Failure Modes and Effects Analysis (FMEA)

Dr. Attia Hussien Gomaa Maintenance Engineering Consultant Engineering service - American University in Cairo (AUC)

2007
FMEA

Failure Modes and Effects Analysis (FMEA)

For each Critical component / item:
Step 1: Function Step 2: Functional Failures (full or partial) Step 3: Failure modes (failure rate date) definition Step 4: Failure Effect:
Local System Plant Criticality parameters: HSE Cost Severity level: Probability level: Risk level:

Step 5: Failure Consequence:

Process

Step 6: Critical failures (Top 5 failures) Step 7: RCFA Step 8: Remedy (best policy selection) Step 9: Policy description and program Step 10: Policy plan and implementation

FMEA

Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

 A functional failure is the inability of an item to fulfill a function to a standard of performance acceptable to the user
Functional failures can either be: Full loss of function or Partial loss of function Example: Function: To transfer water from tank 1 to tank 2 at 800 LPM Functional failure: Unable to transfer any water at all Transfers less than 800 LPM
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Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

Example: Function: A hydraulic pump provides 3000 psi +/- 200 psi. Functional failures might be: Pump provides more than 3200 psi Pump provides less than 2800 psi

Example: Function: Keep system temperature between 50 C and 70 C, Functional failures might be: Unable to raise temperature above ambient Unable to keep system temperature above 50 C Unable to keep system temperature below 70 C
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Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

Example

Function: The function of a hydraulic pump is to provide 3000 psi +/- 200 psi. Once the hydraulic pressure drops below 1000 psi a certain critical component ceases function.
Functional failures: Pump provides more than 3200 psi Pump provides between 1000 psi and 2800 psi Pump provides less than 1000 psi

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Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

Failure Modes:
A failure mode is any event which causes a functional failure
Two step Process: Identify failure modes which are likely to cause functional failure Ascertain failure effects associated with each failure mode

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Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

FMEA

Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

Failure Modes:
Bearing seizes Impeller comes loose Impeller jammed Coupling broken Motor burns out Inlet valve jammed Partially blocked suction line

Failure Modes: Hydraulic system failure mode High temperature

Low viscosity inadequate lubrication Excessive thinning of lube film Low component life
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Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

Failure Modes: Reciprocating Compressor Discharge pressure low:

-

- Knocking:
-

Overheating:
-

- It fails to attain speed:

-

Excessive belt wear:

- Pump bearing overload: FMEA

- Oil in the discharge air:

-

- Others
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Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

Failure Modes: Reciprocating Compressor

Discharge pressure low: Air leaks Leaking valves Restricted air intake Slipping belts Unloading mechanism not operating properly Blown gaskets Worn compressor rings Defective gauge Compressor too small for load

- Knocking: Loose motor pulley or compressor flywheel Loose belts Lack of oil in crankcase Oil pump not functioning Worn connecting rod bearings Worn piston pin bearing Worn main bearing Excessive crankshaft end play Excessive motor shaft end play Loose valve assemblies Loose piston Piston hitting the head, due to foreign matter Piston hitting the head, due to carbon deposits. 10

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Failure Modes: Reciprocating Compressor

Overheating: Poor ventilation Dirty cooling surfaces Incorrect flywheel rotation Defective valves Flywheel too close to wall Restricted air intake

- It fails to attain speed: Loose belts Low voltage Motor overload

- Excessive belt wear: Motor pulley or flywheel out of alignment Belt too loose or too tight Belt slipping Flywheel wobble

- Oil in the discharge air: Worn piston rings Compressor air intake restricted Restricted crankcase breather Excessive oil in compressor Wrong oil viscosity

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- Pump bearing overload: The wrong interference fit between the bearing and the shaft ( the shaft was out of tolerance). Misalignment between the pump and its' driver. Bent shafts. An unbalanced rotating element. Pushing the bearing too far up a tapered sleeve. Operating the pump off of its best efficiency point (B.E.P.). Shaft radial thermal expansion. Cavitation. Water hammer. Axial thrust. The bearing housing is out of round. A futile attempt to cool the bearings by cooling the bearing housing with a water hose or some other similar system. Cooling the outside diameter of a bearing causes it to shrink, increasing the interference and causing additional stress. Pulley driven designs. High vibration. The impeller is located too far away from the bearing. (common problem in many mixer/ agitator applications) A bad bearing was supplied counterfeit part FMEA
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Failure effects describe what happens when a failure mode occurs.

Examples of Failure Effects description

Local effect: Pump leaks hydraulic fluid Next higher effect: Hydraulic system pressure drops below 1000 psi / degraded controls End effect: System stops

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Brainstorming:

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

100% Is the part from the system or subsystem (assembly)

Is the main Task of the item

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

Is the manner by which a failure is observed and is defined as non-fulfillment of one of the equipment functions .

Example: valve the failure mode is open,partially open,closed partially closed and wobble
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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

For each failure mode there may be several failure causes

Select only potential failure to get root cause

By using why -why analysis you can get the root cause for potential failure

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

For each failure cause there is one or several failure mechanisms examples of failure mechanism are Fatigue ,corrosion and wear

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

Means what is happen when each failure mode occurs

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

Effect of failure is described in terms of the worst case outcome with respect to safety and environmental impacts ,production availability and direct economic cost and all that in numerical measure which are defined from ranking criteria

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

Safety and Environment severity degree

Impact degree on Availability of production Impact degree on Cost

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FMEA
HSE severity ranking criteria
RANK 10 79 46
SEVERITY LEVEL

DESCRIPTION A failure results in the major injury or death of personnel. A failure results in minor injury to personnel, personnel exposure to harmful chemicals or radiation, a fire or a release of chemicals in to the environment. A failure results in a low level exposure to personnel, or activates facility alarm system. A failure results in minor system damage but does not cause injury to Personnel allow any kind of exposure to operational or service personnel or allow any release of chemicals into environment.
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Catastrophic I Critical II Major III

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Minor IV

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Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

The probability that a failure will occur during the expected life of the system can be described in potential occurrence per unit time

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FMEA
Occurrence ranking criteria
RANK 1 DESCRIPTION An unlikely probability of occurrence during the item operating time interval. Unlikely is defined as a single failure mode (FM) probability < 0.001 of the overall probability of failure during the item operating time interval. A remote probability of occurrence during the item operating time interval (i.e. once every two months). Remote is defined as a single FM probability > 0.001 but < 0.01 of the overall probability of failure during the item operating time interval. An occasional probability of occurrence during the item operating time interval (i.e. once a month). Occasional is defined as a single FM probability > 0.01 but < 0.10 of the overall probability of failure during the item operating time interval. A moderate probability of occurrence during the item operating time interval (i.e. once every two weeks). Probable is defined as a single FM probability > 0.10 but < 0.20 of the overall probability of failure during the item operating time interval. A high probability of occurrence during the item operating time interval (i.e. once a week). High probability is defined as a single FM probability > 0.20 of the overall probability of failure during the item operating interval.
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46

79

10

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

This section provides a ranking based on an assessment of the probability that a failure of mode will be detected given the controls that are in place . The probability of detection is ranked in reverse order

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FMEA
Detection ranking criteria
RANK 12 34 57 8-9 10 DESCRIPTION Very high probability that the defect will be detected. Verification and/or controls will almost certainly detect the existence of a deficiency or defect. High probability that the defect will be detected. Verification and/or controls have a good chance of detecting the existence of a deficiency or defect. Moderate probability that the defect will be detected. Verification and/or controls are likely to detect the existence of a deficiency or defect. Low probability that the defect will be detected. Verification and/or controls not likely to detect the existence of a deficiency or defect. Very low (or zero) probability that the defect will be detected. Verification and/or controls will not or cannot detect the existence of a deficiency or defect.
Failure Mode Effect Analysis - Dr. Attia Gomaa - 2007

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

Risk Priority Number

Occurrence x Severity x Detection RPN = O x S x D

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FMEA
Item Failure Failure Function mode cause Failure Failure mechanis effects m S Severity A C Occ Det RPN Maintenance task Recommended interval

An appropriate maintenance action may hopefully be found by the decision logic in step 7

The identified maintenance action is performed at intervals of fixed length.the length of the intervals is found in step 8

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