FMECA Worksheet

Equipment

Equipment Function

No. Functional Failures Failure Modes Causes Effect

Unable to raise fuel

Inefficient fuel pump pressure in the
pipeline

Insuffient flow of fuel Not able to contain

to the burner Fuel pipeline leakage sufficient amount of
rotating cup fuel in the pipeline

Pipeline burst at
Pipeline chocked
weakest point

Cannot control the

Damper arm stuck damper
Fresh air cannot go
Insuffient flow of air Air filter clogged into blowing
to the burner chamber
Boiler not able to build up rotating cup
required 10bar pressure
Worn out impeller Cannot build up the
required air pressure

Carbon deposit Block the nozzle

Burner rotating cup

clogged
Fuel sediment from
Fuel will drip. Not
tank base clogging able to atomized
the burner cup

Scaling on the fire Improper water Low heat transfer

tube (water side) softening process efficiency
 Date:

Current
Current Detection Pb Sb Db RPNb Proposed Action Pb S b D b
Prevention
Add flow meter, add
Pressure gauge at
- 5 2 80 another pump on 3 1
the pump outlet
parallel line.

Boilerman hourly
- 6 1 48 -
inspection

Chemical wash every 6

Pressure gauge at
- 2 3 48 months to clear the 1 3
the pump outlet
build ups
Arm joint bush
renewal yearly Visual 3 2 48

Add pressure gauge to

Weekly filter Routine check by 3 3 72 determine the 3 1
cleaning Boilerman
differential pressure
8 8
Hardface the impeller
- Yearly inspection 3 5 120 and balancing for longer 1 5
life

Need to stop boiler

and open the 5 6 240 Montly cleaning 4 6
burner out

Manual swithcing of Need to stop boiler Add oil tank level sensor
fuel tank based on and open the 5 5 200 and automate the 3 2
Boilerman. burner out switching.

Renew the resin in

Monthly QC Check softener tank every 2
Yearly Fire tube
on the Water 3 6 144 year. Conduct weekly 2 6
cleaning
Hardness salt wash at the
softener
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 FMECA

Functional Failure Modes /

P Effect S
Failures Cause

Circuit Breaker
Compressor not able Compressor not able
tripped due to motor 5  7
to start to build up pressure
overload

Motor overloading and

Clogged inlet filter 5 high wear rate of 6
compression element

Fluctuation in
Pressure regulator compressor kW due to
3 5
faulty over/low pressure
operation
Compressor not able
to build up full
Low compressor
discharge pressure
Leaking air 7 operation efficiency 6
and power loss

Low compressor
Worn out screw
3 operation efficiency 6
element
and power loss

Rapids the wear and

Dirty oil 6 tear of compressing 5
element.

Compressor Insufficient level of

temperature reach Oil leaking 5 lubrication for the 8
high level alarm/trip rotating screw
 temperature reach
high level alarm/trip

Cooling exhaust fan High compressor and

5 6
faulty gas temperature

Low compressor
Damaged seal 5 operation efficiency 6
Excessive oil at and power loss
compressor
discharge port High wear rate at
Defective oil
5 downstream 5
separator
equipments

Compressor does
Low compressor
not stop after build Pressure regulator
5 operation efficiency 5
up pressure reaches faulty
and power loss
setpoint

Compressor safety
valve activated Safety relief valve Unable to build up
6 4
before pressure faulty pressure consistantly
reach set point
ECA
Figure 4 RCM Logic Tree : Task Determination
Current Adverse effect on
D RPN Lubrication /
Detection operational safety / Inspection / CBM
Servicing
operation?

Running amps YES. Operation

6 210 NO YES.
check  delay/downtime

YES.
Visual YES. Operation YES
4 120 Monitor differential
inspection delay/downtime Daily filter cleaning
pressure every shift

YES
YES. Downstream
Routine service/
None 9 135 equipment movement will NO
checks based on
be slow/not functional
running hour

YES
YES. Downstream
Routine Routine service/ YES
2 84 equipment movement will
inspection checks based on Pressure monitoring
be slow/not functional
running hour

YES YES
YES. Downstream
Routine service/ Bearing temperature
None 7 126 equipment movement will
checks based on and vibration
be slow/not functional
running hour monitoring

YES
Differential Renew the filter
YES. Operation YES
pressure at air 2 60 weekly and
delay/downtime Oil analysis
filter lubrication oil
yearly

YES
YES
Visual YES. Operation Bearing temperature
3 120 Every 2000H
inspection delay/downtime and vibration
servicing
monitoring
 YES
YES. Hot gas generates YES
Visual Clean the air filter
2 60 high moisture and overload Routine check on the
inspection and grease the
other auxiliary equipment fan functionality
rotating parts

YES. Oil contaminant

None 7 210 overload other auxiliary NO NO
equipment such as filter
YES. Oil contaminant
Routine YES YES
5 125 overload other auxiliary
inspection Annual servicing Rate of oil drain out
equipment such as filter

YES YES
Amps YES. Operation
4 100 Every 2000H Periodic functionality
monitoring delay/downtime
servicing test

YES YES
Pressure YES. Operation
3 72 Every 2000H Periodic functionality
monitoring delay/downtime
servicing test
: Task Determination
Dynamic Maintennace
Programme
Restoration

Thermography to check blown

fuse (periodic)
YES
Real time amps monitoring
Periodic overhauling

Develop routine checklist by

shift, daily, weekly and SOP

Contract out 2000H servicing

YES
job
Renew every 1
Periodic renewal of pressure
year
regulator

Add alarm system during

pressure drop

Add temperature and vibration

YES monitoring application
Annual major Replace bearing, seal kit, gasket
overhauling and lubrication of the screw
element

Review the inspection and

lubrication checklist
Contract out the oil analysis by
quaterly

Renew oil gasket and gasket

during PM.
Add temperature and vibration
monitoring application
Contract out 2000H servicing
job
 Develop routine checklist by
shift, daily, weekly and SOP

YES
Renew during yearly
Annual major
overhauling
overhauling
YES Inspect and renew during yearly
Annual major overhauling
overhauling Establish

Service the pressure regulator

every 2000H of operation.
Renew if found defective
Develop SOP for functionality
test

Service the safety relief vavle

every 2000H of operation.
Renew if found defective
Develop SOP for functionality
test
 FMECA Worksheet
Equipment

Equipment Function

No. Functional Failures Failure Modes Causes Effect

Not able to actuate

Spring jammed
the movement

Safety valve not Wrong adjustment of steam will build up

functioning the spring pressure accordingly

Not able to actuate

Valve thread
the movement
corroded
smoothly
Boiler build up overpressure
more than 10Bar
Firing controller will
Wiring terminal
not get the signal to
shorted
stop the firing

Pressure trol
indicator giving
wrong signal to
Boiler Control Panel
wrong drum
Not calibrated
pressure indication

pressure throll will cut off the firing

boiler controller

low water - mobrey

 Date:

Current
Current Detection Pb Sb Db RPNb Proposed Action Pb S b D b
Prevention
Keep the area clean and
Lubricate with oil free from any
- 3 4 96 2 1
monthly obstruction and Yearly
servicing

Marking on the pressure Visiting Steam Engineer

3 1 24 1 1
body monitoring to verify monthly

Periodic valve testing as

Yearly paint coating Visual 4 1 32 per classification society 2 1
code
9 9
Tidy up the wiring in the
- Visual 3 4 96 panel box. Frequnt 2 4
vacuum clean the dust

Add two Pressure Trol

and to include True and
Yearly calibration - 3 5 120 False Indication. When 1 3
both gives same signal,
then True. If not, No
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FMECA Worksheet
Equipment

Equipment Function

Functional Failures Failure Modes Causes Effect

high oxygen content Rapids the localized

in feed water corrosion
Localized pitting
Fire tube leakage corrosion from steam
side Corrosion happens
improper pH control faster in acidic
condition

pressure throll will cut off the firing

boiler controller

low water - mobrey

 Date:

Current
Current Detection Pb Sb Db RPNb Proposed Action Pb S b D b
Prevention

Yearly inspection 2 7 112 Hydrotest every 2 year 1 7

9 9
Inhibitor pumping
Water treatment 3 7 168 1 7
station
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