R? What Are The Existing Controls, S What Are The Actions: S E V O C C D E T

Component
Product
Function
Potential Failure
Mode
Potential Failure Effects
S
E
V
Potential Causes
O
C
C
Current Process Controls
D
E
T
R
P
N
Actions
Recommended
Resp.&
Target Date
Actions Taken
S
E
V
O
C
C
D
E
T
R
P
N
What is the process
step?
In what ways can the
Component,
Subsystem or System
potentially fail and
cause a safety risk?
What is the impact on Safety?
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List every conceivable failure
and/or failure mechanism for each
failure mode
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?What are the Existing Controls,
Procedures or Specifacations that
prevent either the cause or the
failure mode
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What are the actions
for reducing the
Occurrence of the
cause, or improving
Detection? Should
have actions on high
RPN's or EASY FIXES
Who's
Responsible
for the
recommende
d action?
What date?
What were the actions
implemented? Include
completion month/year.
(Then recalculate
resulting RPN.)
Contain LH2 @~30psi Leakage/Rupture Spill to Storage Area and
Dissipation of H2
8 H2 Embrittlement 4 Specification: Supplier 4 160
Spill to Storage Area and
Combustion of Vapour
10 Corrosion 3 Specification: Supplier 4 120
Spill to Storage Area and Pooling
of LH2
9 Stress Cycling/Fatigue 3 Specification: Supplier 4 120
Mechanical damage (collision) 2 Design: Barrier
Procedure: Restricted Access
6 120
Mechanical damage (impact) 6 10 600 Restricted vehicle
access, ensure
structure can withstand
impact.
Mechanical damage (attack) 5 10 500
Mechanical damage (structural) 6 10 600 Seismic Evaluation
and certification.
Operator Error 4 Procedure: Operator Training 4 160
Isolate LH2 from
Environment
Allow Excess Heat
Conduction
Excess Vapour Pressure 6 Vacuum Jacket Failure 3 Control: Vent to Stack
Specification: Supplier
4 72
6 Mechanical damage (impact) 6 Procedure/Design: Restricted
Access
Procedure: Operator Training
6 216
Vent Excessive Vapour
Pressure
PRD Fails Excess Pressure Buildup 7 H2 Embrittlement 4 Specification: Supplier
Design: Rupture Disk - Vent to
Stack
3 84
7 Mechanical damage (impact) 6 Procedure/Design: Restricted
Access
6 252
7 Debris 7 10 490
Vent Line Blockage Excess Pressure Buildup 7 H2 Embrittlement 4 Specification: Supplier
Stack
3 84
7 Debris 7 10 490
Provide Vapour
Pressure Signal to
Controller
No signal System Fault 3 Electrical Damage (shock) 6 Control: Shutdown 7 126
3 Out of Range 5 Specification: Supplier 4 60
3 Power Failure 4 10 120
3 Calibration Error 7 Procedure: Supplier Calibration 5 105
Signal Bias High Electrical Damage (shock) 6 10 0
Calibration Error 7 Procedure: Supplier Calibration 5 0
Signal Bias Low Excess Vapour Pressure 6 Electrical Damage (shock) 6 Design: Rupture Disk - Vent to
Stack
10 360
Boost LH2 Pressure Low Pressure System Fault 3 Mechanical Wear 2 Control: Shutdown 7 42
3 Control Malfunction 4 10 120
High Pressure Excess Liquid Pressure 7 Incorrect Design Specifications 2 Control: Vent to Stack 2 28
Provide Flow Control
(On/Off, Variable)
Insufficient Flow System Fault 3 Mechanical Wear 2 Control: Shutdown 7 42
3 Incorrect Design Specifications 2 10 60
High Flow Low Process Gas Temp 1 Control Malfunction 4 Control: System warning 0
LH2 Storage
(Dewar)
Cryo Pump
Printed:7/28/2014 Process FMEA Template Page 1 of 10
Contain LH2
@10000psi?
Leakage/Rupture Spill to Storage Area and
Dissipation of H2
of LH2
Mechanical damage (impact) 6 Procedure/Design: Restricted
Access
6 360
Incorrect Design Specifications 2 10 200
Control Malfunction 4 10 400
Thermally Isolate LH2
from Environment
Allow Excess Heat
Conduction
Excess Vapour Pressure 6 Vacuum Jacket Failure 3 Control: Vent to Stack 2 36
6 Mechanical Damage 6 Procedure: Restricted Access
10 360
Reduce LH2 Pressure
from 10000psi to
7200psi
Pressure Too High Excess Liquid Pressure 7 Mechanical Damage 6 Control: Vent to Stack 2 84
7 Debris 6 Control: Vent to Stack 2 84
Pressure Too Low System Fault 3 Debris 6 Control: Shutdown 7 126
3 Mechanical Wear 8 Control: Shutdown 7 168
3 Control: Shutdown 7 0
from Environment
Allow Excess Heat
Conduction
Excess Vapour Pressure 6 Incorrect Design Specifications 2 Control: Vent to Stack 2 24
Provide LH2 Flow Path Flow Blocked Excess Liquid Pressure 7 Debris 6 Control: Vent to Stack 2 84
7 Mechanical Damage 6 10 420
Insufficient Flow
Capability
Decreased Pressure 3 Incorrect Design Specifications 6 Control: Shutdown 7 126
3 Debris 6 10 180
Contain LH2
@10000psi
Dissipation of H2
of LH2
Access
6 360
Mechanical damage (collision) 2 10 200
Mechanical Damage (attack) 5 10 500
Flow Path: LH2-CH2 Flow Blocked Excess Liquid Pressure 7 Debris 7 Control: Vent to Stack 2 98
Excess Vapour Pressure 6 Corrosion 3 Control: Vent to Stack
4 72
Excessive Pressure
Drop
Insufficient Process Pressure 3 Debris 7 Control: Shutdown 7 147
Contain LH2
@72000psi?
Dissipation of H2
of LH2
Access
6 360
Heat Exchange; LH2 to
-30C with Air @Varying
Ambient Temperature
Low Pressure System fault 3 Ambient temperature too low 10 Control: Shutdown 7 210
3 Freezing/ice reducing heat
conduction
10 Control: Shutdown 7 210
High Pressure Excess Vapour Pressure 6 Ambient temperature too high 10 Control: Vent to Stack 2 120
Output Stream Too
Cold
System Fault 1 Incorrect Design Specifications 2 Control: Warning 2 4
1 Ambient Temperature too Low 10 10 100
Output Stream Too Hot Excess Vapour Pressure 6 Ambient Temperature too Hot 10 Control: Vent to Stack 2 120
Cryo Pump
Pressure
Regulator
Vapourizor
Contain CH2
@7200psi
Leakage/Rupture Release to Storage Area and
Dissipation of H2
Release to Storage Area and
Stress Cycling/Fatigue 3 Specification: Supplier 4 120
Access
6 360
Moderate CH2
Temperature Variations
Temperature Too High Excess Vapour Pressure 6 Incorrect Design Specifications 2 Control: Vent to Stack 2 24
6 Debris 7 10 420
Temperature Too Low System Fault 1 Incorrect Design Specifications 2 10 20
1 Debris 7 10 70
Contain CH2
@7200psi
Dissipation of H2
Access
6 360
Low Pressure Drop
Flow Path
Excessive Pressure
Drop
System fault 3 Debris 7 Control: Shutdown 7 147
Flow Blocked Excess Vapour Pressure 6 Debris 7 Control: Vent to Stack 2 84
Contain CH2 @-25C,
7200psi
Dissipation of H2
Stress Cycling/Fatigue 3 10 300
Access
6 360
Flow Path: CH2 to
Dispensor
Excessive Pressure
Drop
Low Process Pressure 3 Debris 7 Control: Shutdown 7 147
Contain CH2
@6000psi
Leakage/Rupture Release into Occupied Area and
Dissipation of H2
Release into Occupied Area and
Mechanical damage (impact) 6 0
Control Malfunction 4 10 400
Flow Path: Vehicle CH2
Supply @6000psi
Dispensor
Vapourizor
Regenerator
Thermal
Storage
Buffer Storage
Excessive Pressure
Drop
Low Fueling Pressure 1 Debris 7 Control: System Fault - abort
fueling
0
Provide CH2
@6000psi @xxpsi
Low Pressure Low Fueling Pressure 1 Incorrect Design Specifications 2 Control: Abort Fueling 2 4
1 Control Malfunction 4 Control: Abort Fueling 2 8
High Pressure Excess Pressure Buildup 7 Incorrect Design Specifications 2 Control: Vent to Stack 7 98
7 Control Malfunction 4 Control: Vent to Stack 7 196
7 Fueling Rate Too High 6 Control: Vent to Stack 7 294
7 Inlet Gas Too Warm 5 Control: Vent to Stack 7 245
Monitor Fueling Status
& Communicate with
Controller
No Signal System fault 3 Electrical Damage (shock) 6 Control: Shutdown 7 126
3 Out of Range 5 10 150
Temp Bias Low Excess Tank Pressure: Potential
Rupture
10 Electrical Damage (shock) 6 Control: Shutdown 7 420
Temp Bias High Decreased tank Pressure:
Incomplete Fueling
Pressure Bias Low Excess Tank Pressure: Potential
Rupture
Pressure Bais High Decreased tank Pressure:
Incomplete Fueling
Provide User
Emergency Shutdown
No Shutdown Initiated Potential Gas Leakage 10 Electrical Damage (shock) 6 Control: Shutdown 7 420
Contain LH2
@10000psi?
Dissipation of H2
of LH2
Mechanical damage (impact) 6 Design: Restricted Access 6 360
System Flow path Flow Blocked Excess Liquid Pressure 7 Debris 7 Control: Vent to Stack 2 98
Excess Pressure Buildup 7 Mechanical Damage 6 Design: Rupture Disk - Vent to
Stack
10 420
Excessive Pressure
Drop
Low System Pressure 3 Debris 7 Control: Shutdown 7 147
Thermaly Isolate LH2
from Environment
Allow Excess Heat
Conduction
Isolate Flowpath
(Open/Close)
Fails Open Cannot Isolate System
Components:
5 Mechanical damage (impact) 6 Design: Restricted Access 6 180
Fails Closed Excess Liquid Pressure 7 H2 Embrittlement 4 Control: Vent to Stack
4 112
Excess Pressure Buildup 7 Corrosion 3 Specification: Supplier
Stack
3 63
Contain CH2
@7200psi
Dissipation of H2
Dissipation of H2
System Flow path Flow Blocked Excess Liquid Pressure 7 Debris 7 Control: Vent to Stack 2 98
Dispensor
LH2 Valve
CH2 Valve
Stack
3 63
Excessive Pressure
Drop
Isolate Flowpath
(Open/Close)
Fails Open Cannot Isolate System
Components:
Fails Closed Excess Liquid Pressure 7 H2 Embrittlement 4 Control: Vent to Stack
4 112
Stack
3 63
from Environment
Allow Excess Heat
Conduction
6 Mechanical damage (impact) Design: Restricted Access 6 0
Provide Single
Direction Flow Path
Flow Blocked Excess Liquid Pressure 7 Debris 7 Control: Vent to Stack 2 98
Stack
3 63
Excessive Pressure
Drop
Fails to Check Backflow of Process Gases:
Potential Rupture?
Contain CH2
@7200psi
Dissipation of H2
Dissipation of H2
from Environment
Allow Excess Heat
Conduction
6 Mechanical damage (impact) Design: Restricted Access 6 0
from Environment
Allow Excess Heat
Conduction
Excess Vapour Pressure 6 Vacuum Jacket Failure 3 Control: Vent to Stack 2 36
6 Mechanical damage (impact) Procedure/Design: Restricted
Access
6 0
Contain LH2 @1000psi Leakage/Rupture Spill to Storage Area and
Dissipation of H2
of LH2
Access
6 360
Provide Flow Path A-B Flow Blocked Excess Liquid Pressure 7 Debris 7 Control: Vent to Stack 2 98
CH2 Valve
Check Valve
Vacuum Jacket
Lines (LH2)
Stack
3 63
Excessive Pressure
Drop
Contain LH2 Under
Pressure
Dissipation of H2
of LH2
Output Pressure Signal High Pressure Bias Calibration Error 7 Procedure: Supplier Calibration 5 0
Electrical Damage (shock) 6 10 0
Low Pressure Bias Excess Liquid Pressure 7 Calibration Error 7 Procedure: Supplier Calibration
Stack
5 245
7 Electrical Damage (shock) 6 Procedure: Supplier Calibration
Stack
10 420
3 Out of Range 5 Control: Shutdown 7 105
3 Power Failure 4 Control: Shutdown 7 84
Contain CH2 Under
Pressure
Dissipation of H2
Dissipation of H2
Output Pressure Signal High Pressure Bias 1 Calibration Error 7 Procedure: Supplier Calibration 5 35
1 Electrical Damage (shock) 6 10 60
Low Pressure Bias Excess Vapour Pressure 7 Calibration Error 7 Procedure: Supplier Calibration
Stack
5 245
Contain LH2 Under
Pressure
Dissipation of H2
of LH2
Output FLow Signal High Flow Bias Decreased Process Flow 3 Calibration Error 7 System Fault: Shutdown
Procedure: Supplier Calibration
7 147
3 Electrical Damage (shock) 6 7 126
Low Flow Bias Excess System Pressure Flow 6 Electrical Damage (shock) 6 Design: Rupture Disk - Vent to
Stack
10 360
Flow Path: Low
Restriction
Stack
3 63
7 Mechanical Damage 6 Control: Shutdown 7 294
Excessive Pressure
Drop
Vacuum Jacket
Lines (LH2)
Pressure
Sensor (LH2)
Pressure
Sensor (CH2)
Flow Meter
(LH2)
3 Incorrect Design Specifications 2 Control: Shutdown 7 42
Contain CH2 Under
Pressure
Dissipation of H2
Output FLow Signal High Flow Bias Decreased Process Flow 3 Electrical Damage (shock) 6 System Fault: Shutdown 0
Excess System Pressure Flow 6 Calibration Error 7 Procedure: Supplier Calibration
Stack
5 210
Low Flow Bias Excess Liquid Pressure 7 Electrical Damage (shock) 6 Control: Vent to Stack 2 84
Flow Path: Low
Restriction
Stack
3 63
7 Mechanical Damage 6 Control: Vent to Stack 10 420
Excessive Pressure
Drop
Contain LH2 under
Pressure
Dissipation of H2
Dissipation of H2
Flow Path: Low
Restriction
Stack
3 63
7 Mechanical damage 6 Control: Vent to Stack 3 126
Excessive Pressure
Drop
3 Mechanical damage 6 Control: Shutdown 10 180
Contain LH2 under
Pressure
Dissipation of H2
of LH2
Flow Path: Low
Restriction
Stack
3 63
7 Mechanical damage 6 Control: Vent to Stack 3 126
Excessive Pressure
Drop
3 Corrosion 3 Specification: Supplier
Control: Shutdown
4 36
3 Mechanical damage 6 Control: Shutdown 7 126
Provide Safe Vent
Stream for Process
Gas
Combustion of Gas Combustion Within Vent Stack 8 Ignition Source 2 10 160
Fittings (High
Pressure)
Fittings
(Cryogenic)
Vent Stack
Flow Meter
(LH2)
Flow Meter
(CH2)
Blockage Rupture Of Process
Lines/Components
10 Mechanical damage (attack) 5 10 500
10 Mechanical damage (structural) 6 10 600 Structural
Modifications and
assesment
Restricted Insufficient Venting 9 Debris 4 10 360
9 Mechanical damage (attack) 5 10 450
9 Mechanical damage (structural) 6 10 540 Structural
Modifications and
assesment
Vent Stack
Process Step or
Variable or Key
Input
Potential Failure Mode Potential Failure Effects
S
E
V
Potential Causes
O
C
C
Current Process Controls
D
E
T
R
P
N
Actions
Recommended
Resp.&
Target Date
Actions Taken
S
E
V
O
C
C
D
E
T
R
P
N
What is the
process step?
In what ways can the
Process Step, Variable, or
Key Input go wrong?
(chance of not meeting
requirements)
What is the impact on the Key
Output Variables (customer
requirements) or internal
requirements?
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What causes the Key Input to
go wrong? (How could the
failure mode occur?)
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?
What are the existing controls that
either prevent the failure mode
from occurring or detect it should it
occur?
H
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p
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What are the actions
for reducing the
Occurrence of the
cause, or improving
Detection?
Should have actions on
high RPN's or Severity
of 9 or 10.
Who's
Responsible
for the
recommended
action? What
date?
What were the actions
implemented? Include
completion month/year.
(Then recalculate
resulting RPN.)

######

9 of10
RATING FACTORS
RATING DEGREE OF SEVERITY
FREQUENCY
( 1 in )
Cpk
Detection
Certainty
1
Safety or environmental impact is insignificant; customer will
not notice any adverse effects
Likelihood of occurrence is
remote 1,000,000 > 1.67
Sure that the potential failure will be found
or prevented before producing a safety
risk
100%
2
Safety or environmental impact is slight; customer will
probably experience slight annoyance
Low failure rate with supporting
documentation 20,000 1.33
Almost certain that the potential failure will
be found or prevented before producing a
safety risk
99%
3
Safety and/or environmental impact will be affected due to
the slight degradation of performance of components;
customer will experience annoyance
Low failure rate without
supporting documentation 5,000 approx. 1.0
Low likelihood that the potential failure will
be prevented before producing a safety
risk
95
4
Safety and/or environmental impact affected due to
continually poor system performance; customer dissatisfied
Occasional failures
2,000 < 1.0
Controls may detect or prevent the
potential failure from occuring during
operation
90
5
Considerable safety and/or environmental Impact due to
failure of components; customer is made uncomfortable
Relatively moderate failure
rate with supporting
documentation
500
Moderate likelihood that the potential
failure will occur before producing a safety
risk
85
6
Considerable safety and/or environmental Impact due to
continued degredation of components; warranty repair, down
time or significant manufacturing or assembly complaint
Moderate failure rate without
supporting documentation
100
Controls are unlikely to detect or prevent
the potential failure during operation
80
7
High safety risk and/or severe environmental Impact without
violating existing codes/standards; High degree of customer
dissatisfaction; productivity impacted by high scrap or
rework levels.
Relatively high failure rate with
50
Poor likelihood that the potential failure will
be detected or prevented before
producing a safety risk 70
8
High safety risk and/or severe environmental Impact
violating existing codes/standards; very high degree of
customer dissatisfaction
High failure rate without
20
Very poor likelihood that the potential
failure will be detected or prevented
before producing a safety risk
60
9
Severe Safety impact with warning before failure or violation
of safety codes/regulations; customer endangered
Failure is almost certain based
on specifications or significant
DV testing 10
Current controls probably will not even
detect the potential failure
50
10
Severe Safety impact without warning before failure or
violation of safety codes/regulations; customer endangered
Assured of failure based on
specifications or significant DV
testing 2
Absolute certainty that the current controls
will not detect the potential failure
< 50
PROBABILITY OF OCCURRENCE ABILITY TO DETECT
Page 10

R? What Are The Existing Controls, S What Are The Actions: S E V O C C D E T

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