2nd IFAC Workshop on Advanced Maintenance Engineering,

Services and Technology

Universidad de Sevilla, Sevilla, Spain. November 22-23, 2012

Methodological proposal for problem resolution in industrial activities based on

failure mode analysis. Case applied in the cellulose industry, Chile
Luis Barberá*, Adolfo Crespo*, Pablo Viveros**, Christopher Nikulin***

* Department of Industrial Management, School of Engineering, University of Seville, Camino de los Descubrimientos s/n.
41092 Seville, Spain.(e-mails: lbm@esi.us.es; adolfo@esi.us.es).
** Department of Industrial Engineering, Universidad Técnica Federico Santa María, Avenida España 1680, Valparaíso,
Chile (e-mails: pablo.viveros@usm.cl; raul.stegmaier@usm.cl)
*** Dipartimento di Meccanica, Politecnico di Milano - Campus Bovisa Sud - via La Masa 1, 20156 Milano, Italy
christopher.nikulin@mail.polimi.it

Abstract: This article proposes an integral methodology based in the failure mode analysis for problem
resolution related to the reliability of industrial assets or problems. The failure mode is an event that
precedes the physical occurrence of a failure and, therefore, the loss of function in the asset in question.
For this reason, the identification and analysis of the modes is the starting point for the proposed
methodology. This methodology takes into account, in addition, key aspects such as: hierarchization of
equipment, identification of root causes and optimal solutions. The paper is structured as follows: section
2 performs a revision of the principal techniques applied in the area of reliability. Section 3 describes step
by step the methodological proposal through a logical sequence of stages. Later, section 4 presents a real
case application of the proposed methodology developed in the Arauco Cellulose Plant, Plant Trupan-
Cholguan, in Yungay, Chile. Concretely, the methodology proposed applies to problem resolution in
fluidized bed combustion. Last, the results and conclusions of the completed investigation are shown.
Keywords: failure mode, integral methodology, problem resolution, fluidized bed combustion
appropriate study and analysis of reliability and
1. INTRODUCTION
maintainability is one of the main pillars for decision making
According to Zio E. (2009), reliability is a fundamental at a tactical and operational level. Furthermore, they remain
attribute for the safe operation of any modern technological correctly aligned with the vision, strategy and economic
system. Focusing on safety, reliability analysis aims at the indicators of a business (Crespo A., 2007). Additionally, the
quantification of the probability of failure of the system and development of methodologies to facilitate the exercise of
its protective barriers. A fundamental issue in reliability analysis and results outcome (Nelson W., 1969) provides a
analysis is the uncertainty in the failure occurrences and framework for the control and monitoring of action plans
consequences. For the objectives of system safety, this entails implemented in terms of maintenance activities. A typical
protecting the system beyond the uncertainties of its problem when generating and controlling action plans for
accidental scenarios. improving reliability and maintainability of equipment, is
primarily the lack of practical mechanisms to support
The reliability of a product determines its operative maintenance management. In particular, there is a need for
productivity, as well as the costs of maintenance and repair tools and methodologies to illustrate, in a clear and simple
(Birolini A., 2007). It can also determine the interval in way, the patterns of deficiencies that can be found in the
which the operating costs are distributed, and in which equipment performance (Barberá et al., 2012). It is therefore
income or services are obtained. Therefore, reliability is a necessary to design control tools aimed at improving problem
central factor to determine the cost of a product’s life cycle. detection, affecting the reliability and maintainability.
Moreover, the relative considerations of life cycle cost, Moreover, usually the lack of quality information make
accident prevention is generally very important. Reliability is accomplishing a reliability analysis that much more difficult.
clearly an essential factor in a product’s security. The total As previously mentioned, the tools and methodologies design
costs for reliability (unforeseen failures) can be characterized that allows a simple interpretation and analysis, is even more
in the following way (Barlow et al., 1993, Ruff & Paasch, necessary to improve operational performance in the global
1993 and Woodhouse, 1993): penalty costs (downtime) and system.
direct costs for corrective maintenance (manual labor,
materials and spare parts). This article presents an integral methodological proposal
based in the analysis of the failure mode for problem solving
The physical assets management of an organization involves related to reliability of assets or industrial processes. The
innovative processes and continuous improvement at all failure mode is an event that precedes the occurrence of a
levels (Crespo A. & Gupta J., 2006) (Crespo et al, 2009). failure (physical evidence) and, therefore the loss of some
Therefore, the need for reliable information to allow function of the asset in question. For this reason, the

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identification and analysis of the modes is the starting point Process (AHP)
for the proposed methodology. This methodology takes into
Root RCA Paradies&Busch, 1988;
account, besides, key aspects like: hierarchization of
Cause Sikos& Klemes, 2010;
equipment, identification of root causes and designs for Analysis Doggett, 2004
optimum solutions. Technique
Logic tree Latino & Latino, 2002
(PROACT)

Fault tree analysis Mobley 1999; Yang 2007

(FTA)

Cause and effect DOE 1992; Parra & César,

diagram 1999

Changes Analysis DOE 1992; Parra & César,

1999

Tree of Risk and DOE 1992

general supervisión
(MORT)

Fig.1. Pillars of the proposed methodology: a conceptual Ishikawa Diagram Mobley 1999; Parra &
framework. César, 1999

The Five Whys Summers D., 2006; Cornell

The paper is structured as follows: section 2 is a review of the
technique K., 2010
main techniques applied to the area of reliability. Section 3
describes the methodological proposal through a logical, step Human DOE 1992; NUREG, 2002
by step sequence of stages. Subsequently, section 5 presents a Performance
case of actual implementation of the proposed methodology Evaluation
in a cellulose industrial (wood processing) plant located in
Kepner-Tregoe DOE 1992
Chile, to demonstrate its effectiveness.
Task Analysis Parra & César, 1999
2. REVIEW OF THE MAIN TECHNIQUES APPLIED TO THE
RELIABILITY AREA Barrier Analysis Parra & César, 1999

Several methods have been proposed in the literature for Inventive Brainstormig Osborn, A.F., 1963; Sutton
planning activities for industrial maintenance management Techniques & Hargadon, 1996
and reliability analysis. Proactive maintenance utilizes tools for
Problem SCAMPER Michalko, M., 2006;
such as Root Cause Analysis (RCA), Failure Modes and Tanner, D., 1997
Solving
Effects Analysis (FMEA), Critical Analysis (CA), and others.
Creative Challenge Silverstein et al., 2008
There is a wide variety of tools and methods, however, this
document presents those tools already accepted in the TRIZ Altshuller G., 1984
industry, which exhibit characteristics such as: adaptability to
cases of high or low complexity, systematic sequence and 3. METHODOLOGICAL PROPOSAL FOR PROBLEM
logic for its analysis and implementation, ability to integrate SOLVING IN THE AREA OF RELIABILITY
different specialties, among others (Moubray, 1997). Table 1
The RCA methodology is a tool for identifying the root
shows a review of the principal techniques applied in the area
causes of a problem, but it does not systematically address
of reliability.
solution. On the other hand, TRIZ, one of the most important
inventive techniques, provides a theoretical framework for
Table.1. Primary techniques applied in the area of
problems, generating creative solutions, but does not identify
reliability.
the root causes of their problems.
Techniques FMEA/FMECA Cai & Wu, 2004; Li & Gao,
for 2010; Rhee & Ishii, 2003;
The following methodological proposal seeks to integrate and
identifying Scipioni et al., 2002 align different reliability and maintainability techniques,
Failure currently used individually to give support to asset
Modes RCM Rausand M., 1998; Barberá management.
et al., 2010; Moubray, 1997
The objective of the proposed methodology is the design of a
Ranking Pareto Analysis Liang K., 2008 logical sequence of steps for problem analysis and
Techniques subsequent proposal for solutions and/or improvements. The
Jack-Knife Analysis Knights P., 2005
shortcomings of all individual techniques can be overcome
Analytic Hierarchy Bevilacqua & Braglia, 1999 by their integration. Figure 2 shows the flowchart of the
integration.

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START
while air is pumped upward during combustion. The result is
the formation of eddies that favor the mixture of gas and fuel.
The present case study has been developed in the Arauco
IDENTIFY THE
PROBLEM Cellulose Plant, Trupan-Cholguan Plant, in Yungay, Chile.
The functioning process in the fluidized bed boiler located in
said plant is shown in Fig. 3. The fuels used are primarily
IDENTIFY CRITICAL CRITICALITY wood chips or pellets from the forest produced by in the bark
EQUIPMENT ANALYSIS
and plant chippers of the plant. The fuel supply delivery is
performed by conveyer belts and air pipelines. The
combustion is controlled by using sand in the process, which
ROUTINE
MAINTENANCE
NO
CRITICAL
EQUIPMENT?
allows it to maintain stable temperature and pressure
objectives in the boiler. The adherent garbage of the fuel
itself is eliminated through a drainage that due to its high
YES
density, fall to the base of the fluidized bed boiler during the
IDENTIFY CRITICAL
combustion process, obstructing air nozzles that allow the
FAILURE MODES
FMECA
sand to keep moving within the boiler.

i = i+1 i: Set of Failure Modes

NO CRITICAL
FAILURE MODE i?

FLUIDIZED BED

YES

SAND OF SÍLICA
IDENTIFY CAUSE OF
RCA
BUBBLING
FAILURE

AIR PIPELINES DRAINS FOR REMOVAL

CAUSES RANK RANK TOOLS OF STONES

j = j+1
Fig.3. Functional Schematic of the fluidized bed boiler.

NO
j: Set of Cause of Failure 4.2 Problem statement
CRITICAL CAUSE
OF FAILURE j?
The process of energy generation from the plant through
YES combustion must be carried out in an optimal and continuous
manner. Eventually, the non/availability of the boiler requires
PROBLEM
OPTIMAL DESIGN
SOLUTIONS
SOLVING
TECHNIQUES
energy consumption from the SIC (Central Grid Service),
delaying and even limiting the normal operation of the plant.
With the objective to identify the different causes for boiler
IMPLEMENT THE failure, the problem solving methodology developed in this
SOLUTION
article was applied. Said methodology has allowed for the
detection of causes, their analysis and posible solutions.
MEASUREMENT
AND CONTROL 4.3 Application of the proposal methodology

GAMM ha permitido la identificación de un conjunto de

END
Fig.2. Analysis Methodology
4. CASE STUDY. APPLIED METHODOLOGY TO PROBLEM
SOLVING IN FLUIDIZED BED COMBUSTION
4.1 Context of the data used
In wood treatment plants with self-generative energy
processes, one of the most used broiler types are so-called
fluidized bed boilers, or fluidized bed combustion (Fluidized
bed combustion, FBC). The fluid bed sustains the solid fuel
patrones que proporcionan información útil para asistir la
toma de decisiones a nivel operacional. Los patrones
identificados en BCP 01-A y BCP 02-B son los siguientes:
4.3.1. Hierarchization of equipment
In the combustion process studied, only critical equipment
has been identified as being primarily responsible for losses
by overall unavailability during the process. Nozzel
obstruction of the boiler is considered a critical high-impact
failure, that once it occurs, the risks associated are costly both
economically and for human safety. Therefore, the causes of
this failure event must be identified and analyzed to identify
the best solutions that can be implemented.

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4.3.2. Failure Mode Identification (MF) The implementation of the Logical Tree allows us to
discriminate the different causes, through which the root
The failure mode is a unique event that causes a functional cause is identified as “High density materials” as the main
failure, meaning it is the mechanism of failure manifestation cause of the problem (drainage nozzle obstruction) and in
or an event that precedes the failure. (Moubray, 1997). There turn the “nozzle oxidation” and “production process
are various failure modes that a boiler can present affecting overload”.
its availability, drainage nozzle blockage being the most
catastrophic. In the boiler under study, the report notes that it
High density
is not possible to remove all the waste from the combustion materials on the
fuel

reaction due to the presence of rocks and other elements

which, even if not participating in the combustion process,
are deposited on the drainage tubes and air nozzles
(obstruction), making an additional maintenance necessary to Overloading of
Combustion out
the production
correct the problem. In the present case study, the so-called of range Oxidation
process Nozzles

“Drainage nozzles obstruction” was identified as a critical

failure mode.
4.3.3. Identification of root causes to control MF Inadequate
Combustion
Escess or lack of
lubrication
Process

The tool used for this case will be the Logical Tree
PROACT, which is already considered a systematic
methodology that can be implemented for high impact events Innadequate
Inadequate There is no
as well as for high frequency events, allowing for the Lubrication and
Innadequate
inspection of
parts
inspection of the
life cycle of the
intervals
identification of not only physical causes of failure, but also parts

human errors that lead to failure and organizational problems

that explain the occurrence of those human errors, in this way
identifying three types of root causes: Physical, Human, and There are no
specifications or Inadequate
No inspection
No replacement
Latent. The following nomenclature will be used to operating
procedures
training
processes of
parts
policies

differentiate them:

FAILURE MODE
Drainage Nozzle
Obstruction
Fig. 9. Logical Tree root physical causes “High Density
PHYSICAL ROOT materials in the fuel”.
CAUSE

For the correct identification of root causes, expert analysis is

HUMAN ROOT CAUSE

Oxidation of the
Overloading of High density
necessary to justify each step of the process of analysis and
LATEN ROOT CAUSE
nozzles
the production
process
Nozzle wear materials on the
fuel identification with theoretical and factual basis. Therefore,
the main root cause is the presence of rocks and other
high/density elements (introduced into the boiler with the
Fig.4 and 5. Symbology of the Logical Tree; Logic tree for fuel) which are not sustainable in the bed and precipitate at
the failure mode “Drainage Nozzle Obstruction” and physical the bottom of the boiler, accumulating and preventing proper
root causes, respectively. drainage as well as obstructing the air nozzles.
Oxidation Of the
Nozzles. STONES
AND WASTE
AIR NOSSLES
BLOCKED

Do not Perform
DRAIN
Nozzles low Fuel Moisture is Excess air is
quality inadequate inadequate
the necessary PIPES
purges

Incorrect Calculation of the Not made a

specification of excess air in not proper screening
moisture performed waste boiler

Fig. 10. Drains and nozzles blocked by high density

materials.
4.3.4. Identification of solutions.
The solution should allow that the combustion process be as
Inadequate
There are not
specifications or
There is no
standarization of No inspection
continuous as possible, maintaining the nozzles free from
materials that could obstruct them and thus ensuring the
parts and processes of
training operating
replacement parts
procedures
parts

correct percentages of air move the sand and generate good

Fig. 6. Logical Tree root physical causes “Oxidation of combustion. Applying the TRIZ technique has allowed for
nozzles”. the identification of two inventive principles based on the
issues raised: principle 10 (early action) and principle 24

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(mediator: element or intermediate process between two 4.3.5. Implementation of solutions.

stages of the process, permanently or temporarily). The
solution generated by using principles 10 and 24, These alternatives are compared in Table 1 according the
recommended by TRIZ, is in the design of a system extractor expected results of each of them.
of high density materials prior to the provision of the boiler,
which might help to minimize the entry of such materials to Table 2. Comparison of Alternatives
the bed. However, this solution can be approached in two Alternative
different ways, namely: 1 2
Expected Results
- Alternative 1: the alternative aims to solve the Decrease the existing downtime due to the existence of
80% 90%
problem by amending the existing conveyor, an more dense materials
inclined belt with a vibration mechanism that causes
Reduce the oxidation in the wear nozzles 50% 60%
the displacement of high density materials using
gravity. In this way, the fuel arrives without, or at Prevent wear of the boiler nozzles 70% 70%
least with a reduced amount of undesirable materials
Increase the process production. 60% 70%
to the boiler.
Average of the solutions (Degree of impact of the
65% 73%
Fall of contaminated fuel
innovative solution)

Clean Fuel Subsequently both alternatives are analyzed to determine the

one that represents a greater opportunity for development,
High density materials which is calculated according to three parameters:

Table 3. Analysis of Development Opportunity.

Vibratiom

Alternative Grade of impact Degree of Cost Development

Conveyor Belt Material of the innovative system´s Opportunity
1
solution complexity USD

Vibrator 1 65% 100% 15.000 -15.035%

Fig. 11. Schematic of alternative 1, Conveyor belt with 2 73% 70% 5.000 -4.997%
vibration mechanism.
According to Table 2, the alternative that presents itself as the
- Alternative 2: the alternative aims to solve the better solution from the point of view of the enterprise is
problem through the incorporation of a controlled air alternative 2, mainly for economic motives, given that the
injection system (fluidization) prior to the boiler for company has blowers in its recycling yard, in addition, this
all of the transported material, which will cause the alternative does not require major modifications to the initial
lightest material to float (fuel) and the precipitation installation.
of the unwanted materials by gravity through a
discharge duct installed for this purpose. By 5. RESULTS Y CONCLUSIONS
installing a blower and using air power similar to the
The methodological application proposed has allowed for the
existing air nozzles in the boiler, high density
detection of the main problem of low availability of the boiler
materials are forced through a pipeline so that the
was the excessive presence of pollutants which are not
clean fuel can continue toward the boiler.
involved in combustion, especially high-density materials
such as significantly sized rocks. Based on this, the most
Fall of contaminated Fuel critical failure mode was analyzed, called “obstruction of
nozzles” of air inside the boiler. The use of TRIZ in the
Pipeline Transportation of
generation of solutions for technical problems, helped reduce
Clea Fuel
Fuel
the latent risk from the moment of implementing the
improvements in the processes. However, it is a tool that
should be complemented with failure search tools and critical
analysis. While TRIZ doesn’t have this type of
Fluidized air
chamber
1
The Development Opportunity is calculated as (Ulwick, 2005):
Air supply duct

Pipeline to drop high-density

materials

Ventilator

Fig. 12. Schematic of alternative 2, Fluidized system prior to

the boiler.

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characteristics, by which if the problem is not identified in
the correct way, it will be working towards the wrong
direction. This is why this paper seeks to fortify this
weakness using techniques such as AMEF and RCA, which
focus their analysis on the identification, elimination and/or
mitigation of the failure mode affect in the equipment. It is
important to mention the role of the people who participated
in the development of the methodology, which is
fundamental for the correct development and achievement of
the objectives. The main profile that should participate are:
Operator (an expert in management and operation of the
systems and equipment under analysis), Maintainer (expert in
repair and maintenance of the systems and equipment under
analysis), Programmer (offers a systemic view of the
activity), Specialist (expert in specific domain areas),
Facilitator (methodological advisor) and Process Engineer
(provides overview of the production business). Finally,
future investigative works intend to complement each other
with new tools to generate distinctive scenarios for solutions
according to the implementation of real-time decisions that
can generate a solution in order to assess the possible strategy
implementation.
ACKNOWLEDGEMENTS
This research is funded by the Spanish Ministry of Science
and Innovation, Project EMAINSYS (DPI2011-22806)
“Sistemas Inteligentes de Mantenimiento. Procesos
emergentes de E-maintenance para la Sostenibilidad de los
Sistemas de Producción, besides FEDER funds. The research
work was performed within the context of iMaPla (Integrated
Maintenance Planning), an EU-sponsored project by the
Marie Curie Action for International research Staff Exchange
Scheme (project PIRSES-GA-2008-230814 iMaPla).
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