FAILURE MO

ITEM / PROCESS : Leach tank tank agitator (400 area)

DESCRIPTION : 40-A08A/B
CORE TEAM :

FUNCTION

Severity
POTENTIAL

Class
S No.

S No.
PROCESS POTENTIAL FAILURE
EFFECT(S) OF
NAME MODE
FAILURE

2
1

1
REQU
IREM
ENTS 2
2

2
2
3

3
Abnormal Sound No Effect
2
4

4
2
5

5
Production Stop 8
6

6
Poor agitation
Reduced Production 8
7

1
8

1
9

1
10

10

High Vibration No Effect

Agitator 1
11

11

Agitators 100/200/300/ 400/

Utility area
1
12

12

8
13

13

Agitator Bearing High

Temperature Bearing Failure
8
14

14

1
15

15

Gearbox High
No Effect
Temerature 1
16

16

8
17

17

Production Stop
8
18

18

Tripping
8
19

19

Reduced Production
 Tripping
Reduced Production
8

20

20
Product
Gearbox Oil Seal
Contamination, 3

21

21
leakage Unsafe Operation

1
2

2
2

3
Abnormal Sound No Effect
2

4
2
5

5
Production Stop 8
6

6
Poor agitation
Reduced Production 8
7

7
1
8

8
1
9

9
1
10

10
High Vibration No Effect
1
11

11
Agitator
Centrifugal
100/200/300/ 400/
Pumps
Utility area
1
12

12

8
13

13

Agitator Bearing High

Temperature Bearing Failure
8
14

14

1
15

15

Gearbox High
No Effect
Temerature 1
16

16

8
17

17

Production Stop
8
18

18

Tripping
8
19

19

Reduced Production
8
20

20

Product
Gearbox Oil Seal
Contamination, 3
21

21

leakage Unsafe Operation

ILURE MODE AND EFFECTS ANALYSIS
PROCESS RESPONSIBILITY :

FMEA DATE 03.04.2018(ORIGINAL) :

Occurrence

Detection
S No.

S No.

S No.
POTENTIAL CAUSE(S)/ CURRENT PROCESS

RPN
MECHANISM(S) OF FAILURE CONTROLS PREVENTION

Gear/ pinion/ bearings

LLF 1 4
1

1
damaged
Bottom bush damaged PM 1 6
2

2
Gearbox bearings damaged Condition monitoring 1 4
3

3
Agitator Shaft Bearing
Bi-weekly Inspection 1 4
4

4
damaged
Oil in gearbox
Current AMP in DCS, 5 30
5

5
emptied/lowered

Agitator blades broken/Bent PM 1 8

6

6
Gearbox drive failure LLF/ CM 2 32
7

7
Gearbox oil contamination Bi-weekly Inspection 1 2
8

8
Botttom support bush wear DCS indication
(Amperes drop, ) 1 3
9

9
out
Gearbox bearings damaged PM 1 2
10

10

10
2

Oil in gearbox
Shift LLF 5 15
11

11

11
3

emptied/lowered

Agitator blades broken/Bent Condition monitoring 1 1

12

12

12
1

Grease contamination 1 16
13

13

13
2

Shift LLF, PM,

Bearing grease Condition monitoring 1 16
14

14

14
2

emptied/lowered
Gearbox oil contamination 5 10
15

15

15
2

Shift LLF, PM,

Oil in gearbox Condition monitoring 5 15
16

16

16
3

emptied/lowered
Tank choked with rubber
Current AMP in DCS, 1 8
17

17

17
1

crumbs
Gearbox drive failure Shift LLF 1 16
18

18

18
2

2
Agitator blades broken/Bent Condition monitoring 16
19

19

19
1
 Equipment operating in 2
PM, 16
20

20

20
1
reverse DOR

Wearing of seal over a period

Shift LLF, PM 2 12
21

21

21
2
of continuous operation

Gear/ pinion/ bearings

LLF 1 4
1

1
damaged
Bottom bush damaged PM 1 6
2

2
Gearbox bearings damaged Condition monitoring 1 4
3

3
Agitator Shaft Bearing
Bi-weekly Inspection 1 4
4

4
damaged
Oil in gearbox
Current AMP in DCS, 5 30
5

5
emptied/lowered

Agitator blades broken/Bent PM 1 8

6

6
Gearbox drive failure LLF/ CM 2 32
7

7
Gearbox oil contamination Bi-weekly Inspection 1 2
8

8
Botttom support bush wear DCS indication
(Amperes drop, ) 1 3
9

9
out
Gearbox bearings damaged PM 1 2
10

10

10
2

Oil in gearbox
Shift LLF 5 15
11

11

11
3

emptied/lowered

Agitator blades broken/Bent Condition monitoring 1 1

12

12

12
1

Grease contamination 1 16
13

13

13
2

Shift LLF, PM,

Bearing grease Condition monitoring 1 16
14

14

14
2

emptied/lowered
Gearbox oil contamination 5 10
15

15

15
2

Shift LLF, PM,

Oil in gearbox Condition monitoring 5 15
16

16

16
3

emptied/lowered
Tank choked with rubber
Current AMP in DCS, 1 8
17

17

17
1

crumbs
Gearbox drive failure Shift LLF 1 16
18

18

18
2

2
Agitator blades broken/Bent Condition monitoring 16
19

19

19
1

Equipment operating in 2
PM, 16
20

20

20
1

reverse DOR

Wearing of seal over a period

Shift LLF, PM 2 12
21

21

21
2

of continuous operation
 Rev. Number : 3
IS Rev. date : 07.02.2022

FMEA NUMBER : FMEA/Department/no. Mechanical

PREPARED BY : Praveen Sangwan

ACTION RESULTS

Occurrence
Detection
Severity
RESPONSIBILITY & TARGET ACTION TAKEN
RECOMMENDED ACTION(S)
COMPLETION DATE
22

ULTS
RPN
 Severity
Effect Criteria: A failure could...

Severity Injure a customer or employee

Hazardous: With Warning Be illegal

100% of product may have to be scrapped. Line

Very High
shutdown or stop ship.

A portion of the production run may have to be

scrapped. Deviation from primary process
High
including decreased line speed or added
manpower.

100% of production run may have to be reworked

Moderate
off line and accepted.

A portion of the production run may have to be

Low
reworked off line and accepted

Very Low Cause minor performance loss

Cause a minor nuisance; can be overcome with no

Minor
loss

Very Minor Be unnoticed; minor effect on performance

None Be unnoticed and not affect the performance

Occurance
Probability of Failure Time Period
Very High: More than once per day
Failure is almost inevitable Once every 3-4 days
High: Generally associated with
Once per week
processes similar to previous
processes that have often failed Once per month
Moderate: Generally associated with
Once every 3 months
processes similar to
previous processes which have Once every 6 months
experienced occasional failures, but
Once per year
not in major proportions

Low: Isolated failures associated with

Once every 1-3 years
similar processes

Very Low: Only isolated failures

associated with almost identical Once every 3-6 years
processes
Remote: Failure is unlikely. No
failures ever associated with almost Once every 6-100 years
identical processes

EXAMPLE FOR IDENTIFICATION OF SPECIAL CHARACT

Classification To Indicate
CC Critical Characteristic
SC Significant Characteristic
OS Operator Safety
 Severity
For equipment

[Very high severity ranking when a potential failure mode Immediate equipment stoppage causing operation
affects safe operation and or involves noncompliance with disturbance to the extent leading to stoppage/ or requirement
government regulation without warning.] of stoppage of all Polymer or Finishing area

[Very high severity ranking when a potential failure mode Immediate equipment stoppage causing operation
affects safe operation andor involves noncompliance with disturbance to the extent leading to requirement of reduction
government regulation with warning.] in plant throughput of Polymer area

Immediate equipment stoppage causing operation

[Item inoperable (loss of primary function)] disturbance to the extent leading to requirement of reduction
in plant throughput of Polymer area

Item operable but at a reduced level of

performance.Customer very dissatisfied.

Item operable but ComfortConvenience item(s)

inoperable.Customer dissatisfied

[Item operable but at a reduced level of performance.]

Fit and finish item does not conform.Defect noticed by

most customers (greater than 75%)

Fit and finish item does not conform.Defect noticed by

50% of customers. [Equipment operable with minor loss of
other factors like lube oil ,seal leakage]

Fit and finish item does not conform.Defect noticed by

discriminating customers (less than 25%)

No discernible effect [Be unnoticed and not affect the

performance]

Occurance
Probability
> 30 %
< 30 %

<5%

<1%

< 0.03 %

< 1 per 10,000

 < 6 per 100,000

< 6 per million

< 3 per 10 million

< 2 per billion

XAMPLE FOR IDENTIFICATION OF SPECIAL CHARACTERISTICS

Criteria
Severity = 9 or 10
Severity = 5 to 8 & Occurrence = 4 to 10
Severity = 9 or10
 Detection
Ranking Detection

Almost
10
Impossible

9 Very Remote

8 Remote

7 Very Low

6 Low

5 Moderate

4 Moderately High

3 High

2 Very High

1 Almost Certain

Ranking
10
9

5
 4

Control
Required
Required
Safety Sign
Off
 Detection
Criteria: Liklihood the existence of a defect will be detected by test
Ranking
content before product advances to next or subsequent process

No current process control; Cannot detect or is not analyzed. [Cannot

10
be detected, sudden failure]

Failure Mode and/or Error (Cause) is not easily detected (e.g.,

9
random audits)

Failure Mode detection post-processing by operator through

8
sampling/ visual/tactile/audible means

Failure Mode detection in-station by operator through

visual/tactile/audible means or post-processing through use of
7
sampling / attribute gauging (go/no-go, manual torque check/clicker
wrench, etc.

Failure Mode detection post-processing by operator through use of

variable gauging or in-station by operator through the use of attribute 6
gauging (go/no-go, manual torque check/clicker wrench, etc.)

Process is monitored via statistical process control (SPC) and

manually inspected [LLF, Field Rounds from Maintenance Team, 5
Operators]

Failure Mode detection post-processing by automated controls that

4
will detect discrepant part and lock part to prevent further processing.

Failure Mode detection pre processing by automated controls that

will detect discrepant part and lock part to prevent further processing. 3
[identified during PM, CM]

Controls are almost certain to detect defect before it moves to next

2
process. [DCS Display]

Controls are certain to detect defect before it moves to next process.

1
[online monitoring,Alarms, interlocks etc]
 FMEA Documents
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