Pump FMEA

: 1.
To export fluid with a

Function
Functional Failure : 1.1 Unable to export flu
Item Identification
Item Name Tag No.
Pump
Project :
System :
Sub system :
Issued :
Sheet :
t fluid with any set pressure to desired location.
to export fluid to the desired location.
Failure Mode Caused by
No output/ Low Driven motor

output deficiency
Low voltage to
control box/
starter
Discharge pipe
leaked
Casing leakage
Pump cavitation
Internal part
(rotating)
imbalance or
loose
Air lock
Intake screen
plugged
Coupling motor
to pump
disengaged
Motor cannot
No voltage
start
Fuse blow or
overload
protector trip
Open circuit
Cable splice/
motor winding
shorted or not
grounded
High vibration/ Pump support

noise misalignment
Mechanical
defects such as
shaft bent,
misalignment,
rotating parts
loose or out of
balance, etc.
High
Bearing damage
temperature
Insufficient
lubrication
Seal (gland
packing) /
mechanical seal
damage
Coupling driver
Driver free run
parted
Support Mounting base
misalingment bolting loose
Leakage Casing crack
Mechanical seal/
seal (gland
packing)
damage
Rotor Internal part

assembly (rotating)
jammed damage
Bearing damage
of
sired location.
Failure Effect
Local Effect
Abnormal sound/
vibration
Motor trip
Intermittent operation
Motor trip
Insufficient discharge
pressure
Insufficient discharge and
delivery pressure
Content release
Low suction/ discharge
pressure/ flow
Abnornal sound/ vibration
Power demand excessive
Abnormal sound/
vibration
pressure
pressure
Parts worn out/ erosion
pressure
Abnormal sound/
vibration
Power demand excessive
Motor trip
Motor trip
Motor trip
Motor trip
Abnormal sound/
vibration
pressure
Abnormal sound/
vibration
pressure
Abnormal sound/
vibration
Short bearing life
No liquid in pump housing
Leakage at seal and

pump housing
Insufficient lubrication
Related fitting damage

Misalignment
Abnormal sound/
vibration
Leakage at seal and
pump housing
Leakage at seal and

pump housing
Abnormal sound/
vibration
Abnormal sound/
vibration
Short bearing life
Date
Prepared by
Checked by
Approved by
Failure Effect
End Effect
Motor damage
Pump stop
Pump stop
Low liquid delivery

Content release
Pump run dry
Shorten pump lifespan
Pump damage
Failure of pump housing
Impeller damage
Heavy vibration and noise, bearing
failure and consequently pump trip
Overheated pump bearings

Heavy vibration, bearing failure and
consequently pump trip
Pump damage
Insufficient delivery
Pump run dry
No liquid delivery
Pump cavitation
Pump run dry
Pump stop
Pump stop
Pump stop
Pump stop
Pump stop

Pump damage

Pump damage
Pump damage
Pump damage
Lube oil degraded
Pump damage
Internal part damage
Insufficient discharge pressure
Insufficient capacity
No liquid delivery
Pump poor performance
Pump run dry
Insufficient discharge pressure
Insufficient capacity
No liquid delivery
Pump poor performance
Pump run dry
Pump damage
Pump damage
:
: Khairul Ikhwan Basri
:
:
Criticality
3
3
3
3
3
3
3
3
3
Detection
Low differential/ discharge pressure

Vibration reading higher than normal
Low differential pressure/ discharge
pressure
Low motor amphere
Low suction and discharge pressure
Low suction and discharge pressure
Vibration higher than normal

Pump stop
Pump seized/ damage

No power source or low voltage when
measure
Pump seized/ damage
measure
Pump seized/ damage
measure
Pump seized/ damage
measure

High temperature alarm
Lube oil low pressure alarm


Low discharge/ differential pressure

Pump seized

Low discharge pressure/ differential
pressure
Leaking at seal or pump housing
Low discharge pressure/ differential

pressure
Leaking at seal or pump housing

Pump seized/ damage

Pump seized/ damage
Remark
Perform continuity check

Perform amp./ resistance check
Check all wire connection in control
box
Perform amp./ resistance check
Check discharge pipe integrity

Check mechanical seal gland
Check casing integrity
Check mechanical seal gland
Check filter and strainers
Check pump curve
Check abnormal noise and vibration

Overhaul pump
Check air relief valve
Monitor pump operating parameters to

check for abnormality
Clean strainer if plug
Reconnect coupling
Pull out the pump and repair
Perform amp./resistance check

Perform amp./resistance check
Check all wire connection

Perform ground check

Check and tigthen foundation bolts
and pump alignment

Overhaul pump
Overhaul pump

Check for excessive leakage

Perform rectification by attaching the

coupling and perform alignment
Visually check of pump structure
condition
Perform rectification on a damage part
Visually check on pump structure
condition
Check for excessive vibration

Check for unusual noise
Overhaul pump
Check for excessive vibration

Check for unusual noise
Overhaul pump (replace bearing)
INFORMATION REFERENCE
F FF
Furnace
Boiler furnace
Refractory
Refractory
Boiler Tubes (Front ,rear , side ,Screen Tube, Riser,
Boiler tubes
Membrane Wall
Boiler Tubes
Boiler Sliding Feet
Support (external) Stays / Buckstay

Sight Glass for furnace ( peep holes)
Drum and Header
Steam Drum
Steam Drum Safety Valve
Water Drum
Water Wall Headers
Boiler Superheater
Primary Superheater & Secondary Superheater

EDS (External Desuperheater)/ Attemperator
Superheater Safety Valve
Superheater and economiser Headers
Heat Recovery
Economizers
Economizers Safety Valve
Steam Air Heaters
Tubes
Steam trap
Boiler Mounting
Check Valves
Flangesless check valve
Fuel gas and Accessories

Uniflow butterfly valve
Filter regulator, speed

controller, quick exhaust
valve
Actuator
Steam, Water and other valve body
Filling, Drain &

Vent,blowdown Valve
Steam Trap
Piston Valve and accessories
Piston valve body
Actuator
Filter regulator, speed

controller, quick exhaust
valve
4-way solenoid valve / 3
way solenoid valve limit
switch
Piston valve Isolation/ Shutdown
Valve body
Valve actuator
Quick Exhaust valve
Speed controller
Long stroke and rotary sootblower
Soot Blower
Motor and electrical fault
Control system
Lance tube
Roller bracket
Valve/ Valve head/ valve
mechanism
Wall box
Funnel, Trunking and bellows
Exhaust Trunking/ Funnel
Expansion Bellows
Burner & combustion equipment
Burner atomizer
Swirler
Igniter
Fuel Oil
Atomizing Steam
Flame eye UV and IR
Fuel Oil rail Accumulator
Air register
Sprayer carriage,Gas
nozzle,gas header
Burner Sprayer
( lance) ,Burner carrier
Flame arrestor
Flame arrestor
Motor and Fan
FD Fan motor and fan
Motor and fan
Vibration sensor
Vanes control
Boiler Hood Fan/motor
Damper
Flame Detector Cooling Fan
Cooling Motor and fan
Monitoring and control equipment
BGB (Boiler Gauge Board Panel)

BGB (Boiler Gauge
Board Panel)
Isolator Module
Monitor Switch Module
Control Valves
Control Valves
Booster relay, valve
body,diaphragm
Valve Gland
Control valve stem,seat
plug
Control valve stem,seat
plug
EP positioner
Analogue gauge(Bourdon tube Pressure gauge and m

Analogue
gauge(Bourdon tube
Pressure gauge and
mercury temperature
gauge)
Analogue thermometer/
pressure
Oxygen sensor
Flow Meter
Level sensor
Smoke meter
Transmitter
Transmitter
Transmitter
Analogue indicator for

system signal
Temp and pressure switch
Boiler water level gauge glass
Boiler water level gauge glass
Associate Valves
Gas Detector (as part of Gas Detection System)
Gas Detector (as part of

Gas Detection System)
Others
Insulation and Cladding

Insulation and Cladding
Silencer for Dump Steam Piping
System
Sub System
Sub Sub System
Issued
CONSEQU
MATION REFERENCE
EVALUA
FM H
Poor combustion N
Overloaded/ overpressure N
Detachment/ crack from the tube or
Y
surface
Thinning refractory N
Crack refractory N
Damp N
de ,Screen Tube, Riser, etc )
Tube failure Y
Tube deterioration Y
Overheating N
Cyclic thermal failure N
Tube failure N
Overheating N
Cyclic thermal failure N
Excessive tube expansion or restricted

N
tube expansion/contraction
Seizure N
uckstay
Seizure N
Deteriorated N
p holes)
Broken glass N
Protection flap N
Leaking joints N
Dirty N
Drum wall deteriorating / failure Y
Internal drum fitting failure Y
Man hole cover leak N

External Downcomer failure Y
Joint leaking N
Internal leaking N
Spring tension Y
Failure to operate N
Jammed valve Y
Drum wall deteriorated/failure N
Block outlet/drain line Y
Man hole cover leak N

Leaking hand hole N
ndary Superheater
Tube failure N
Burnout Support Y
Tube deterioration/distort due to
Y
overheated
Seizure of expansion arrangement Y
er)/ Attemperator
Crack N
Crack/Desuperheater failure N
Leak/Passing internal Y
External leaks N
Low temperature desuperheater output N
High temperature, no control of

N
desuperheater output
Joint leaking N
Internal leaking N
Spring N
Jammed valve Y
Defective seat N
r Headers
Header leaking N
Tube failure/ deterioration N
Tube deterioration and block of hot gas

Y
flow
Joint leaking N
Internal leaking N
Spring tension N
Valve jammed Y
Internal leaks N
Tube failure N
external Leaking of steam N
Insufficient rise of air temperature N
Increase of draft loss N
Steam trap failure Y
Insufficient of fluid flow Y
Mechanical Welding failure N
Leaking N
Faulty flow N
Welding failure N
Valve teflon seat leak Y
Plug failure Y
Gland leak N
Insufficient flow N
Failure actuator N
e body
Welding failure N
Valve seat leak Y
Plug failure Y
Gland leak N
Steam trap failure Y
External and internal Leak N
Seizure N
Failure actuator N
Insufficient flow Y
Malfunction N
Leak
Crack Y
Seizure N
Leak, failure to close, seizure N
Air leaking even unit been though the

air is flowed in the shutdown N
direction,air leaks outside
Poor performance N
lower
Motor failure/ overload N
Power failure N
PLC failure N
Lance failure/ N
Accumulation of soot N
Roller bracket failure N
Bearing and sprocket failure N

Roller bracket failure N
Valve failure N
Wall box failure N
Exhaust trunk leak N
Gasket leak N
Exhaust trunking failure ( collapse) N
Bellows leak N
Gasket leak N
Fouling N
Eroded burner atomizer N
Poor flame quality such as fire flake
N
and smoke
Swirlers failure Y
Igniter failure N
fuel cracking Insufficient/ excess of FO

Y
supply/ leakage /
Atomizing Steam supply failure / Poor

Y
burner flame
Flame eye failure UV and IR N
Fuel rail accumulator failure Y
Defective air register Y
Poor quality of gas flame N

Leaking sprayer/ oil/atomizing steam N
Blockage / fouling Y
Damage arrestor Y
Leak Y
Insufficient capacity N
Overload prime mover N
Abnormal bearing temperature N
High vibration N
Incorrect supply of combustion air N
Fail to extract air from gas valve room Y
Damper failure Y
Fail to supply cooling air Y
Unable to operate boiler manually Y

Failure of isolator module N
Lost of signal/Alam N
Leak N
Crack N
Seizure Y
Leak, failure to close, seizure Y

Air leaking even unit been though the
air is flowed in the shutdown N
direction,air leaks outside
Poor performance N
be Pressure gauge and mercury temperature gauge)

Faulty / inaccurate readings of
N
analogue pressure gauge
Faulty /inaccurate readings of

N
temperature/ pressure
Faulty /inaccurate readings of Oxygen N
Faulty /inaccurate readings of flow N
Faulty /inaccurate readings of level N
Faulty readings of smoke intensity

N
meter
Faulty of combustion air ratio N

Leaking connection of sensor,
N
transmitter or gauges
Incorrect /abnormal reading of
N
transmitter
Faulty reading of Moving coil type
N
current/ voltage signal indicator
Malfunction of Temp & pressure switch N
Leaking of steam/water N
gauge glass's valve seizure Y
Detection System)
Fail to detect gas/ trip the associate

N
equipment
Defective insulation N
Silencer running noisy N
b System
b Sub System
H1 H2 H3
CONSEQUENCE S1 S2 S3
DEFAULT ACT
EVALUATION E1 E2 E3
O1 O2 O3
S E O N1 N2 N3 H4 H5
N Y N Y N N N N
Y N N Y N N N N
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N Y N Y N N N N
Y N N Y N N N N
Y N N Y N N N N
Y N N Y N N N N
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N N Y Y N N N N
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Y N N Y N N N N
Y N N Y N N N N
Y N N Y N N N N
Y N N Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
gauge)
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
N Y N Y N N N N
N Y N Y N N N N
N N Y Y N N N N
N N Y Y N N N N
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N N Y Y N N N N
N N Y Y N N N N
N N Y Y N N N N
Y N N Y N N N N
Y N N Y N N N N
Y N N N N N Y N
:
FAULT ACTION
S4/E4 S5/H5
N N
N N
N N
N N
N N
N N
N N
N N
N N
N N
N N
N N
N N
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N N
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N N
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N N
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N N
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N N
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N N
N N
PROPOSED TASK
EBC.Daily inspection during round,peep hole, O2 ana
Calibration of O2 analyzer
Clean and Calibration of FD fan vanes
Overhaul and Cleaning of burner
Alarm and tripping system test / calibration
Calibration of combustion control equipment

Visual inspection during the 6-month.Repair as neces
6 Monthly inspection
6 Monthly inspection
UTS inspection, visual external inspection during dryd
Scheduled general inspection every 6-month & cleani
Internal tube measure and inspection
Greasing of sliding feet

economizers (Tube).
Condition assessment every drydocking & detailed ND
Monthly submission boiler water test result to head of

Sootblow boiler ( Depending amount of fuel oil used
Boiler burner cleaning and overhaul
Calibration of combustion equipment
Boiler support and buckstay check
Combustion equipment calibration
Conduct EBC for checking the thermal load cycle dur
Internal tube measure and inspection
Greasing of sliding feet

economizers (Tube).
Monthly submission boiler water test result to head of
Boiler burner cleaning and overhaul
Calibration of combustion equipment
Monthly greasing
Condition assessment by specialist during drydocking

Visual inspection
Visual inspection
EBC.Daily round check for sign of leakage
EBC.Daily round check for cleanliness.
Cleaning
Internal drum inspection

Replacement covered on drydocking during drum insp
rounds and flashing up ops
Visual inspection
Renew every overhaul
Overhaul and check during 30M overhaul
Overhaul and check during 30M overhaul
Annual test during Annual survey
Condition assessment every drydocking
Internal boiler inspection
Visual inspection and overhaul at 30M
Replacement covered on drydocking during drum insp

rounds and flashing up ops
economizers (Tube)
Scheduled general inspection & cleaningevery 6-mon
Calibrate combustion equipment and associated instr
Cleaning and overhaul burner
Condition assessment every drydocking, cleaning
EBC.Condition assessment every drydocking.6 month

EBC.Condition assessment every drydocking.6 month
Calibrate combustion equipment and associated instr
6 monthly inspection
Conditional assessment during drydocking.Daily roun

EBC Daily inspection during rounds.Restoration durin
Overhaul and replace parts during docking, (Pressure
EBC Daily inspection during rounds.Renew and inspe

Scheduled general inspection and cleaning every 6-m
Mechanical and water wash /cleaning boiler economiz
Combustion equipment calibration
Mechanical and water wash /cleaning boiler economiz
Effective sootblowing
EBC Daily inspection during rounds.Restoration durin
Overhaul and internal parts check/replace during doc
Pressure Test - 6 month. Overhaul and internal parts

Scheduled general inspection every 6-month
Inspection and cleaning of air heater
Inspection and cleaning of air heater
Inspection and cleaning of steam trap
Inspection and cleaning of steam trap
6M Boiler inspection. Condition assessment every dry



Megger test motor

EBC.Daily round check for sign of leakage.Cleaning o
Visual check through sight glass and funnel (EBC).6 m

Overhaul burner atomizer
Visual check through sight glass and funnel (EBC).6
Visual check on daily basis and cleaning on 6M
Pressure check every 3 month

Cleaning every 6 mont .Will be conducted every 30-m
Will be conducted every 30-month
Will be conducted every 30-month
Check , motor,fan and vanes control equipment
Monthly greasing on motor .
Cleaning of fan, alignment check
Monthly greasing on motor, bearing and foundation
Motor greasing and securing foundation

Calibration and vanes equipment greasing
Main: Periodic maintenance & EBC.
Standby system: Functional Test of auto cut-in and ru
Fan motor and dampe check and cleaning.Megger te
Main: Periodic maintenance & EBC.
Standby system: Functional Test of auto cut-in and ru
Fan motor and dampe check and cleaning.Megger te
Test during 6M and 30M.

Inspection of panel wiring, cable and PCB
Check,calibration, overhaul
Annual calibration by ship staff, 30M 3rd party calibra

Visual inspection. Repair only leaking or found deterio
Regular maintenance/operate unit during trip test and
Conduct functional test (covered under gas detection

Visual check and external check during boiler survey
Daily inspection
INITIAL
DONE
INTERVAL
BY
(MONTH)
0.5
6
6
30
30
30
1
0.5
30
30
1
0.5
30
3
30
30
30
30 D
D
30
30
30
12
12
30
6 30 D
6 30
30
30 D
6 30
0.5
30
6 30
6 30
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
30 D
12 30
12 30
12
12
12 30
30 D
6
30
30
30
6 30
12
12
12 30
6
30
30
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6
6
30 D
30 D
D
6 D
0.5 D
6 D
6 D
6 D
6 D
6 30
6 30
6
6 30
30
6 30
6 12 30
1 6
6
6
30
6 30
6
3 6 30
3 6 30
3 6 30
3 6 30
3 6 30
3 6 30
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
6 30 D
30
1 12
30
Date :
Date :
Date :
Failure of
Abnormal sound/ vibration, insufficient
lubricating Wear of internal parts / pump seize
pressure
system
Leaking pass of pressure relief valve Generation of heat
Overheat to main engine bearings,
Filter chocked
insufficient lubrication to gearing
Pump cavitation,low suction pressure,
Air inhalation from suction pipe
excessive noise and vibration
Overheat to main engine bearings,
Excessive leakage
insufficient lubrication to gearing
No
Delivery valve closed No suction
discharge
Suction valve closed No suction
Blocked suction strainer No suction

Water level beyong maximum lift of
No suction
pump
Priming device failure No suction
Pump starts
and
diacharges
Oil is not poured sufficiently Pump is air lock
oil, but soon
ceases to
discharge oil
Valves are not opened Valves shut
Air is not pushed out sufficiently Pump air lock
Pump is sucking air Pump air lock
Suction pipe strainer clogged Poor suction
Pump starts
and
diacharges
oil, but
Pump is sucking air Pump air lock
specified
capacity and
pressure are
not reached.
Pump speed too low RPM too low
Safety valve is opened Oil flowing out from safety valve
Suction pipe strainer clogged Poor suction
Liquid viscosity too low Liquid flow slow
Gears are worn Noise and vibration
Suction pressure too high High vacuum at suction side
Gauges showing wrong readings Wrong readings

Heavy vibration, bearing failure and High vibration alarm, lub oil low pressure alarm, differential pressure
consequently main engine trip alarm
Heavy vibration, bearing failure and High temperature alarm, lub oil low pressure alarm, sump low level
consequently main engine trip alarm, differential pressure alarm
Heavy vibration, bearing failure and High temperature alarm, lub oil low pressure alarm, differential
consequently main engine trip pressure alarm
High temperature alarm, lub oil low pressure alarm
consequently main engine trip
Heavy vibration, bearing failure and High temperature alarm, lub oil low pressure alarm, differential
consequently main engine trip pressure alarm
CSW pump unable to deliver water for No discharge, high suction vacuum created, zero delivery pressure
cooling purpose
cooling purpose
cooling purpose
cooling purpose
cooling purpose
Suction and delivery pressure gauges and low motor amphere
Low discharge pressure and low

quantity of oil delivered
Low / high discharge pressure and low Suction and delivery pressure gauges and low motor amphere
Low discharge pressure and low Suction and delivery pressure gauges and low motor amphere
Suction and delivery pressure gauges and low motor amphere
Low discharge pressure and low

Open delivery valve
Open suction valve
Clean strainer
Change the set up to improve suction head
Overhaul and rectify defects in priming devices
Throttle discharge valve to prevent suction pipe

partially filled
Open closed suction or discharge valves

partially filled
partially filled
Open up and clean suction strainer
Retify leakages at suction side
Check voltage supply
Retify defects in safety valve
Open up and clean suction strainer
Heat up the oil in settling tank
Renew the gears
Check for restriction in suction side or chocked

filters
Renew or calibrate the pressure gauges

Pump FMEA

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Copyright:

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Pump FMEA

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: 1.

To export fluid with a

Functional Failure : 1.1 Unable to export flu

to export fluid to the desired location.

Failure Mode Caused by

No output/ Low Driven motor

High vibration/ Pump support

Rotor Internal part

No liquid in pump housing

Leakage at seal and

Related fitting damage

Leakage at seal and

Low liquid delivery

Overheated pump bearings

Overheated pump bearings

Overheated pump bearings

Low differential/ discharge pressure

Low differential/ discharge pressure

Low differential/ discharge pressure

Low differential/ discharge pressure

Vibration reading higher than normal

Low suction and discharge pressure

Low suction and discharge pressure

Vibration higher than normal

Pump seized/ damage

Vibration reading higher than normal

Vibration reading higher than normal

Vibration reading higher than normal

Vibration reading higher than normal

Low discharge/ differential pressure

Vibration reading higher than normal

Low discharge pressure/ differential

Vibration reading higher than normal

Vibration reading higher than normal

Perform continuity check

Perform amp./ resistance check

Check discharge pipe integrity

Check abnormal noise and vibration

Check air relief valve

Monitor pump operating parameters to

Perform amp./resistance check

Check all wire connection

Perform ground check

Check abnormal noise and vibration

Check abnormal noise and vibration

Check abnormal noise and vibration

Check abnormal noise and vibration

Perform rectification by attaching the

Check for excessive leakage

Check for excessive vibration

Check for excessive vibration

Boiler Tubes (Front ,rear , side ,Screen Tube, Riser,

Support (external) Stays / Buckstay

Drum and Header

Primary Superheater & Secondary Superheater

Superheater and economiser Headers

Flangesless check valve

Fuel gas and Accessories

Filter regulator, speed

Steam, Water and other valve body

Filling, Drain &

Piston Valve and accessories

Piston valve body