint
connection seperates. The ID fan
speed will vary, and the fan will
use more energy. The feedback
from the pressure transmitter
will send a (true) signal that
5 None Current PMs 3 60Lock-tite and re-torque all fasteners
in the expansion joint.None PUMPs Up to $1,000 2 1 1 4 2 3 24
2I.D. Fan system fails to
function.
The ID fan housing fasteners
loosen.1 1 1 3
Over time, any of the ID housing
fan fasteners loosen up, drop off,
and the joint connection
seperates, potentially vibrating.
The ID fan speed will vary, and
the fan will use more energy. The
feedback from the pressure
transmitter will send a (true)
5 None None 5 75Lock-tite and re-torque all fasteners.
Check on an annual PM.None PUMPs 2 days x 2 PUMPs 1 1 1 3 2 3 18
3I.D. Fan system fails to
function.
Wrong gasket materials (or
size) are used.1 1 1 3
During installation, the wrong
gasket material (or size) is used.
Pre-mature failure allows the
fasteners to loosen, drop off,
and the joint connection
seperates, potentially vibrating.
The ID fan speed will vary, and
the fan will use more energy. The
2 None None 5 30 None None
4I.D. Fan system fails to
function.The gasket deteriorates. 1 1 1 3
Over time, the gasket
deteriorates and weakens,
allowing the fasteners to
become loose, drop off, and the
joint connection seperates,
potentially vibrating. The ID fan
speed will vary, and the fan will
use more energy. The feedback
2 None None 5 30 None None
5I.D. Fan system fails to
function.
Incorrect gasket
installation.1 1 1 3
During installation, the gasket is
installed incorrectly, allowing
the fasteners to become loose,
drop off, and the joint
connection seperates,
potentially vibrating. The ID fan
speed will vary, and the fan will
use more energy. The feedback
2 None None 5 30 None None
6I.D. Fan system fails to
function.
Induction side differential
visual pressure gauge fails.1 1 1 3
No dominant failure mode.
Equipment is not currently used.
1 None None 1 3 None None
7I.D. Fan system fails to
function.
Duct work thermocouple
near expansion joint fails.1 1 1 3
Equipment is used for
observation only.
1 None None 1 3 None None
8I.D. Fan system fails to
function.
The spring-loaded isolation
dampeners (beneath the ID
fan base) fatigue.
1 1 2 4
Over time, the isolation
dampeners (1 of 16) fatigue,
crack and break. Eventually
enough of the dampeners break,
and there is more vibration
between the ID fan base and the
floor. The mortar in the concrete
base will break apart. This could
1 None None 5 20Visually inspect the isolation
dampeners for fatigue.None
Maintenance
Manager to
include in PM
1 1 1 3 1 3 9
Current State Remediation
Process or Equipment:
Team:
Facilitator:
Equipment / Process Function:
33
NEORSDFMEA Case Studies
34
35
Pump Performance Requirements
1. Must pump 500 GPM on consistent basis
2. Must pump 24/7
3. Pump flow monitored in control room, but not an alarm function
4. Operator rounds conducted every 2-4 hours. Unless other problems are being handled
5. Pump leakage detected by observation only
6. Might take operator 24 hours to discover pump performance is sub-standard. Due to rise in sludge blanket in clarifiers
7. 2 pumps normally operate at one time
8. Pump speed and flow managed by VFDs36
Pump Performance FMEA Outcome
What was the Top Failure Mode?
What do You Think the RPN (Risk Priority Number) Was?
What do You Think Were the Most Critical Components of the System?
What Part of the System Needed the Most Attention to Ensure Consistent Operation and Pumping?
37
Pump Performance FMEA Outcome
Answer:
The Fractional horsepower motor on the VFD cabinet cooling Fan!!
and
Pump shaft packing problems
38
39
ID (Induced Draft) Fan Performance Requirements. Fluidized Bed Sludge Incinerator
1. Provide significant air flow to maintain negative pressure through collectors and scrubbers
2. Fan must perform to maintain incinerator function
3. Fan shuts down and system goes into emergency shut-down
4. After 48 hours of downtime, trucking of sludge to landfill commences and cost escalates dramatically
40
ID (Induced Draft) Fan Performance Requirements. Fluidized Bed Sludge Incinerator
1. 500 horse power motor
2. 60 inch fan impeller
3. 24 inch SS duct work
4. Numerous flanged connections
5. 4 inch shaft
6. Lubricated pillar block bearings
7. Predictive maintenance using:a) Thermography
b) Vibration analysis
41
ID Fan Performance FMEA Outcome
What was the Top Failure Mode?
What do You Think the RPN (Risk Priority Number) Was?
What do You Think Were the Most Critical Components of the System?
What Part of the System Needed the Most Attention to Ensure Consistent Operation and Pumping?
42
43
ID Fan FMEA Outcome
Answer:
The batteries powering the automatic bearing lubricators
and
Fasteners on flanges and motor base housing
44
Questions?
45
References Used in Developing Content:
The Basics of FMEA, 2nd editionRobin E. McDermott
Raymond J. Mikulak
Michael R. Beauregard
46
Michael Cowley, President, CE Maintenance Solutions, LLC
Michael CowleyPresident
Contact information
CE Maintenance Solutions, LLC
189 Peck Drive
Buffalo Junction, VA 24529
Mobile: +1-434-738-8484
Office: +1-434-734-0866
Email:[email protected]
Established CE Maintenance Solutions, LLC in 2004 to provide training, coaching and consulting services to facility and manufacturing organizations
30+ years of hands-on experience in production maintenance and facility engineering fields
My Mechanical Engineering education as well as my extensive experience gives me an unusual insight into how organizations work
My fundamental understanding and knowledge of the components and the culture needed helps me to properly structure, organize and maintain a World Class maintenance organization
47
Steven D. Schneider, Asset Reliability Manager, Northeast Ohio Regional Sewer District
Steven D. SchneiderAsset Reliability Manager
Contact information
Northeast Ohio Regional Sewer District
Westerly Wastewater Treatment Center
5800 Cleveland Memorial Shoreway
Cleveland, Ohio 44102-2192
Mobile: +1-216-280-3134
Office: +1-216-961-2187 x3228
Email: [email protected]
Bachelor’s of Mechanical Engineering - 1993
Class 1 Wastewater Operator License
RCMII Practitioner – Can Train, Teach and Coach RCMII Classes and facilitations
TPM Instructor – 5S, Cost Deployment, Autonomous Maintenance, etc.
10+ years of Reliability Engineering Experience in Steel Making and Wastewater
10+ years of Linear Motion Applications Experience
48
Scott A. McBrayer, P.E. Project Engineer, Donahue IDEAS, LLC
Scott A. McBrayer, P.E.Project Engineer
Contact information
Donahue IDEAS, LLC
2780 Airport Drive, Suite 333
Columbus, OH 43219
Mobile: +1-614-507-8231
Office: +1-614-532-6771
Email: [email protected]
B.S. Civil Engineering, Rose-Hulman - 1999
M.B.A., The Ohio State University - 2007
Professional Engineer
LEED GA + PACP/MACP/LACP Accredited
Over 15 years of civil and environmental engineering experience involving the management and improvement of water, wastewater and stormwater facilities.
3 years of experience in Asset Management
49