IRJET- Risks Prioritization using FMEA Method -A Case Study

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 07 | June 2019 www.irjet.net p-ISSN: 2395-0072
© 2019, IRJET | Impact Factor value: 7.211 | ISO 9001:2008 Certified Journal | Page 355
RISKS PRIORITIZATION USING FMEA METHOD -A CASE STUDY
Dulendra Kumar Patle1, Manish Kumar Mishra2, R. K. Mishra3
1M.Tech Scholar, Mechanical Engineering Department
2Assistant Professor& Head, Mechanical Engineering Department
3Professor, Civil Engineering Department
Bhilai Institute of Technology, Raipur, Chhattisgarh, India
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Abstract - The electricity power generation plays the
important role of every business or industrial, since it must be
supplied to cove with the full consumption on demand sites. A
survey has been conducted to identifythechancesoffailuresof
various machinery/ equipment which may occur in thermal
Power Plant at Jaiswal Neco Industries Limited, Raipur. Many
factors for failure are come to be known, out of which some
major critical factors are identified for which FMEA is
conducted. Failure Modes and Effects Analysis (FMEA) is
methodology for analyzingpotentialreliabilityproblemsearly
in the development cycle where it is easier to take actions to
overcome these issues, thereby enhancing reliability through
design. Failure mode, effects and criticality analysis (FMECA)
is the also most popular systematic assessment of a process
(product) that enables us to determine the location and the
mechanism of potential failures, with the aim of preventing
process (product) failures. FMEA is precisely an analytical
methodology used toensurethatpotential problemshavebeen
considered and addressed throughouttheproductandprocess
development cycle. A process or a design should be analyzed
first before it is implemented and also before operating a
machine the failure modes and effect must be analyzed
critically. A comparative analysis of various risks factors
reduces the chance of its occurrence. The main motive of this
paper is risk Prioritization using FMEA method, which are
more severe for the Company. Finally the most risky failure
according to the RPN numbers is found and the cause and
effects along with the preventive measures are tabulated.
Key Words: FMEA, RPN, FMECA,
1. INTRODUCTION
Risk management is a critical component of strategy
development and execution, and a driver of firm success.
Maintenance is the crucial issue for the plant with highly
complexity and a variety of machines such as thermal power
plant, cement plant, oil refining plant and so on. The main of
maintenance propose is to suppress the risky of plant
suddenly shutdown with uncontrollable system.Athousand
of equipments at each plant unit must be take care
depending on maintenance policy such time based
maintenance, break down maintenance etc. All equipments
are mostly importance to be maintained in order to keep
them working stability supposed with ill-conditioning
operation.
Failure mode, effects and criticality analysis (FMECA) is the
also most popular systematic assessment of a process
(product) that enables us to determine the location and the
mechanism of potential failures, with the aim of preventing
process (product) failures. FMECA is characterized by a
bottom-up approach by which any complex production
system is decomposed into its constituent parts, which are
successively analysed to find all the potential failure causes
and their effects.
Failure Modes and Effects Analysis(FMEA)isa techniquefor
evaluate possible reliability troublesinthe earlyhoursatthe
progress cycle where it is simpler to acquire actions to
overcome these matters, thereby improving consistency
through design.
Failure mode, effects and criticality analysis (FMECA) is the
most popular systematic assessment of a process (product)
that enables us to determine thelocationandthemechanism
of potential failures, with the aim of preventing process
(product) failures. FMECA is characterized by a bottom-up
approach by which any complex production system is
decomposed into its constituent parts, which are
successively analyzed to find all the potential failure causes
and their effects.
FMEA can be apply to recognize probable failure modes,
conclude their effect on the process of the product, and
categorize actions to diminish the failures. A vital step is
anticipating what might go incorrect with a product.
Whereas anticipating each failure mode is not possible, the
improvement squad ought to invent as extensive a record of
likely failure modes as probable.
Case study
This paper is based on process FMEA which analyses the
failure of Turbine auxiliaries and its effect on power
generation of Power Plant. In this research the thermal
power plant of Jaiswal Neco Industries Limited, Raipur is
selected to analye the failure mode. The developed method
can help the maintenance team for making decision in spare

part management and it is friendly-user to pursuit the
maintenance policy focused on critical maintaining
equipments in overall systems. Some of the problem arised
are:
1. Problem in Heat Exchanger of Oil System of
Turbine.
a. Remains high Thrust Pad temperature of
Turbine Shaft.
b. High Axial and differential expansion of
turbine.
2. Found high vibration in Turbine body.
a. Problem in Recirculation cooling water pump.
b. Auxiliary power consumption of plant become
high due to running of stand by pump.
c. Increase in Steam consumption of turbine due
to decrease in condenser vacuum.
d. Exerts high pressure, due to running of
standby pump, on oil cooler fins and reduce life
of oil cooler.
Major Equipment in which problem has arised are:
OIL COOLERS
Normally two oil coolers of 100%capacityeachareprovided
to cool entire oil supplied to turbine bearings, gearbox, and
generator bearings for lubrication. Governing oil is not
cooled at oil cooler. This oil is taken out before oil cooler.
One cooler is put on line and another one is kept as standby.
Online changeover facility is provided to take the standby
cooler in to service while turbine is running without
interruption of oil supply. Before changeover, it is to be
ensured that the standby cooler is filled with oil and air is
vented out properly. Otherwise there will be air lock and oil
supply to bearings may interrupt.
SHAFT VIBRATION:
Vibration of the turbine indicates condition of turbine in
running condition. Rotor rotates at highspeedthroughsetof
journal bearings. There islittleclearancein betweenrotating
and stationary parts. Due to misalignment, disturbance in
balancing, rubbing of moving part etc.,rotortendstovibrate.
This vibration is supposed to be within permissible limit.
Excessive vibration may damage turbine and lead to
extensive maintenance.
THRUST PAD/ BEARING TEMPERATURE:
Journal bearings are used to take radial load of the shaft. But
it can't axial load. Shaft is permitted to float to both axial
float is restricted to certain limit. Excessive axial shift may
damage rotating and fixed parts. For this thrust bearing are
provided. Particularly in turbine, fluid film tilting pad type
thrust bearing is used.
Due to friction heat is generated in journal bearing which is
cooled by help of lubricating oil. At higher temperature,
babbating material of the bearing can damage. So it is
required to keep the bearing temperature within safe limit.
For this, temperature of bearing is monitored continuously.
TURBINE BEARING TEMPERATURE:
Journal bearing is a cylinder which surrounds the shaft and
is filled with lubricating oil. It consists of a split outershell of
hard metal and a soft metal at the inner cylindrical part. In
this bearing a shaft or journal rotates insidethebearingover
a layer of lubricating oil, separating the shaft and bearing
due to fluid dynamics principle. This lubricating oil layer
supports the shaft preventing metal to metal contact. Oil is
pumped into the bearing through oil pump. When rotor
rotates lubricating oil is drawn up around the journal due to
hydro dynamic effect of lubrication. When lubrication is
introduced between twosurfacesofrollingcontact,itcreates
a large increase in pressure. Some of the failure mechanisms
are
1-Overload
2-Overheating
3-Fatigue
4-Erosion
COOLING WATER SYSTEM:
In a condenser cooling water is circulated to condense
exhaust steam of turbine. Exhaust steam is having
considerable amount of heat energy. This heat energy is
required to be transferred to cooling water to condense
steam. So the cooling water temperature rises. This cooling
water is required to be cool down, again use it in condenser.
This cooling is done at cooling tower. From cooling tower,
cooling water is circulated through condenser by help of
cooling water pumps. This exhaust steam is to be cool down
to 41.2oC.There are two types of cooling water circulation
system. These are:
1-Open or once through System
2-Closed system

COOLING TOWER:
Cooling tower is a structure in which hot water is made
droplets with the help of nozzle to increase contact surface
of water and allowed to come in contact with atmospheric
air. Atmospheric air is having certain capacity to absorb
water vapors at a given temperature. Water vapors is
created due to evaporation of water heat is required. This
heat is obtained from remaining water. So this remaining
water is cooled as heat is heat is removed from it for
evaporation. Rate of evaporation and hence drop in cooling
water temperature depends upon following factors.
INDUCED DRAFT COUNTER FLOW COOLING TOWER:
A mechanical fan is located at top of the tower. Water is
distributed throughout the area of tower and made droplets
with the help of spray nozzles. Mist eliminators are placed
above distributed pipe line and nozzle to restrict escape of
vapor mist to atmosphere. Hot water is allowed to flow
down to the basin by gravity. When fan is started
atmospheric air is socked and enters through the louvers.
This air moves up and comes in contact with downward
droplets. It carries the heat of water and discharge to
atmosphere through the fan. Flow of air and water is in
counter direction. SO the temperature between the hot
water and cool air is almost same throughout the mixing
area. So this type of tower is thermodynamically most
suitable. Cold water is collected in a basin from where water
is drawn out for further use in condenser. This complete
arrangement is called as a cell. Cells are connected side by
side in parallel to meet the requirement of plant.
2. METHOD AND PROCEDURE
The FMEA is a powerful design tool that provides a mean to
compare, from a risk point of view, alternative machine
system configurations. The FMEA is a formalized but
subjective analysis for the systematic identification of
possible Root Causes and Failure Modes and the estimation
of their relative risks. The main goal is to identify and then
limit or avoid risk within a design. Hence the FMEA drives
towards higher reliability, higher quality, and enhanced
safety. It can also be used to assess and optimize
maintenance plans.
An FMEA is usually carried out by a team consisting of
design and maintenance personnel whose experience
includes all the factors to be considered in the analysis. The
causes of failure are said to be Root Causes, and may be
defined as mechanisms that lead to the occurrence of a
failure. While the term failure has been defined, it does not
describe the mechanism by which the component has failed.
Failure Modes are the different ways in which a component
may fail. It is vitally important to realize that a Failure Mode
is not the cause of a failure, but the way in which a failure
has occurred. The effects of one failure can frequently be
linked to the Root Causes of another failure.
The FMEA procedure assigns a numerical value to each risk
associated with causing a failure, using Severity, Occurrence
and Detection as metrics. As the risk increases, the values of
the ranking rise. These are then combinedintoa risk priority
number (RPN), which can be used to analyze the system. By
targeting high value RPNs the most risky elements of the
design can be addressed. RPN is calculated by multiplying
the Severity by the Occurrence by the Detection of the risk.
Severity refers to the magnitude of theEndEffectofa system
failure. The more severe the consequence, the higher the
value of severity will be assigned to the effect. Occurrence
refers to the frequency that a Root Cause is likely to occur,
described in a qualitative way. That is not in the form of a
period of time but rather in terms such as remote or
occasional.
FMEA is the methodology designed to identify potential
failure modes for a product or process before the problems
occur, to assess the risk. Ideally, FMEA’sareconductedin the
product design or process development stages, although
conducting an FMEA on existing products or processes may
also yield benefits.
For calculating the risk Prioritization in FMEAmethod,Risks
have been evaluated by set of Questionnaire respond from
SME (Table 1).Risks have been evaluated in three
components which are multiplied to produce a Risk Priority
Number (RPN):
1) Severity (S): Severity is described on a 10-point scale
where 10 is highest.
2) Occurrence (O): Occurrence is described on a 10-point
scale where 10 is highest.
3) Detection (D): Detection is described on a 10-point scale
where 10 is highest.
RPN= S*O*D.
Note: Table 2 is below in Appendix
3. RESULT ANALYSIS
The FMEA method in this study is formed to prioritize the
various risks within the organization. As per this method
first priority considers the severity of risk and then
Occurrence of those risks comes in precedence, last but not
least is Detection of risk. Higher the RPN value, higher the
priority of risk. Thus the firm has Risk Priority by the use of
FMEA method Here the most critical risks is shown
according to their RPN value (see in table 1) that require
optimization at maximum level.

Table 1. Priortizing risk on the basis of RPN value.
Process Input
RPN value on the basis of
Process Input
Turbine Bearing
Temperature
84
Shaft Vibration 75
Cooling Tower 72
Thrust Pad Temperature 60
Oil Cooler 40
LP Dosing 18
RCW 16
QC NRV 12
Fig. 2. Critical risk factors on the basis of RPN value
Note: There is no threshold value for RPNs. In other words,
there is no value above which it is mandatory to take a
recommended action or below which the team is
automatically excused from an action.
4. CONCLUSIONS
A survey has been conducted to identify the chances of
failures of various machinery/ equipment which may occur
in thermal Power Plant at Jaiswal Neco Industries Limited,
Raipur. Many factors for failure are come to beknown,out of
which some major critical factors are identified for which
FMEA is conducted.
From the survey conducted is it is found that Turbine
Bearing Temperature, shaft vibration, problem in Cooling
Tower are major concern which are to be taken in account.
Once FMEA data was produced, it was ranked in assembly
order giving a clear picture of the unreliabilityofassemblies,
subassemblies and parts. This could be a useful tool for
designers to identify weak points in the plant design.
REFERENCES
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Kamble “FMEA for Manufacturing and Assembly Process”
International Conference on Technology and Business
Management March 26-28. 2012.
[2]. Aravinth, subramanian .s, sri vishnu . “Process Failure
Mode And Effect Analysis On Tig Welding Process - A
Criticality Study” International Journal of Advances in
Engineering & Technology, may 2012. ©ijaet
[3] B.G. Dale and P. Shaw, “Failure Mode and Effects Analysis
in the U.K. Motor Industry: A State-of-Art Study,” Qualityand
Reliability Engineering International, Vol. 6, 184, 1990.
[4]. Marcello braglia1,Marco frosolini1 and Rroberto
montanari “fuzzy topsis approach for failure mode,
effects and criticality analysis” quality and reliability
engineering international Qual. Reliab. Engng. Int. 2003;
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[5]Ramadhan RH, Wahhab HIA, Duffuaa SO. (1999). The use
of an analytical hierarchy process in pavement maintenance
priority ranking, J Qual Mainte Eng 5(1): 25–39.
[6]. Suebsomran A., Talabgeaw S. “Critical Maintenance of
Thermal Power Plant UsingtheCombinationofFailureMode
Effect Analysis and AHP Approches” AIJSTPME (2010) 3(3):
1-6.
Appendix
Step 1: Structuring the Questionnaire for risk factor in the
thermal power plant.
Step 2: Identifying the critical risk factors and calculating
RPN values for each.

Table 2: Calculation of Risk Priority Number(RPN)

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