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FMEA FOR BOILER

Potential Cause (s)/ Mechanism(s) of


Potential Effect (s) of Failure Criticality Analysis
Process Step Function Potential Failure Mode Failure
Local System Plant Sev Occur Detect RPN
GAS FIRING Gas line leaks Low Effect Low Effect No Effect
Gas line repair Low Effect Low Effect No Effect
High gas pressure Low Effect Low Effect No Effect
STEAM EXPLOSION Low water level Boiler trip Steam system trip Lower production
Defective safety valves Low Effect Low Effect No Effect
Defective steam pressure gauges Low Effect Low Effect No Effect
Scaling or corrosion in boilers internal Boiler shutdown Steam system trip Production stooping
surfaces.

Boiler shutdown Steam system trip Production stooping


Bypassed controls
Tampering with
controls
Poor maintenance
Condensate tank
explosion.
EXPLOSION IN FURNACE Inadequate pilot/igniter.
IMPLOSIONS Excessive negative pressure

Equipment undergoing maintenance.


Sudden starting of remotely controlled
equipment. Release of fluid pressure.
Electrical shock.
MAINTENANCE
Cleaning

Entering a confined or enclosed space


such as furnace, ducts, drums,
shell, gas passes, flues, tanks, bunkers,
hoppers, etc.

Airborne contaminants such as gases,


fumes, vapours, dust and mist.
Moving equipment or parts and fan
blades in exposed condition
Congestion in work area

Accidental opening of the access door.

Boiler shutdown Steam system trip Production stooping


ELECTRICAL Exposed/ naked electrical wiring

Boiler shutdown Steam system trip Production stooping


Exposed electrical boxes.
Switch box opens without turning off Boiler shutdown Steam system trip Production stooping
powers.
FMEA FOR BOILER

Process Step Potential Effect (s) of Failure Potential Cause (s)/ Criticality Analysis
Potential Failure Mode
Function Local System Plant Mechanism(s) of Failure Sev Occur Detect RPN
Failed to open Low Effect Low Effect No Effect Valve failure 3 1 2 6
Check Valve Remain open Low Effect Low Effect No Effect Valve failure 3 1 2 6
Crack valve Low Effect Low Effect No Effect Valve failure 3 2 2 12
Incorrect burner sequence Boiler trip Steam system trip Production stooping Bearing failure 6 1 2 12
Too much fuel being fired Boiler trip Steam system trip Production stooping Valve failure 6 2 2 24
Boiler low
Too much excess air Steam system trip Lower production 2
Combustion room performance Valve failure 2 2 8
Faulty flam detector Boiler trip Steam system trip Production stooping Sensor failure 6 1 3 18
Combustion air very low flow Boiler trip Steam system trip Lower production Valve failure 3 2 2 12
Combustion gas pass failure Boiler trip Steam system trip Lower production Sensor failure 5 2 3 30
Over maximum permissible working
Boiler trip Steam system trip Lower production 1
pressure Tank failure 1 1 1
Low water level Boiler trip Steam system trip Lower production Tank failure 1 2 1 15
Control
Extra water level Boiler trip Steam system trip Lower production Pipe failure 2 1 1 15
Power Failure Boiler trip Steam system trip Production stooping Tank failure 5 1 4 1
Water treatment Boiler trip Steam system trip Lower production Enviroment effect 3 1 1 20
Forced draft fan Noise in motor Boiler trip Steam system trip Lower production Motor failure 5 1 2 23
Low effect on
Air filter Dirt on sureface Low effect No effect 1
boiler Air filter failure 3 1 27

Hole in tube Boiler low Low output


Furnace efficiency Low effect Tank failure 2 3 4 11
Relieve valve damage Boiler trip Steam system trip Production stooping Valve failure 5 4 3 3
Fuel system Faulty of the trip valve Boiler trip Steam system trip Production stooping Valve failure 6 2 3 3

Corrosion Boiler shutdown Steam system trip Production stooping


Piping system Pump failure 1 4 2 23

Failed to open Boiler shutdown Steam system trip Low productivity


Safety valve Valve failure 2 2 2 12
Water softener Water contamination Boiler trip Low output Low productivity Bearing failure 3 1 2 20
Feed water system Pump trip Boiler trip Steam system trip Production stooping Pump failure 3 2 4 1