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System

Steam Turbine Piping (Blenod)

Subsystem

Steam Piping

Component

Steam Piping

Potential
Failure Mode and Effects Analysis
(Design FMEA)

Design Lead

FMEA Number DDE / 001


Prepared By AKG

Key Date

Core Team

FMEA Date

4/16/2010

Revision Date

4/23/2010

Page

Item / Function

Potential Failure Mode(s)

Delay in MPP approval

Potential Effect(s)
of Failure

S
e
v

Delay in project completion 1

Cutting & Marking

Reworking

Review of BOMs by Sr. Manager

Misunderstanding of Specs Manufacturing of wrong


of spool drgs
spool

Spool drawing not clear

Review of spool drawing by


Engineering

Delay in supply of material Delay in start of fabrication

Delay in transportation

Very close monitoring of material


movement

Wrong size pipe cuting

Delay in start of fabrication

Wrong cutting plan prepared


by Fitter

Review of cutting plan by


Production

10

Delay in start of fabrication

Shop capacity constraints

Prioritisation of Fittings
Manufacturing

Delay in start of fabrication

Shop capacity constraints

Prioritisation of bending operation

Delay in start of fabrication

Ensure correct machining thru


stage inspection

Delay in start of fabrication

Ensure correct fit up thru stage


inspection

Delay in fabrication
completion

100% Weld visual inspection

18

Delay in fabrication

Wrong machining of edges


Wrong fit up
Weld defects (u/cuts, cap
reinforcements)

Blasting & Cleaning

Packing

Error in fit up
Improper weld technique

6
2

Prioritisation of welding operation


thru planning

Heat treatment capacity


constraints

Prioritisation of HT operation thru


planning

Error in dissemination of
proper information

Three stage verification process


with final review by Welding
Engineer

12

worn out valve gland

Replace valve when first leakage is


observed

Delay in project completion 1

NDT facility constraints

Prioritisation of RT examination thru


1
planning

Delay in Blasting &


Painting

Delay in project completion 1

Insuffient surface preparation

Ensure thru stage inspection

Non uniform paint DFT

Delay in project completion 1

Improper mixing of paint

Ensure proper mixing of paint using


correct mixing equipment

Delay in dispatch

Boxes not ready

Ensure boxes are ready before


start of blasting & painting activity

Delay in Heat Treatment


due to non availability of
furnace
Improper selection of HT
cycle

NDT

Error in machining

Shop capacity constraints

Delay in welding

Hydro Testing

Delay in bending

Heat Treatment

Review of BOMs by Sr. Manager

Hot Bending of Pipes

Welding

18

Delay in manufacturing

Fit up

Specs not clear / complete

Fittings Manufacturing

Edge Preparation

R
P
N

Misunderstanding of Specs Creation of wrong BOM


of bom

Proactive approach in completing


all documents timely

D
e
t

Loose time

Procurement

Current Design Controls

Delay in review and approval


of special processes and
procedures

MPP Approval
Review of Drawings

Potential Cause(s)/
Mechanism(s) of Failure

Delay in project completion 1

Improper HT of product
resulting in repeat of
process

Leakage observed from iso Delay in Hydro test


valve glands
completion
Delay in RT Examination

Delay in packing

0
Page 1

Recommended
Action(s)

Responsibility & Target


Completion Date

Actions Taken

New Sev

Action Results
P
r
o
b

Page 2

DDE / 001
AKG
4/16/2010
4/23/2010
1

of

New RPN

New Det

New Occ

Action Results

Page 3

Page 4

Severity

Effect
Hazardous without
warning
Hazardous with
warning
Very High

SEVERITY of Effect

Ranking
10

High

Very high severity ranking when a potential failure mode


affects safe system operation without warning
Very high severity ranking when a potential failure mode
affects safe system operation with warning
System inoperable with destructive failure without
compromising safety
System inoperable with equipment damage

Moderate

System inoperable with minor damage

Low

System inoperable without damage

Very Low

System operable with significant degradation of performance

Minor

System operable with some degradation of performance

Very Minor

System operable with minimal interference

None

No effect

9
8
7

Return to Descriptions

Page 5

Severity

Page 6

Severity

Return to Descriptions

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Severity

Page 8

Severity

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Severity

Page 10

Probability

PROBABILITY of Failure
Very High: Failure is almost inevitable

High: Repeated failures

Moderate: Occasional failures

Low: Relatively few failures

Remote: Failure is unlikely

Failure Prob Ranking


>1 in 2

10

1 in 3

1 in 8

1 in 20

1 in 80

1 in 400

1 in 2,000

1 in 15,000

1 in 150,000

<1 in 1,500,000

Return to Descriptions

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Probability

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Probability

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Probability

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Probability

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Probability

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Detectability

Detection
Absolute
Uncertainty
Very Remote
Remote
Very Low
Low
Moderate
Moderately High
High
Very High
Almost Certain

Likelihood of DETECTION by Design Control

Ranking
Design control cannot detect potential cause/mechanism and
10
subsequent failure mode
Very remote chance the design control will detect potential
cause/mechanism and subsequent failure mode
Remote chance the design control will detect potential
cause/mechanism and subsequent failure mode
Very low chance the design control will detect potential
cause/mechanism and subsequent failure mode
Low chance the design control will detect potential
cause/mechanism and subsequent failure mode
Moderate chance the design control will detect potential
cause/mechanism and subsequent failure mode
Moderately High chance the design control will detect
potential cause/mechanism and subsequent failure mode
High chance the design control will detect potential
cause/mechanism and subsequent failure mode
Very high chance the design control will detect potential
cause/mechanism and subsequent failure mode
Design control will detect potential cause/mechanism and
subsequent failure mode

9
8
7
6
5
4
3
2
1

Return to Descriptions

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Detectability

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Detectability

Return to Descriptions

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Detectability

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Detectability

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Detectability

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Detectability

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Detectability

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