FAILURE MODE & EFFECT ANALYSIS (FMEA)

FMEA
Part : Rotary Kiln Cement Plant
Team : Group ALPHA (WIDY WIBISONO - NIM: 2019610030, MULIA FADLY NASUTION - NIM: 2019610031, ADE YOGA PRASETYA - NIM: 2019610006)

Occurence

Detection
Current Control Action Results Action Taken

Severity
Potential Person
Sub Potential Potensial Effect(s) Remarks &
System cause(s) of RPN in
System Failure Mode of Failure Recommendation
Failure Charge
Preventive Detection Action taken S O D RPN

Periodically check shell

Periodically check shell
thickness and relining
Periodical thickness and relining with
Excessive wear Damage on shell, Thermal Visual check, with new plate when
5 1 check shell 2 10 new plate when remaining Inspector - - - -
of kiln shell crack or breaking corrosion thickness check remaining thickness less
thickness thickness less than 50 % or
than 50 % or change
change shell partially.
shell partially.

Roller trunnion
1 5 Inspector - - - -
bearing overheat
Shell Monitor
Kiln Shell Wear of roller Bearing Periodically check Periodically check
5 1 bearing
misalignment and tyre temperature alignment and adjust alignment and adjust
Abnormal contact temperature
between girth gear 1 5 Inspector - - - -
and pinion

Periodical
Unproper shell
Brick lining easily Deformation check shell Visual check,
profile and run 5 1 1 5 Inspector - - - -
fallen down of shell profile and temperature
out
run out

Periodically
( normal migration : 3 - 12 ( normal migration : 3 -
check
1 5 mm/rev )/ check every 3 Inspector 12 mm/rev )/ check every - - - -
migration/slip
years 3 years
shell to tyre

Wear of pad
High ovality on Brick lining easy Measure
5 liner or wear 1
tyre segment fallen down migration, ovality Replace pad liner - - - -
of inside tyre Replace pad liner
according to actual gap
according to actual gap
Periodically between shell and tyre or
1 5 between shell and tyre or Inspector
check ovality insert additional shim
insert additional shim
between pad liner and
between pad liner and shell - - - -
shell

Periodical
check stop
Tyre and When stop ring damage, no When stop ring damage,
ring and
Roller Tyre release Breaking of part hold tyre position. So, no part hold tyre position.
Kiln shutdown 5 1 stopper Visual check 1 5 Inspector - - - -
from position stop ring tyre will shift and can So, tyre will shift and can
condition,
release from roller release from roller
especially
welding point
 FAILURE MODE & EFFECT ANALYSIS (FMEA)
FMEA
Part : Rotary Kiln Cement Plant
Team : Group ALPHA (WIDY WIBISONO - NIM: 2019610030, MULIA FADLY NASUTION - NIM: 2019610031, ADE YOGA PRASETYA - NIM: 2019610006)

Tyre and

Occurence

Detection
Current Control Action Results Action Taken

Severity
Roller Potential Person
Sub Potential Potensial Effect(s) Remarks &
System cause(s) of RPN in
System Failure Mode of Failure Recommendation
Failure Charge
Preventive Detection Action taken S O D RPN

Radical wear of
Too much Adjust roller
trust roller Kiln shutdown 5 1 Visual check 1 5 Inspector - - - -
thrusting position
surface

ROTARY
KILN

Excessive wear
Kiln cannot move Adjust roller
of surface tyre 5 Misalignment 1 Visual check 1 5 Inspector - - - -
up/down easily position
and roller

Make sure good

Make sure good installation
Looseness installation of brick
Brick retainer Visual check of brick retainer by tag weld
Brick Shell deform 5 and breaking 1 Visual check 1 5 Inspector retainer by tag weld nut - - - -
fallen down bolt condition nut and use stainless steel
of bolt and use stainless steel
bolt
bolt

Centralized
vibration and
bearing Raise of bearing
Vibration, abnormal
Shortage of temperature temperature,
noise of teeth 5 1 1 3 Periodically check Inspector Periodically check - - - -
oil monitoring, abnormal noise,
contact
trending on oil flow rate
vibration and
temparature

Damage of
bearing

Centralized
vibration and
Bearing Vibration, metal bearing Vibration,
contamination on oil Excessive temperature abnormal noise, Periodically check, and Periodically check, and
5 1 1 3 Inspector - - - -
lubrication, bearing load monitoring, raise of bearing coupling alignment coupling alignment
damage, noise trending on temperature
vibration and
temparature
 FAILURE MODE & EFFECT ANALYSIS (FMEA)
FMEA
Part : Rotary Kiln Cement Plant
Team : Group ALPHA (WIDY WIBISONO - NIM: 2019610030, MULIA FADLY NASUTION - NIM: 2019610031, ADE YOGA PRASETYA - NIM: 2019610006)
Bearing

Occurence

Detection
Current Control Action Results Action Taken

Severity
Potential Person
Sub Potential Potensial Effect(s) Remarks &
System cause(s) of RPN in
System Failure Mode of Failure Recommendation
Failure Charge
Preventive Detection Action taken S O D RPN

Raise of bearing
Vibration, abnormal Check oil flow
Damage of Shortage of temperature,
noise of teeth 5 1 from pressure 1 5 Inspector - - - -
bearing Truster oil abnormal noise,
contact gauge
oil flow rate

Excessive wear Check Periodically check Periodically check

Vibration, noise,
Gear of theeth gear Kiln stop 5 Misalignment 1 misalignment, 1 5 misalignment, wear of Inspector misalignment, wear of - - - -
visual check
coupling wear of theeth theeth theeth