Effect Ranking Criteria: Severity of effect (Example)

May endanger machine or operator. Failure will occur without warning, Very high
Hazardous - without warning 10 severity ranking when the failure mode affects safe operation and/or involves
noncompliance with statutory requirements
May endanger machine or operator. Failure will occur with warning, Very high severity
Hazardous - with warning 9 ranking when the failure mode affects safe operation and/or involves noncompliance
with statutory requirements
Major disruption of production. 100% of the product may not pass quality standards.
Very High 8
Loss of primary function. Customer very dissatisfied

Minor disruption of production. A portion of the product may not pass quality standards.
High 7
Machine operable but at a lower performance level. Customer dissatisfied

Minor disruption of production. A portion of the product may not pass quality standards.
Moderate 6
Machine operable but some item(s) inoperable. Customer experience discomfort

Minor disruption of production. Some equipment full operability lost. Customer

Low 5
experiences some dissatisfaction
Very Low 4 Minor disruption of production. For some equipment, part operability lost
Minor 3 Minor disruption of production
 FAILURE MODE AND EFFECTS ANALYSIS for SERVICE WATER PUMP #NAME?

S O D R S O D R
Equipment System Primary Component/ Potential Failure Mode Potential Failure Effects E Potential Causes C Current Controls E P Actions Recommended Execution Resp. Finalized Target Date Status Actions Taken E C E P Remarks
Equipment/Process Sub-Proc ess V C T N V C T N

H ow often does cause or FM

Wh ose Respo nsibl e for the

How wel l can you d etect
How Severe is the effect?

recomme nded acti on?

Risk Priority Number
What are th e existin g contro ls

cau se o r FM?
an d pro ce dure s (i nspectio n What ar e the action s fo r Wh at are the com plete d
I n wh at ways doe s the red ucing the occurre nce of the action s taken with the

occur?
Wh at is the im pact on the Key What causes the Key Inpu t an d test) that pr event ei ghth
Eq uip ment/ Process go Cau se , o r impro ving detectio n? recalcul ated RPN? Be
wr ong? Outp ut Var iabl es? to go wrong ? th e cau se or the Fai lu re Should have ac tions only sure to include
Mode ? Should include an
SOP number. on high R PN's or easy fixes. completion month/year

pump un available
n o leakag e checked d urri ng PM as per
Suction pipe assembly Leakage 10 Normal wear and tear/ 2 Visual inspection from 2 40 D-metering needs to be done Maint engg Durring monthly PM 2 3 6 36
cur rentl y p ersist checkli st
Internal corrosion outside To be checked on next PM
pump un available
Discharge pipe n o leakag e checked d urri ng PM as per
Leakage 10 Normal wear and tear/ 2 Visual inspection from 2 40 D-metering needs to be done Maint engg Once in a year 2 4 5 40
cur rentl y p ersist checkli st
Internal corrosion outside To be checked on next PM
Service water transfer completely
All l ekages has
stopped to main plant
b een atte nded checked d urri ng PM as per
under ground pipe Leakage 10 2 8 160 D-metering needs to be done Maint engg Once in a year 6 2 6 72
wi th ne w pi pe checkli st
Normal wear and tear/ Visual inspection from
lin es.
Internal corrosion outside To be checked on next PM
Service transfer completely
stopped to main plant Befo re excavation depa rtment Du rrin g Excavati on work don e
cl earan ce i s r equi red an d und ergro und pip e All l ekages has wi th pro per gu ida nce and
Leakage 10 Improper Excavation 2 8 160 prop er mean s of excavati on as Maint engg closel y mo nite red for 4 5 6 120
mai nten ance been a tte nde d.
per safety standar ds i s un derg roun d pi peli ne whil e
Visual inspection from wo rk. To b e closely mo nitor whi le
outside requ ired . di ggi ng. di ggin g wo rk
individual pump is not available I n goo d condi tion checked d urri ng PM as per
Coupling Coupling damage 10 Over loading of coupling/ 2 Checking of coupling 2 40 inspection in every AOH. Maint engg Durring monthly PM 2 2 6 24
Improper alignment of shaft condition during PM observed checkli st To be checked on next PM
Re gul ar moni torin g of CBM checked d urri ng PM as per
Play in coupling High vibration 6 2 Checking of coupling 4 48 Maint engg Durring monthly PM Healthy 2 3 5 30
Failure of spider/bore size condition during PM repo rts i s req ui red checkli st To be checked on next PM
pump unable to deliver flow, Prop er materi al shou ld b e Ch ecked on no de fect fou nd ti ll
Pump casing Failure of pump casing pressure 10 Improper material of 1 Visual inspection from 2 20 menti oned in PR . Maint engg PMI test done 2 1 6 12
construction outside augu st 2 015 no w To be checked on next PM

10 Corrosion/Erosion/abrasion 1 Observation during 8 80 Insfection in every AOH Maint engg Durring monthly PM no de fect fou nd ti ll checked d urri ng PM as per 5 3 5 75
in service Overhauling no w checkli st To be checked on next PM

leakage of Service water Durri ng P M and

Discharge side flange flange bolts failure Loss of Service Water 3 4 2 24 checking in PM Maint engg r utin e Healthy checked d urri ng PM as per 2 2 5 20
from flange looseness due to vibration/ checkli st
rusting/Corrosion Observation during PM mai nten ance
To be checked on next PM

Damage of gasket under No defe ct checked d urri ng PM as per

flange Gaskets 3 pressure/ poor gasket 4 2 24 checking in PM Maint engg Durring monthly PM 2 2 5 20
observed checkli st
material Observation during PM To be checked on next PM

leakage of Service water bei ng do ne as per checked d urri ng PM as per

suction side flange flange bolts failure from flange Loss of Service Water 3 looseness due to vibration/ 4 2 24 checking in PM Maint engg Durring monthly PM sch edu le checkli st 2 2 5 20
rusting/Corrosion Observation during PM To be checked on next PM

Damage of gasket under bei ng do ne as per checked d urri ng PM as per

flange Gaskets 3 pressure/ poor gasket 4 2 24 checking in PM Maint engg Durring monthly PM 2 2 5 20
sch edu le checkli st
material Observation during PM To be checked on next PM
leakage of Service water
NRV flange bolts failure from flange Loss of Service Water 8 2 2 32 checking in PM Maint engg Durring monthly PM bei ng do ne as per checked d urri ng PM as per 4 2 4 32
looseness due to vibration/ sch edu le checkli st
rusting/Corrosion Observation during PM To be checked on next PM
leakage of Service water
from flange Damage of gasket under bei ng do ne as per checked d urri ng PM as per
Flange gasket Loss of Service Water 7 2 2 28 checking in PM Maint engg Durring monthly PM 3 2 4 24
pressure/ poor gasket sch edu le checkli st
material Observation during PM To be checked on next PM
P ump can n ot be kept u nder stan d Normal wear and tear of No control bei ng do ne as per
passing 6 valve seats 1 3 18 checking in PM Maint engg Durring AOH checked on august 2016 2 1 5 10
by mode sch edu le To be checked on next PM
Premature failure of valve No control bei ng do ne as per
6 components 1 8 48 checking in PM Maint engg Durring AOH checked on august 2016 2 1 5 10
sch edu le To be checked on next PM
leakage of Service water
Service Water pump

from flange bei ng do ne as per checked d urri ng PM as per

Suction valve flange bolts failure Loss of Service Water 8 looseness due to vibration/ 2 2 32 checking in PM Maint engg Durring monthly PM sch edu le checkli st 2 2 5 20
rusting/Corrosion Observation during PM To be checked on next PM
val ve bei ng do ne as per checked d urri ng PM as per
Loss of Service Water 10 2 7 140 checking in PM Maint engg Durring monthly PM 2 1 5 10
fai lur e/dam age/jammi ng rusting/corrosion No control sch edu le checkli st To be checked on next PM
leakage of Service water
from flange Damage of gasket under
Flange gasket Loss of Service Water 7 pressure/ poor gasket 2 2 28 checking in PM Maint engg Durring monthly PM bei ng do ne as per checked d urri ng PM as per 2 1 6 12
sch edu le checkli st
material Observation during PM To be checked on next PM
P ump can n ot be kept u nder stan d Normal wear and tear of No control bei ng do ne as per checked d urri ng PM as per
passing by mode 6 valve seats 1 3 18 checking in PM Maint engg Durring monthly PM sch edu le checkli st 2 2 5 20
To be checked on next PM
Premature failure of valve No control
components 1 8 48 checking in PM Maint engg Durring AOH bei ng do ne as per Ch ecked as per 4 2 5 40 To b e checked on AOH /
6 sch edu le observa tion Leakag e persist
leakage of Service water
Discharge valve flange bolts failure from flange Loss of Service Water 8 looseness due to vibration/ 2 2 32 checking in PM Maint engg Durring monthly PM bei ng do ne as per checked d urri ng PM as per 3 2 5 30
sch edu le checkli st
rusting/Corrosion Observation during PM To be checked on next PM
val ve bei ng do ne as per checked d urri ng PM as per
fai lur e/dam age/jammi ng Loss of Service Water 10 rusting/corrosion 2 no control 7 140 checking in PM Maint engg Durring monthly PM sch edu le checkli st 5 3 5 75 To be checked on next PM
leakage of Service water
from flange Damage of gasket under
Flange gasket Loss of Service Water 7 pressure/ poor gasket 2 2 28 checking in PM Maint engg Durring monthly PM bei ng do ne as per checked d urri ng PM as per 2 2 5 20
sch edu le checkli st
material Observation during PM To be checked on next PM
Normal wear and tear of No control
P ump can n ot be kept u nder stan d bei ng do ne as per checked d urri ng PM as per
passing by mode 6 valve seats 1 3 18 checking in PM Maint engg Durring monthly PM sch edu le checkli st 2 2 5 20
To be checked on next PM
Premature failure of valve No control
bei ng do ne as per
6 components 1 8 48 checking in PM Maint engg Durring AOH sch edu le checked as per obervation 3 3 5 45 To b e checked on AOH /
Leakag e persist
Normal wear and tear/Poor
Lubrication/ Overload of
bearings/ Condi tion based inspe cti on i n AO H and no de fect fou nd ti ll
Pump bearing High Temp & vibration Bearing damage 10 6 5 300 Maint engg Durring monthly PM checked on last PM 2 2 4 16
Premature failure in service chan gin g/ye arly chan gin g lub ricatio n sch edu le no w
To be checked on next PM
Improper lubrication beari ng
10 2 fol low prop er lub ricati on 1 20 follow proper lubrication schedule Maint engg Durri ng ru tin e temp eratu re Ch ecked as per CBM rep ort 2 2 4 16 Mo nito r to be do ne on dail y
sche dul e che cku p and by ruti ne check up
pump seize no rmal ti ll no w basis
High vibration and temperature of
the bearings, other collateral Unbalance rotor/ Condi tion based D urri ng corre cti ve no ab normal iti es
Shaft Shaft Buckling damages 3 Damaged bearing 3 chan gin g/ye arly chan gin g 1 9 Inspection in AOH Maint engg mai nten ance detected ti ll n ow checked on august 2015 2 1 5 10 To b e checked on next PM/as
per CBM rep ort
Shaft Broken Complete failure of pump Material Failure Mai nt en gg & D urri ng corre cti ve no ab normal iti es checked o n dai ly basis by
10 Over torque/load 1 Motor amperage 4 40 Inspection in AOH 3 2 5 30 To b e checked on dail y basis
emd mai nten ance detected ti ll n ow DCS ope rator by DCS eng g
Impeller damage Insufficient flow , pressure
Impeller developed by pump. 5 Normal wear and 2 Discharge pressure 2 20 Inspection in AOH Mai nt Daily no ab normal iti es Checked daily 2 2 5 20
eng g,Oper ator detected ti ll n ow
tear/Internal corrosion indicator / Flow meter To be monitor on daily basis

Leakage Loss of Service Water 9 2

Checking of static leakage 1 18 follow SMP Maint engg
Durri ng mo nthl y no de fect fou nd ti ll SMP trai nni ng g iven to a ll
2 1 5 10
SMP trai nni ng to b e give n on
Mechanical seal Improper assemble of seal before trial PM &CM no w fitters. regu lar b asi s
Mai nt en gg bei ng do ne as per
Leakage Loss of Service Water 9 2 18 monitoring the quality of water Daily Checked on daily basis 2 2 5 20 Dail y water p arameter to be
Failure of sealing fluid Checking during PM &Ch emist sch edu le moni tor.
no ab normal iti es
Leakage Loss of Service Water 9 Normal wear and tear 2 Regular LLF 18 inspection in every AOH. Maint engg Durring PM &CM detected ti ll n ow Checked durring last PM 2 2 4 16
To be checked on next PM

9 secondary damage due to 2 Static leakage testing before

no ab normal iti es
Leakage Loss of Service Water 18 inspection in every AOH. Maint engg Durring PM &CM Checked durring last PM 2 1 5 10
other component failure trial detected ti ll n ow To be checked on next PM
Damage of bearing
Oil leakage 5 High vibration 5 1 25 Replace in every AOH Maint engg Durring monthly PM no ab normal iti es Ch ecked as per CBM rep ort 3 2 5 30 To b e checked on next PM/as
Oil Seal Observation during PM detected ti ll n ow per CBM rep ort.
looseness due to vibration Tightness checked during PM
Durri ng P M and
bei ng do ne as per
Base Bolts Vibration Dislocation of pump from the base 10 2 2 40 follow LLF Maint engg r utin e Checked durring last PM 3 3 4 36
sch edu le To b e checked on next PM or
mai nten ance ruti ne mai nten ance .
Corrosion due moist Conditioning monitoring
environment/ Normal wear during PM bei ng do ne as per
and tear 2 2 40 follow LLF Maint engg Durring PM &CM Checked durring last PM 3 2 5 30
sch edu le
To be checked on next PM
0 0
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 Probability of failure Ranking

Very high: failure is almost inevitable 10

9
High: Generally associated with processes/systems similar to 8
previous processes/systems that have failed 7
Moderate: Generally associated with processes/systems similar to 6
previous processes/systems which have experienced occassional 5
failures 4
Low: Isolated failures associated with similar processes/systems 3

Very low: Only isolated failures associated with almost identical 2

processes/systems
Remote: Failure is unlikely. No failures ever associated with 1
almost identical processes/systems
 Criteria: Likelihood that the existence of a defect will be
Detection detected by process controls before next or subsequent Ranking
process, or before the product leaves the process/system

Almost impossible No known control(s) available to detect failure mode known 10

Very remote Very remote likelihood that current control(s) will detect failure 9
mode
Remote Remote likelihood that current control(s) will detect failure mode 8

Very Low Very low likelihood that current control(s) will detect failure 7
mode
Low Low likelihood that current control(s) will detect failure mode 6

Moderate Moderate likelihood that current control(s) will detect failure 5

mode
Moderately high Moderately high likelihood that current control(s) will detect 4
failure mode
High High likelihood that current control(s) will detect failure mode 3

Very high Very High likelihood that current control(s) will detect failure 2
mode
Almost certain Current control(s) almost certain to detect the failure mode. 1
Reliable detection controls are known with similar
processes/systems