Action Required: Yes X No

Due Date: 10 April 2009

Response to: John Hughes

Reliance Infrastructure Ltd. B&V Project 161890

Sasan UMPP B&V File 14.0100
4 April 2009
C-BV-RE-0783
E-mail
Attn: Vipin Gupta
Building A-31
Sector – 64
Noida – 201 307 (U.P.)
India
Subject: FMEA for Coal Handling System

Gentleman:

Enclosure 1 is the updated Failure Modes and Effects Analysis (FMEA) Report for the
SUMPP Overland Conveyor that was revised based on our conference call on
Wednesday, 1 April 2009. Enclosure 2 is the same results sorted by highest RPN
number to the lowest.

Black & Veatch has reviewed in greater detail all the material handling components with
a RPN of 30 or greater. Greater explanation on how to reduce the RPN's of the
conveyor components is summarized in the columns in the enclosure that are entitled
"Detection Controls" and "Actions Required". Numerical ratings were revised and
recalculated for both yellow and green-highlighted RPN columns. As you know, the
yellow shaded RPN numbers assume no mitigation actions are implemented whereas
the green shaded RPN numbers are assessed assuming mitigation actions are
implemented.

As discussed in the conference call B&V believes that for us to answer some of the
questions raised by RInfra requires a Reliability, Availability, Maintainability (RAM)
analysis on the Coal Handling System from the beginning of the overland conveyor at
the mine up to the coal silos.

The enclosed results of our FMEA study are considered complete and final. As a next
step, we recommend that B&V develop a RAM model of the system and complete a
Monte Carlo simulation of the Sasan UMPP plant coal handling system. To complete
such analysis B&V would utilize B&V's PowrRAM Model.

Following the development of the RAM model for the Coal Handling System, an initial
Monte Carlo Simulation would be run which would assess the likely availability of the
coal handling system as currently envisaged. A second Monte Carlos simulation would
then be run after the impact of mutually agreed mitigation actions are included in the
RAM model. This run would result in an assessment of the likely availability of the coal
handling system with the mitigation actions in place. The availability determined from
the second run would be greater than that of the first due to the implementation of
mitigation measures. With such information, RInfra then could decide what design
changes or operating changes might be cost effective or necessary.

Below are listings of required input to run the Monte Carlo simulation as well as the
resulting output of the simulation analysis.

Black & Veatch Corporation ⋅ 11401 Lamar ⋅ Overland Park, KS 66211 USA ⋅ Telephone: 913.458.2000
 Page 2

RINFRA B&V Project 161890

Sasan UMPP 4 April 2009

REQUIRED INPUT
• Expected plant burn rates
• Estimated Mean Time Between Failure (MTBF) and Mean Time To Repair (MTTR)
• Equipment redundancy
• Equipment type
• Key Equipment specifications
• Short term storage capacity
• Scheduled equipment outages
• Mitigation Measures (Applied prior to second RAM analysis)

EXPECTED OUTPUT OR RESULTS

• Inherent availability and reliability of the base design
• Inherent availability and reliability of the design with mitigation actions implemented
• Equivalent availability of system and components
• Impacts of design modifications and changes to operating and maintenance
conditions
• Identification of critical equipment significantly affecting overall availability
• Impacts on plant generation based on failure of various components in the coal
handling system.

The model would simulate failures, repairs, scheduled outages, coal storage, and coal
burn rates and predict the expected impacts on plant availability/generation of the coal
delivery system. In addition to modeling the coal handling system including the overland
conveyor, we will also address the ability of the system to replenish storage while
meeting plant coal consumption rates following an equipment failure.

With this information, RInfra could determine the optimum or preferred amount of onsite
coal storage necessary to achieve a preferred level of inherent power plant availability

Please confirm whether or not RInfra would like to have B&V set up the RAM model and
complete the recommended simulation runs. We can discuss this during this coming
weekly conference call.

Very truly yours,

BLACK & VEATCH

John Hughes
Project Manager

WCH
Enclosures

cc: RInfra Communication Center, P. Padmanabhan, S. Kapur, J. Srikant, T.

Guenther, A. Pattani, Sasan – By E-mail
 Enclosure 1

Risk Risk
Potential Potential S Potential O D S O D
Component Item/ Detection Priority Priority
Failure Effect(s) of Severity Cause(s) of Occurrence Detection Action(s) Required with Notes Severity Occurrence Detection Additional Notes
Number Component Control(s) Number Number
Mode(s) Failure Rating Failure Rating Rating Rating Rating Rating
(RPN) (RPN)
Damage from Stop conveyor
1 Conveyor 4 Accident 1 None N/A 4 Replace section of conveyor 4 1 N/A 4
truck impact (catastrophic)

Bridge structure and conveyor

Damage from sustain significant damage;
2 Conveyor 8 Natural disaster 1 None N/A 8 Replace bridge and conveyor section 8 1 N/A 8
flooding Stop conveyor
(catastrophic)

Install antennas for belt rip detection

Longitudinal Stop conveyor for repair Accident or sabotage With action S=3
3 Belt 8 2 None N/A 16 system 3 2 1 6
splitting of belt (catastrophic) (foreign object damage) With action D=1
(every 100 meters)

Tearing of belt Install magnetic flux inspection > 5 years MTBF per occurrence
Stop conveyor for repair, dig out
4 Belt splice 3 Improper jointing 3 None 5 45 system Cord Guard (GoodyearTM) or 3 3 1 9 (down at least a number of days to put in new belt
conveyor and pull belt.
(belt breaks) equivalent splice)

Tearing of belt > 5 years MTBF per occurrence

5 Belt Stop conveyor for repair 2 Failure of belt runoff limit switch 3 Belt runoff limit switches 3 18 None 2 3 3 18
(no break) (down 8-10 hours, no coal removal required)

Fire control only at ends of conveyor, fire trucks

6 Belt
Continuous thermister wire (fire detection) along
Stop conveyor for repair would need to be used along length of conveyor for
Belt fire 8 Coal combusts on belt 2 length of conveyor, open header piping/spray fire 2 32 Keep spare belt in inventory 4 2 2 16
(catastrophic) fire control.
control on each conveyor end
With spare belt S=4

Destroyed by
hurricane Stop conveyor for repair to transfer
7 Transfer Tower 3 Natural disaster 1 None N/A 3 None 3 1 N/A 3 (Out of service for 7-15 days)
(or other natural tower
disaster)

Need hoist and spreader bar. Replace complete

Faulty welding;
pulley assembly. NDT part of
Overload conditions Consider specifying low shaft
8 Pulley Assembly Pulley end disc Stop conveyor for repair 2 3 NDT (for welding) 3 18 2 2 3 12 Design/Manufacturing control
(excessive belt tension, shaft deflection) deflection criteria
(<24 hours out of service)
(>5 years per MTBF occurrence)

Need hoist and spreader bar. Replace with spare

9 Pulley Assembly
Overheating of bearing;
Bearings
Stop conveyor for repair
Lack of lubrication; Include heat and vibration sensors in bearing assembly.
2 Contamination of lubrication 3 None 5 30 bearing housing; 2 2 2 8 (<24 hours out of service)
Larger diameter bearings (6-7 years per MTBF occurrence)
With action D=2

Idlers do not work properly Loss of bearing lubricant; Proper maintenance practices
10 Idlers Bearings 0 5 4 0 None 0 5 4 0 Acceptable that 10% fail within 60,000 hours
(does not stop conveyor) Failed bearing seal (visual/ audio inspection of entire conveyor)

Continuous thermister wire (fire detection) along

length of conveyor;
Risk of belt fire if bearing failures Keep spare belt in inventory;
Idler bearing Loss of bearing lubricant; Open header piping/spray fire control on each With spare belt S=4
11 Idlers not detected and idlers allowed to 8 2 2 32 Frequent inspection and using 4 2 2 16
failure Failed bearing seal conveyor end; Without spare belt S=8
overheat translucent enclosure (hood covers)
Proper maintenance practices
(visual/ audio inspection of entire conveyor)

Need crane and replace complete drive assembly

Include thermocouple sensors in in inventory;
bearing housing; Need spare gear box in inventory;
Lack of lubrication;
Perform routine oil analysis; With detection D=2
12 Gear Box Bearings Stop conveyor for repair 4 Contamination of lubrication 3 None 4 48 2 2 2 8
Keep spare gear box and complete Without detection D=4
drive assembly in inventory; With spare S=2
Repair in shop, not in field Without spare S=4
(10 years per MTBF occurrence)

Could be replaced in field;

(one between reducer/pulley; one between
Rigid Coupling motor/reducer);
13 Mechanical failure Stop conveyor for repair 3 Fatigue or overload 2 None 5 30 Keep spare drive in inventory 2 2 5 20
Mounted Drive (very low probability of failure)
With spare S=2
Without spare S=3

Caliper fails;
Cannot stop loaded conveyor Could be replaced in field, need spares
14 Brake Pad fails; 2 Wear and tear 2 Limit switch 2 8 None 2 2 2 8
(will flood head chute) (very low probability of failure)
Actuator failure

Material carry over, potential

environmental impact;
15 Scrapers Wears out 0 Wear and tear 4 Visual 2 0 None 0 4 2 0
Maintenance/cleaning issues
(does not stop conveyor)
 Enclosure 1

Risk Risk
Potential Potential S Potential O D S O D
Component Item/ Detection Priority Priority
Failure Effect(s) of Severity Cause(s) of Occurrence Detection Action(s) Required with Notes Severity Occurrence Detection Additional Notes
Number Component Control(s) Number Number
Mode(s) Failure Rating Failure Rating Rating Rating Rating Rating
(RPN) (RPN)
Need complete spare set on hand, work should be
Take-up Winch Overload; Load cell (strain gauge); Keep spare in inventory; done in the shop
16 Bearing Shut down belt 3 3 2 18 2 3 2 12
(mechanical) Lack of lubrication Low oil level sensor Work done in shop With spare S=2
Without spare S=3

More conservative design (higher Need spares on site;

Overstress;
Take-up Winch Wire rope system; safety factor); Work should be done at site
17 Shut down belt 3 Wear and tear on rope; 3 Load cell (strain gauge) 4 36 1 2 4 8
(mechanical) Sheave assembly Keep spare in inventory; With spares S=1
Lack of lubrication in sheaves
Work done at site Without spares S=3

Single phasing;
Contaminants, abrasion, and transient voltage surges can
Install RTD's or thermocouples in Need complete spare set on hand;
cause phase to phase shorting of windings, turn to turn
motor windings and bearings; Work should be done in the shop
Take-up Winch shorting, and grounding of winding;
18 Motor failure Shut down belt 2 3 None 5 30 Ensure application of proper 2 3 2 12 With RTD D=2
(electrical) Thermal deterioration of insulation due to unbalanced
protective relaying and good Without RTD D=5
voltages, high load demand, undervoltage, overvoltage,
preventive maintenance practices (replace in 2 shifts)
locked rotor condition and excessive starts;
Insulation failure due to transient voltage surges

Faulty welding; NDT part of Design/Manufacturing control

Belt Turn Over
19 Pulley end disc Stop conveyor for repair 2 Overload conditions (excessive belt tension, shaft 3 NDT (for welding) 3 18 None 2 3 3 18 (>5 years per MTBF occurrence)
Pulley Assembly
deflection) (<24 hours to repair)

Include heat and vibration sensors in With action D=2

Belt Turn Over Lack of lubrication; bearing housing; Without action D=5
20 Bearings Stop conveyor for repair 2 3 None 5 30 2 2 2 8
Pulley Assembly Contamination of lubrication Larger diameter bearings; (6-7 years per MTBF occurrence)
Better bearing seals (<24 hours to repair)

Belt Turn Over Idlers do not work properly Loss of bearing lubricant; Proper maintenance practices Acceptable that some fail within 60,000 hours.
21 Bearings 0 5 4 0 None 0 5 4 0
Idlers (does not stop conveyor) Failed bearing seal (visual/ audio inspection) NOTE: THERE ARE LESS THAN 10 IDLERS.

Stop at end of shift to repair

22 Skirt Board Wears out 0 Wear and tear 4 None 5 0 None 0 4 5 0 (1 shift to repair)
(does not stop conveyor)

Conveyor Hood Stop at end of shift to repair

23 Wears out 0 Wear and tear 2 None 5 0 None 0 2 5 0 (1 shift to repair)
Covers (does not stop conveyor)

Chutes and Liner Stop at end of shift to repair

24 Wears out 0 Wear and tear 4 None 5 0 None 0 4 5 0 (1 shift to repair)
Plates (does not stop conveyor)

Need spare motor on site

Conveyor Drive
Mechanical failure Worn bearing; Include RTD's or thermocouples in bearings; Without spare motor S=4
26 Motors Stop conveyor for repair 4 3 2 24 Keep spare motor in inventory 2 3 2 12
(bearing failure) Lubrication problem; Include vibration detection equipment With spare motor S=2
(mechanical)
(1-2 shifts to replace motor)

Need spare motor on site

Conveyor Drive
Mechanical failure Include RTD's or thermocouples in bearings; Without spare motor S=4
27 Motors Stop conveyor for repair 4 Excessive vibration 2 2 16 Keep spare motor in inventory 2 2 2 8
(shaft damage) Include vibration detection equipment With spare motor S=2
(mechanical)
(1-2 shifts to replace motor)

Excessive vibration;
Single phasing; Keep spare motor in inventory; Need spare motor on site;
Contaminants, abrasion, and transient voltage surges can Include RTD's or thermocouples in if no spare, take motor to winding shop
Conveyor Drive cause phase to phase shorting of windings, turn to turn motor windings; With action D=2
Electrical failure
28 Motors Stop conveyor for repair 4 shorting, and grounding of winding; 1 None 5 20 Ensure application of proper 2 1 2 4 Without spare S=4
(short in winding)
(electrical) Thermal deterioration of insulation due to unbalanced protective relaying and good With spare S=2
voltages, high load demand, undervoltage, overvoltage, preventive maintenance practices Motor trip detected by protected relays
locked rotor condition and excessive starts; (1-2 shifts to replace motor)
Insulation failure due to transient voltage surges

Electronic
controls;
Variable
Power rectifiers; High temperatures; None
29 Frequency Drive Stop conveyor for repair 3 3 2 18 Keep spare parts on site for repair 3 3 2 18 (2 days to repair)
Power Defective power electronics (has its own control panel)
(VFD)
transformers;
Power inverters

Under/Over Speed Mechanical or Mechanical or electrical failure With action O=1

30 Motor stops, stop conveyor 1 2 None 5 10 Could add redundant switches 1 1 5 5
Switches electrical failure (fails safe) (1 shift to replace switch)

Belt Misalignment Mechanical or Mechanical or electrical failure With action O=1

31 Motor stops, stop conveyor 1 2 None 5 10 Could add redundant switches 1 1 5 5
Switches electrical failure (fails safe) (1 shift to replace switch)

Pull Cord Mechanical or Contacts broken and shuts down

32 1 Mechanical or electrical failure 1 None 5 5 None 1 1 5 5
Switches electrical failure conveyor
 Enclosure 1

Risk Risk
Potential Potential S Potential O D S O D
Component Item/ Detection Priority Priority
Failure Effect(s) of Severity Cause(s) of Occurrence Detection Action(s) Required with Notes Severity Occurrence Detection Additional Notes
Number Component Control(s) Number Number
Mode(s) Failure Rating Failure Rating Rating Rating Rating Rating
(RPN) (RPN)

PLC Controller / Fail over to redundant module;

33 Electrical failure 0 Electrical failure 1 On-line diagnostics 1 0 None 0 1 1 0
Processor (does not stop conveyor)

Loss of output;
Internal component failure;
Unregulated
Motor Power Internal rectifier or condenser failure; Ensure application of proper
output;
34 Supply Stop conveyor for repair 2 Internal regulator failure; 1 On-line diagnostics 1 2 protective relaying and good 2 1 1 2
Incorrect voltage
(switchgear) Filter failure; preventive maintenance practices
level;
Short circuiting, arcing, phase fault to ground
Excessive noise

Electronic PLC to be in controlled environment;

Motor stops, stop conveyor No on-line detection
35 I / O Modules component on 1 Electronic component on card fails 2 2 4 Could add redundant I/O modules 1 1 2 2 With action O=1
(tested at factory)
card fails (quick change out)

Graphical User Redundancy exists for LCD Flat Panel;

No impact to operation
36 Interface Screen fails 0 Screen failure 2 None 5 0 None 0 2 5 0 If one fails, continue to operate and replace when
(does not stop conveyor)
(LCD Flat Panel) possible

Electronic
No emergency stop
controls; Will have redundant system to cover electronic
Uninterruptible (does not stop conveyor);
Power rectifiers; High temperatures; modules,
37 Power Supply Controlled shutdown takes place 0 2 None 5 0 Keep spare in inventory 0 2 5 0
Power Defective power electronics Need to have spare parts on site
(UPS) (redundancy exists as well as
transformers; (fix in 2 days)
battery backup)
Power inverters

Electronic No impact to operation;

Modules Does not stop conveyor
38 PC failure 0 PC failure 3 None 5 0 None 0 3 5 0 Running operator interface
(Personal (no redundancy for PC, but backup
Computer) PCs exist that can be used)

Communication
Fail over to redundant module
39 Module Electrical failure 0 Electrical failure 1 On-line diagnostics 1 0 None 0 1 1 0
(does not stop conveyor)
(PLC to PC)
 ENCLOSURE 2

Failure Mode and Effects Analysis (FMEA)

Sasan UMPP - Overland Conveyor

Results of Actions
Potential Potential S Potential O Detection D Risk Action(s) Required with Notes S O D Risk Additional Notes
Component Item/ Failure Effect(s) of Severity Cause(s) of Occurrence Control(s) Detection Priority Severity Occurrence Detection Priority
Number Component Mode(s) Failure Rating Failure Rating Rating Number Rating Rating Rating Number
(RPN) (RPN)
Bearings Stop conveyor for repair 4 Lack of lubrication; 3 None 4 48 Include thermocouple sensors in 2 2 2 8 Need crane and replace
Contamination of lubrication bearing housing; complete drive assembly in
Perform routine oil analysis; inventory;
Keep spare gear box and complete Need spare gear box in
12 Gear Box drive assembly in inventory; inventory;
Repair in shop, not in field With detection D=2
Without detection D=4
With spare S=2
Without spare S=4
Tearing of belt Stop conveyor for repair, dig out 3 Improper jointing 3 None 5 45 Install magnetic flux inspection 3 3 1 9 > 5 years MTBF per
splice conveyor and pull belt. TM occurrence
4 Belt system Cord Guard (Goodyear ) or
(belt breaks) equivalent (down at least a number of
days to put in new belt
17 Take-up Winch Wire rope Shut down belt 3 Overstress; 3 Load cell (strain gauge) 4 36 More conservative design (higher 1 2 4 8 Need spares on site;
(mechanical) system; Wear and tear on rope; safety factor); Work should be done at
Sheave Lack of lubrication in sheaves Keep spare in inventory; site
assembly Work done at site With spares S=1
6 Belt Belt fire Stop conveyor for repair 8 Coal combusts on belt 2 Continuous thermister wire (fire detection) along 2 32 Keep spare belt in inventory 4 2 2 Withcontrol
16 Fire t onlySat3ends of
(catastrophic) length of conveyor, open header piping/spray fire conveyor, fire trucks would
control on each conveyor end need to be used along
length of conveyor for fire
control
11 Idlers Idler bearing Risk of belt fire if bearing failures 8 Loss of bearing lubricant; 2 Continuous thermister wire (fire detection) along 2 32 Keep spare belt in inventory; 4 2 2 16 With spare belt S=4
failure not detected and idlers allowed to Failed bearing seal length of conveyor; Frequent inspection and using Without spare belt S=8
overheat Open header piping/spray fire control on each translucent enclosure (hood covers)
conveyor end;
Proper maintenance practices
(visual/ audio inspection of entire conveyor)
9 Pulley Assembly Bearings Overheating of bearing; 2 Lack of lubrication; 3 None 5 30 Include heat and vibration sensors in 2 2 2 8 Need hoist and spreader
Stop conveyor for repair Contamination of lubrication bearing housing; bar. Replace with spare
Larger diameter bearings bearing assembly.
(<24 hours out of service)
(6-7 years per MTBF
occurrence)
With action D=2
13 Rigid Coupling Mechanical Stop conveyor for repair 3 Fatigue or overload 2 None 5 30 Keep spare drive in inventory 2 2 5 20 Could be replaced in field;
Mounted Drive failure (one between
reducer/pulley; one
between motor/reducer);
(very low probability of
failure)
With spare S=2
18 Take-up Winch Motor failure Shut down belt 2 Single phasing; 3 None 5 30 Install RTD's or thermocouples in 2 3 2 12 Need complete spare set
(electrical) Contaminants, abrasion, and transient voltage surges can motor windings and bearings; on hand;
cause phase to phase shorting of windings, turn to turn Ensure application of proper Work should be done in the
shorting, and grounding of winding; protective relaying and good shop
Thermal deterioration of insulation due to unbalanced preventive maintenance practices With RTD D=2
voltages, high load demand, undervoltage, overvoltage, Without RTD D=5
locked rotor condition and excessive starts; (replace in 2 shifts)
Insulation failure due to transient voltage surges

20 Belt Turn Over Bearings Stop conveyor for repair 2 Lack of lubrication; 3 None 5 30 Include heat and vibration sensors in 2 2 2 8 With action D=2
Pulley Assembly Contamination of lubrication bearing housing; Without action D=5
Larger diameter bearings; (6-7 years per MTBF
Better bearing seals occurrence)
(<24 hours to repair)

26 Conveyor Drive Mechanical Stop conveyor for repair 4 Worn bearing; 3 Include RTD's or thermocouples in bearings; 2 24 Keep spare motor in inventory 2 3 2 12 Need spare motor on site
Motors failure Lubrication problem; Include vibration detection equipment Without spare motor S=4
(mechanical) (bearing failure) With spare motor S=2
28 Conveyor Drive Electrical failure Stop conveyor for repair 4 Excessive vibration; 1 None 5 20 Keep spare motor in inventory; 2 1 2 4 Need spare motor on site;
Motors (short in Single phasing; Include RTD's or thermocouples in if no spare, take motor to
(electrical) winding) Contaminants, abrasion, and transient voltage surges can motor windings; winding shop
cause phase to phase shorting of windings, turn to turn Ensure application of proper With action D=2
shorting, and grounding of winding; protective relaying and good Without spare S=4
Thermal deterioration of insulation due to unbalanced preventive maintenance practices With spare S=2
voltages, high load demand, undervoltage, overvoltage, Motor trip detected by
locked rotor condition and excessive starts; protected relays
Insulation failure due to transient voltage surges (1-2 shifts to replace motor)
5 Belt Tearing of belt Stop conveyor for repair 2 Failure of belt runoff limit switch 3 Belt runoff limit switches 3 18 None 2 3 3 18 > 5 years MTBF per
(no break) occurrence
(down 8-10 hours, no coal
removal required)
 Potential Potential S Potential O ENCLOSUREDetection
2 D Risk Action(s) Required with Notes S O D Risk Additional Notes
Component Item/ Failure Effect(s) of Severity Cause(s) of Occurrence Control(s) Detection Priority Severity Occurrence Detection Priority
Number Component Mode(s) Failure Rating Failure Rating Rating Number Rating Rating Rating Number
(RPN) (RPN)
8 Pulley Assembly Pulley end disc Stop conveyor for repair 2 Faulty welding; 3 NDT (for welding) 3 18 Consider specifying low shaft 2 2 3 12 Need hoist and spreader
Overload conditions deflection criteria bar. Replace complete
(excessive belt tension, shaft deflection) pulley assembly. NDT part
of Design/Manufacturing
control
(<24 hours out of service)
(>5 years per MTBF
16 Take-up Winch Bearing Shut down belt 3 Overload; 3 Load cell (strain gauge); 2 18 Keep spare in inventory; 2 3 2 12 Need complete spare set
(mechanical) Lack of lubrication Low oil level sensor Work done in shop on hand, work should be
done in the shop
With spare S=2
Without spare S=3

19 Belt Turn Over Pulley end disc Stop conveyor for repair 2 Faulty welding; 3 NDT (for welding) 3 18 None 2 3 3 18 NDT part of
Pulley Assembly Overload conditions (excessive belt tension, shaft Design/Manufacturing
deflection) control
(>5 years per MTBF
occurrence)
29 Variable Electronic Stop conveyor for repair 3 High temperatures; 3 None 2 18 Keep spare parts on site for repair 3 3 2 18 (2 days to repair)
Frequency Drive controls; Defective power electronics (has its own control panel)
(VFD) Power rectifiers;
Power
transformers;
3 Belt Longitudinal Stop conveyor for repair 8 Accident or sabotage 2 None N/A 16 Install antennas for belt rip detection 3 2 1 6 With action S=3
splitting of belt (catastrophic) (foreign object damage) system With action D=1
(every 100 meters)

27 Conveyor Drive Mechanical Stop conveyor for repair 4 2 Include RTD's or thermocouples in bearings; 2 16 Keep spare motor in inventory 2 2 2 8 Need spare motor on site
Motors failure Excessive vibration Include vibration detection equipment Without spare motor S=4
(mechanical) (shaft damage) With spare motor S=2
(1-2 shifts to replace motor)

30 Under/Over Mechanical or Motor stops, stop conveyor 1 Mechanical or electrical failure 2 None 5 10 Could add redundant switches 1 1 5 5 With action O=1
Speed Switches electrical failure (fails safe) (1 shift to replace switch)

31 Belt Misalignment Mechanical or Motor stops, stop conveyor 1 Mechanical or electrical failure 2 None 5 10 Could add redundant switches 1 1 5 5 With action O=1
Switches electrical failure (fails safe) (1 shift to replace switch)

2 Conveyor Damage from Bridge structure and conveyor 8 Natural disaster 1 None N/A 8 Replace bridge and conveyor 8 1 N/A 8
flooding sustain significant damage; section
Stop conveyor
14 Brake Caliper fails; Cannot stop loaded conveyor 2 Wear and tear 2 Limit switch 2 8 None 2 2 2 8 Could be replaced in field,
Pad fails; (will flood head chute) need spares
Actuator failure (very low probability of
failure)
32 Pull Cord Mechanical or Contacts broken and shuts down 1 Mechanical or electrical failure 1 None 5 5 None 1 1 5 5
Switches electrical failure conveyor

1 Conveyor Damage from Stop conveyor 4 Accident 1 None N/A 4 Replace section of conveyor 4 1 N/A 4
truck impact (catastrophic)

35 I / O Modules Electronic Motor stops, stop conveyor 1 Electronic component on card fails 2 No on-line detection 2 4 Could add redundant I/O modules 1 1 2 2 PLC to be in controlled
component on (tested at factory) environment;
card fails With action O=1
(quick change out)

7 Transfer Tower Destroyed by Stop conveyor for repair to transfer 3 Natural disaster 1 None N/A 3 None 3 1 N/A 3 (Out of service for 7-15
hurricane tower days)
(or other natural
disaster)

34 Motor Power Loss of output; Stop conveyor for repair 2 Internal component failure; 1 On-line diagnostics 1 2 Ensure application of proper 2 1 1 2
Supply Unregulated Internal rectifier or condenser failure; protective relaying and good
(switchgear) output; Internal regulator failure; preventive maintenance practices
Incorrect Filter failure;
voltage level; Short circuiting, arcing, phase fault to ground
Excessive noise

10 Idlers Bearings Idlers do not work properly 0 Loss of bearing lubricant; 5 Proper maintenance practices 4 0 None 0 5 4 0 Acceptable that 10% fail
(does not stop conveyor) Failed bearing seal (visual/ audio inspection of entire conveyor) within 60,000 hours

15 Scrapers Wears out Material carry over, potential 0 Wear and tear 4 Visual 2 0 None 0 4 2 0
environmental impact;
21 Belt Turn Over Bearings Idlers do not work properly 0 Loss of bearing lubricant; 5 Proper maintenance practices 4 0 None 0 5 4 0 Acceptable that some fail
Idlers (does not stop conveyor) Failed bearing seal (visual/ audio inspection) within 60,000 hours.
NOTE: THERE ARE LESS
THAN 10 IDLERS
22 Skirt Board Wears out Stop at end of shift to repair 0 Wear and tear 4 None 5 0 None 0 4 5 0 (1 shift to repair)
(does not stop conveyor)
 ENCLOSURE 2

Potential Potential S Potential O Detection D Risk Action(s) Required with Notes S O D Risk Additional Notes
Component Item/ Failure Effect(s) of Severity Cause(s) of Occurrence Control(s) Detection Priority Severity Occurrence Detection Priority
Number Component Mode(s) Failure Rating Failure Rating Rating Number Rating Rating Rating Number
(RPN) (RPN)
23 Conveyor Hood Wears out Stop at end of shift to repair 0 Wear and tear 2 None 5 0 None 0 2 5 0 (1 shift to repair)
Covers (does not stop conveyor)
24 Chutes and Liner Wears out Stop at end of shift to repair 0 Wear and tear 4 None 5 0 None 0 4 5 0 (1 shift to repair)
Plates (does not stop conveyor)

33 PLC Controller / Electrical failure Fail over to redundant module; 0 Electrical failure 1 On-line diagnostics 1 0 None 0 1 1 0
Processor (does not stop conveyor)

36 Graphical User Screen fails No impact to operation 0 Screen failure 2 None 5 0 None 0 2 5 0 Redundancy exists for LCD
Interface (does not stop conveyor) Flat Panel;
(LCD Flat Panel) If one fails, continue to
operate and replace when
37 Uninterruptible Electronic No emergency stop 0 High temperatures; 2 None 5 0 Keep spare in inventory 0 2 5 0 Will have redundant system
Power Supply controls; (does not stop conveyor); Defective power electronics to cover electronic
(UPS) Power rectifiers; Controlled shutdown takes place modules,
Power (redundancy exists as well as Need to have spare parts
transformers; battery backup) on site
Power inverters (fix in 2 days)

38 Electronic PC failure No impact to operation; 0 PC failure 3 None 5 0 None 0 3 5 0 Running operator interface
Modules Does not stop conveyor
(Personal (no redundancy for PC, but backup
Computer) PCs exist that can be used)

39 Communication Electrical failure Fail over to redundant module 0 Electrical failure 1 On-line diagnostics 1 0 None 0 1 1 0
Module (does not stop conveyor)
(PLC to PC)