Root Cause Analysis

Figure 19 : Asset FMECA Example

SEV = SeverityOCC = Occurrence Prepared by:Approved by:

DET = DetectionRPN = Risk Priority Number (SEV x OCC x DET) Rev. No.:Date:

F# FF# C# FM# SEVOCCDETRPN SEVOCCDETRPN
1.0To be able to safely granulate and blend limestone, phosphoric acid and recycle at a rate of up to 350 ton per hour, while meeting all environmental, health and quality requirements (21% P and 15%
Ca)
1.3Unable to granulate and blend at all Main drive motor bearing seized Motor amps high lack of lubrication Vibration Monthly 8 3 3 72 0
1.3 Main drive motor bearing seized Motor amps high lack of lubrication PM route Daily 8 3 7168 0
1.31.3 Main drive motor bearingMain drive motor bearing seizedseized Motor amps highMotor amps high misalignmentmisalignment Precision MaintenanceVibration As NeededMonthly^8833351207200
1.3 Main drive motor winding failed Motor amps high insulation breakdown None 8 210160 0
1.31.3 Motor starterFluid drive leakingfailed Low oil level in reservoirPug mill alarm random reasonloose connections PM routeIR DailyMonthly^834334963600
1.3 Fluid drive crown tooth coupling seized Pug mill alarm lack of lubrication PM route Daily 8 1 3 24 0
1.31.3 GearboxGearbox seizedseized Pug mill alarmPug mill alarm lack of lubricationlack of lubrication Oil AnalysisPM route MonthlyDaily^8855262408000
1.31.3 GearboxGearbox bearing seizedseized Pug mill alarmPug mill alarm lack of lubricationlack of lubrication PM routeOperator Rounds DailyShift^8855321208000
1.3 Gearbox bearing seized Pug mill alarm lack of lubrication Oil Analysis Monthly 8 5 6240 0
1.31.3 Gearbox bearingGearbox leakingseized Pug mill alarmPug mill alarm lack of lubricationlack of lubrication PM routeOperator Rounds DailyShift^8355331204500
1.31.3 GearboxGearbox leakingleaking Pug mill alarmPug mill alarm lack of lubricationlack of lubrication Operator RoundsOil Analysis DailyMonthly^335544606000
1.31.3 Gearbox out put coupling (2)Pillow block bearings (2) seizedbroken spring Motor amps highPug mill alarm lack of lubricationlack of lubrication VibrationQPM MonthlyAnnual^4856331446000
1.3 Pillow block bearings (2) seized Motor amps high lack of lubrication PM route Daily 8 6 4192 0
1.31.3 Pillow block bearings (2)Cooper bearings (2) seizedseized Motor amps highMotor amps high lack of lubricationlubrication contamination PM routePM route DailyDaily^88666428819200
1.3 Cooper bearings (2) seized Motor amps high Improper installation Precision Maintenance As Needed 8 6 5240 0
1.31.3 Cooper bearingsCooper bearings seizedseized Pug mill alarmPug mill alarm misalignmentmisalignment Precision MaintenanceVibration As NeededMonthly^881135244000
1.31.3 Vessel shaft sealZero speed switch (2) failed openleaking Motor amps highPug mill seal leaking random stressesabrasive wear Operator RoundsOperator Rounds ShiftShift^289442726400
1.3 Zero speed switch wiring (2) failed to ground Motor amps high random stresses Operator Rounds Shift 8 4 2 64 0
1.3 Zero speed switch coupling (hose) (2) broken pug mill alarm random stresses Operator Rounds Shift 8 8 2128 0
1.31.3 Packing (2)Packing (2) wornworn No packing water flowPacking sleeve leaking excessively lack of water flowabrasive wear Operator RoundsOperator Rounds ShiftShift^2766252102400
1.31.3 Packing (2)shaft sleeve (2) wornworn Packing sleeve leaking excessivelyNo packing water flow abrasive wearlack of water flow PM routePM route DailyDaily^7261672521400
1.31.3 shaft (2)Pins brokenworn Wet product at discharge chutePug mill alarm overloadsabrasive wear Operator RoundsQPM ShiftQuarterly^26112848400
4.0Unable to meet quality requirements Paddles worn Wet product at discharge chute abrasive wear Operator Rounds Shift 6 2 8 96 0
4.0 Paddle shear bolt not relieving at correct shear point Wet product at discharge chute hard bolt Operator Rounds Shift 6 2 9108 0
4.0 Field start and stop station failed Machine does not start or stop random stresses None 8 110 80 0
3.0Unable to meet EHS requirements Machine guards damaged Defective guard wear or impact damage Operator Rounds Shift 5 2 1 10 0
3.03.0 Fume ductCentral lubrication system pluggedleaking No bearing lubricationHigh odor levels in room pinched lines or contaminationdefective joints or damaged piping PM routeOperator Rounds DailyShift^26212636800
3.03.0 Central lubrication systemLubrication pump inoperablebroken line Low grease line pressureLubrication pump fast cycling random stresseswear or damage PM routePM route DailyDaily^661533189000
3.03.0 Machine doorsLubrication system low air switch hard to removeinoperable at low pressure Door stuck closedHidden failure product build up around the door edgesrandom stresses 0 None 16 101101 6010 00
3.0 Pre-mixer discharge plugged Plugged feed chute high moisture content in the incoming material Operator Rounds Shift 8 6 2 96 0
3.0 Discharge chute plugged up Discharge chute plugged high discharge volume Operator Rounds Shift 8 10 2160 0
3.0 Base Crack/Corrosion Excessive vibration Vibration, Fatigue, Machine Load, Moisture, Damage to pug mill floor from cleaning Vibration Monthly 1 10 2 20 0
3.0 Vessel corroded Product leak moisture NDT Annual 4 1 2 8 0

POTENTIAL EFFECT(S) OF FAILURE POTENTIAL CAUSE(S) OF FAILURE CURRENT CONTROLS CURRENT PROCESS

FREQUENCYKNOWN

FUNCTION FUNCTIONAL FAILURE COMPONENT POTENTIAL FAILURE MODE(S)

FAILURE MODE, EFFECTS, AND CRITICALITY ANALYSIS (SFMECA)

ACME AggregatesGranulation

J. Doe Smiley^1

System:Plant: Tim Richter

Subsystem:Analysts:

ASSESSMENT (AS RISK

IS)

ASSESSMENT (TO RISK

BE)

TASK FREQUENCYRESPONSIBILITY /DATE

9/23/2013

RECOMMENDED RISK MITIGATION ACTIONS