Centrifugal Pump Using Failure Mode Effect and Critical Analysis Based on Fuzzy

Cost Estimation: A Case Study

1.Introduction
In every factory that must deal with fluids as an integral aspect of its operations, centrifugal pumps have
traditionally been regarded as one of the most critical components that must be present. The primary function of
moving those fluids that are undergoing any kind of transformation through other components of the plant such
as furnaces, reactors, heat exchangers, and so on, makes the pumps a special focus of attention from the
perspectives of reliability, safety, and financial aspects of the plant. When it comes to determining a proper
maintenance strategy, one of the most essential roles that an analysis of the effect that the dependability and
maintainability of pump systems have on the overall plant availability plays is a very significant one. Not only is
the elimination of important components and the unscheduled downtime and unplanned shutdowns caused by
their frequent failures, but also the reduction of unplanned shutdowns and component repair times, both of
which are key challenges in this method.

Components within Centrifugal Pump

Centrigual
Pump

mechanical
Bearing Shaft Coupling Impeller
Seal
Failure Mode Effect and Criticality Assessment (FMECA)

Failure Mode, Effect, and Criticality Analysis, abbreviated as FMECA, is a technique that is widely used to
improve the centrifugal pump's reliability. With the assistance of FMECA, prospective failure modes and
functional failures within a system and its equipment can assess the cause and effect of the mode of failure,
identify potential weak links, and provide improvement methods. [1]
 Type of Failures Symptoms
No liquid delivered
Functional Not enough liquid delivered
Failure Pump works for a while then
quits.
Pump takes too much power.
The criticality index is calculated Pump loses prime after starting. by adding the
severity index to the probability Viscosity of liquid differs from index and
design
dividing the result by two. It is a condition. measurement
of the overall risk that is associated
with each possible combination of degree of harm and likelihood of occurrence. This probability is utilised for
failure prediction for a specific frequency, and then diagnoses the failures with the most effective maintenance
strategies, such as condition based maintenance (CBM), time based maintenance (TBM), etc.

Figure 1: Basics of applied Failure Modes Effects and Criticality

Information gained from FMECA :

1. A listing of likely failure modes and the cause of the failure, which helps guide the testing and inspection
methodologies for the system

2. The severity of any prospective failures that may have an effect on the overall performance of the system.

3. Detection and control mechanisms specific to each mode of failure.

4. Information for management purposes.

5. Data that will be used in subsequent analyses

3. Methodology of Analysis of Centrifugal Pump

Group Criticality Index

I 3 - 2.5
II 2.5 - 2
III 2.1 - 5
IV 1.5 - 1

Table 2: Criticality Priorities Group [4]

Type of Failures Symptoms

Bearing Failure
Potential Failure Seal Leakage
Shaft Cracks
Pitting marks on impeller
Misalignment

Table 1: Failure Mode Effect and Criticality Analysis [Reputed Manufacturing Company]
 Studied all collection of Develop
Examine all Evaluate critical index Assigned the
causes Data failure task of Evaluate
the data Critical parts according
failure in of maintenance resutl and
failure with of failure their
centrifugal Centrifugal for critical Profit
frequency frequency components
pump pump
Table 3 Criticality Analysis for CentrifugalPump [Reputed Manufacturing Company]

Failure Compone Failure Modes Criticality Analysis Criticali

Modes nts or (components) ty
(System) Sub- Production Safet Co Index Grou
system y st p
Shaft Worn 1 2 3 1.4 IV

Excessive 1 2 3 1.4 IV
Deformation
Bearing Misalignment 3 3 3 3 I

Seizur e 3 3 2 2.8 I

Broken 3 3 2 2.8 I

Mechanic Fracture 2 2 2 2.5 II

al
seal Leakage 2 3 1 2.2 II
Centrifug
al pump Impeller Pitting marks 3 2 1 2.2 I
not
Functioni Blade damaged 3 1 2 2.2 I
ng

From table 3, it is clear that criticality component rank given below:

1. Bearing
2. Mechanical Seal
3. Impeller
4. Shaft

Therefore, the priority of critical components, the maintenance strategies like as – Condition Based
Maintenance (CBM), Time Based Maintenance (TBM) and Planned Maintenance (PM) as per schedule
would
vary which is given table 4.

System Failure Mode Rank Task Frequency

Group
Centrifugal Bearing I CBM Weekly
pump not Mechanical Seal II TBM Weekly
Functioning Impeller III PM Monthly
Shaft IV PM Six Monthly

Table 4: Maintenance Strategies of Centrifugal Pump on the Basis of Component Criticality

4. Profitability of Centrifugal Pump after Implementation of Optimum Maintenance
Tasks

Frequency Time No. of Man – hour

(Hours) Workers per stage
Six Monthly 2 18 4 144
Monthly 9 6 3 162
Weakly 45 8.2 1 369

Table 4: Total Labor Required For Maintenance [Reputed Manufacturing Company]

 Item Labor Type Number of Number of
Labors Per Labors Per Day
Day (After
(Current implementation)
Maintenance)

Engineers Mechanical 4 3
(45,000 Electrical 3 2
`/Month) Control 4 2
Technicians Mechanical 6 4
(25,000 `/ Electrical 6 4
Month)
Total Cost (`/ Year) 7,95,000/- 5,15,000/-
Saving Cost (%) = 35.22

Table 5: Labor Saving Cost [Reputed Manufacturing Company

Average downtime cost rate = Actual After

8,500 `/ hour implementation
Average downtime of centrifugal 35 hr/year 22 hr/ year
pump
Average downtime of the system 22 hr/year 12 hr/year
auxiliaries
Total downtime 54 hr/year 34 hr/year
Total downtime Cost 4,59,000 2,89,000 `/year
`/year
Saving Downtime Cost (%) = 37.04

Table 6: Downtime Cost [Reputed Manufacturing Company]

5. Results
1. The labor cost decreases from ` 7,95,000/- to ` 5,15,000/-
2. The downtime cost decreases from ` 4,59,000/- to `
2,89,000/-
3. The spare parts cost decreases from ` 1,15,000/- to `
62,000/-
4. The net profit is 4,53,000 `/year.

S.No. Parameters Actual (`) After Savings

Impleme- (`)
ntation (`)
1 Labor saving cost 7,95,000 5,15,000 2,80,000 35.22 %
2 Downtime cost 4,59,000 2,89,000 1,17,000 37.04 %
3 Spare Parts 1,15,000 62,000 53,000 46.32 %
Table 6: Cost Saving and parameter involved
 Equipment Spare Part Quantity Cost Quantity Cost
(Current) (current) (After (After
?/ year implementation implementation)
)
Bearing 6 18 000 4 12 000
Centrifugal
Mechanical 6 7 500 4 5 000
Seal
Pump
Shaft 4 30 000 2 15 000
Impeller 2 60 000 1 30 000
TotalCost (?/ year) 115   62 000/-
500/-
Sav ng Spare Parts Cost (%) = 46.32
Table 7 Spare Parts [Reputed Manufacturing Company}

6. Conclusions
1) Profitability is a new criterion that has been employed in order to examine economic issues. It is based on
expenses and potential profit, and its purpose is to limit the losses that are generated by the occurrence of
failure.

2) The cost-based FMECA gives a graphical depiction and an effective classification of failures based on fault
priority and economic profit. This is accomplished in a very organised manner.

3) To select the best mix of failures to be repaired, and this sort of problem is easily resolvable through the
priority of critical index of components and appropriate maintenance procedures, and to diagnose any problems
that arise with these components.

4) By making the right choice of maintenance techniques with the assistance of FMECA, an increase in annual
profit of 36.74% can be accomplished. This increase takes into account the costs of personnel, downtime, and
spare parts only.

5) As a result, in order to have a solid maintenance system using the FMECA strategy of failure cost
consideration:

a) Decreased amounts of downtime and failure rate.

b) Increase the amount of money made.

c) Improve the centrifugal pump's level of dependability.

d) Raise the level of production without introducing any new failures into the process.

References
[1] Ying Chen, “Status of FMECA
Research and Engineering Application”,
Prognostics & health management
Conferences Beijing, 2010.
[2] http://wildeanalysis.co.uk/casestudies/
reducing-product- development-risk-
reliability engineering.
[3] O’Conner, Practical Reliability
Engineering, 3rd edition, Revised, John
 Wiley & Sons, Chichester, England,
1996.
[4] Islam H. Afefy, “Reliability Centered
Maintenance methodology and
Application: A case Study”, scientific
research, p.g.no. 863-873, 2010.