Risk Identification-GradingRef NoEquipment NumberEquipment DescAssemblySub-Assy or PartsSub-Sub Assy or PartsRisks - Possible Causes of FailureEffect of a Worst Likely FailureDAFT Cost of Worst Failure($)Comments1Pump SetP-45ACirculation PumpPower SupplyPower FailureDowntime$100,000$25,000 per hour DAFT Cost. Minimum 4 hours if power is turned off2Transmission lineLightening strikeDowntime$200,000Minimum 8 hours if power is lost due to failure3TransformerOil degradationDowntime$200,0004Switch BoardFireDowntime, Fire$200,000Liquid ingressImpact5Panel ConnectionLoose cable clamp boltDowntime, Fire$200,000Poor cable crimping6Drive RackDust from ProductDowntime$100,000Poor assemblyRusted into placeMotor StarterOverloadDowntime, Fire$200,0007Short circuit8Power Cable9Electric Motor10Connection11Motor frame12Base Plate13Holding Bolts14Pedestal15Foundation16Stator17Brushes18Rotor19Bearings20Shaft

&C&AConsider only those failures that are possible at the site of the equipment. Do not include far-fetched events, such as a metorite strike. Include Acts of God, such as flood, lightning, earthquake, etc, that can be expected at the site

DAFT CostsDefect And Failure True (DAFT) Cost EstimateEquipment No:Item Description:ClassificationCategoryDescriptionUnit of MeasureCost per UnitTotal No of Units UsedDAFT CostCommentsEQUIPMENTProductionSetup personnelQuality ControlDeliveryEngineeringOther Production related personnelMaintenanceRepair personnelParts personEngineeringOther Maintenance Support personnelManagementFloor SupervisorsMaintenance ManagerProduction ManagerEngineering ManagerGeneral ManagerAdministrativeMaintenance SecretaryMISAccountingLegalCost per UnitRaw MaterialDirect Labour InputIndirect Labour InputProcessing CostsUnits per HourRated Equipment RateEnergy Surge CostElectrical (Eg: High torque motors)Gas (Eg: oven temperatures)Set-upExtra material, product/tool deliveryManpower (supervisory too)Percent Reduced ProductionParts per hour lostEquipment FatigueHigh torque motor, heater elementsComputer monitors, mechanical fatigueScrap producedIs it recyclable, salvageable?QualityInspection cost, Rework costOther CostSite specific start up cost factorsBottleneck LossesCost per Time UnitDownstream Equipment StoppagesCost per Time UnitSales LostCost per Time Unit or per Saleable UnitLost Value from Curtailed Life of PartsProportion of Lump Sum Cost for Parts or Equipment Wasted Because Parts Did not Last Full LifeProportin of Lump Sum Cost for Outsourced Services WastedLABOURProductionSetup personnelQuality ControlDeliveryEngineeringOther Production related personnelMaintenanceRepair personnelParts personEngineeringOther Maintenance Support personnelManagementFloor SupervisorsMaintenance ManagerProduction ManagerEngineering ManagerGeneral ManagerAdministrativeMaintenance SecretaryMISAccountingLegalCost per UnitRaw MaterialDirect Labour InputIndirect Labour InputProcessing CostsUnits per HourRated Equipment RateEnergy Surge CostElectrical (Eg: High torque motors)Gas (Eg: oven temperatures)Set-upExtra material, product/tool deliveryManpower (supervisory too)Percent Reduced ProductionParts per hour lostEquipment FatigueHigh torque motor, heater elementsComputer monitors, mechanical fatigueScrap producedIs it recyclable, salvageable?QualityInspection cost, Rework costOther CostSite specific start up cost factorsBottleneck LossesCost per Time UnitDownstream Equipment StoppagesCost per Time UnitSales LostCost per Time UnitValue from Curtailed Life LostLump Sum Cost Proportion of Labour for Past Repairs Wasted Because Parts did not Last Full LifeDOWNTIMELost TimeLabour and Manpower Resources WastedReducedCapacity lossMaintenance timeScrapBand AidOEMTime and materialExpensesDowntime lossesToolingTooling damage caused by Machine failureMachine failure caused by Tooling damageParts & ShippingCost of this occurrenceAssociate cost to permanent fix done laterParts used for band-aid repairAmount of times band-aided till permanent fix, etc.Percentage of all other Downtime MetricsWhat percent of full speed, increased scrap, extra manpower, tool breakage, etc.TOTAL DAFT COST

Equipment CriticalityRef NoEquip Tag NoEquip DescriptionAssemblySub-Assy or PartsSub-Sub Assy or PartsRisks - Possible Causes of FailureEffect of Most Severe Possible FailureDAFT Cost of FailureLikelihood of Failure EventEquipment Criticality by Risk Matrix RatingYears Equip in Service or Expected Service Life TimeNo of Historic Failure Events to this Equipment or Possible in Life TimeAnnualised No of Failure Events due to CauseEquipment Criticality by Calculated Rating(or Estimated Inherent Risk)Comments($)L, M, H, EYr(/ Yr)($/Yr)1Pump SetP-45ACirculation PumpPower SupplyPower FailureDowntime$100,000CertainH50100.2$20,000$25,000 per hour DAFT Cost. Minimum 4 hours if power is lost2Transmission lineLightening strikeDowntime$2,000,000PossibleE5010.02$40,000Minimum 8 hours if power is lost due to failure3TransformerOil degradationDowntime$200,000LikelyH5020.04$8,0004Switch Board5Panel ConnectionFireDowntime, Safety$2,000,000PossibleE5010.02$40,0006Drive RackPower LossDowntime$200,000PossibleH5010.02$4,0007Motor StarterFireDowntime, Safety$2,000,000PossibleE5010.02$40,000

&C&ADivide Failure Events by Years in Service.The chance of failure - need to know 1) how many opportunities there are and 2) how many of them turn into a failure. Divide Failures by Opportunities.This is a numerical value for the cost of risk in your business when the equipment fails due to any cause.The assumption being made is that what happened in the past will happen in the future unless reliability is improved. If reliability improvements were made to the equipment after a previous failure, the historic number of failures will no longer be a fair representation of the equipment's future risk. You need to assess the new risk after the reliability improvement. Use the Risk Idenification Table to identify the risk before the improvement and use the Risk Treatment Table to estimate the risk after the improvement. From the analysis estimate the number of future failures in the equipment's remaining life - this will be a guess, but an educated guess.Ensure the risk matrix is calibrated to what your business is willing to pay for failure. Take the worst foreseeable failure and estimate the criticality rating from the risk matrixThese items are taken from the process map created to identify every step/equipment in the process. Do not leave any step/equipment out, because it will never be analysed and it will not be protected against the risk of failure.Here is where you start compromising your future well being - the $4000 per year risk may be seemingly so small for a business, that they would not worry about it. But when it happens they will loose a minimun $200,000.

What you must do before chosing to do nothing is know how many ways there are to have a loss of power due to equipment failure. If there are many ways for power to failure then there is far greater chance it will happen than if there is only one way to have a power failureIn this case the equipment is 10 years oldThere has been 2 power failures in the ten years

FMECA ReportFailure EffectsID NoEquip NoEquipment DescAssemblySub-Assy or PartsSub-Sub Assy or PartsEquipment CriticalityRisk Matrix or CalculatedRequired Failure-Free Service Life (Months/Years)Failure DescriptionFailure Mechanism CauseItem Failure Mode EffectsNeighbours Failure Mode EffectsSystem Failure Mode EffectsFailure SiteWhat Stage of OperationHow to Detect Onset of Failure (Symptoms)Strategies to Prevent Failure1Pump SetP-45ACirculation PumpPower SupplyH1) Power Provider failure1) Power provider outage1) Complete shutdown of operation1) Process line1) Request notification of planned outages from Power Provider2Transmission lineE50 YrInsulator failure1) Transmission line damage2) Dust/salt build-up causes tracking1) Complete shutdown1) Transmission pole insulator1) Inspect transmission poles condition1) Preventive Maintenance round to inspect poles every 2 years2) Vehicle impact1) Damage to pole2) Pole fall causes complete shutdown1) Transmission pole1) Bollards around transmission poles3TransformerE50 Yr1) Transformer fails1) Oil dielecric degrades from contamination1) De-rate transformer1) Transformer oil1) Transformer oil analysis1) Annual transformer oil analysis2) Lightning strike1) Electrical overload1) Process computer burn-out2) Complete process line shutdown1) Power system1) Install lightning protection2) Install power surge protection and UPS to key computers4Switch BoardE50 Yr1) Loss of switchboard1) FireDowntime, Safety2) Liquid ingressDowntime3) ImpactDowntime5Panel ConnectionE50 Yr1) Damage to bus bar connection1) Loose cable clamp boltsDowntime, Safety2) Poor cable crimpingDowntime, Safety6Drive RackE50 Yr1) Internal drive damage1) Dust from ProductDowntime2) Poor assemblyDowntime, Rate Loss3) Rusted into placeDowntime7Motor StarterE25Yr1) Motor starter failure1) OverloadDowntime2) Short circuitDowntime, Safety

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Risk Mgmt PlansRef NoEquip Tag NoEquip DescriptionAssemblySub-Assy or PartsSub-Sub Assy or PartsEquipment CriticalityFailure DescriptionFailure Mechanism CauseFailure Mode EffectsRisk Control StrategiesOperating, Maintenance and Work Quality StandardsFailure Strategy(Replace or Repair on Failure)Actions to be TakenImprovement ExpectedFreq of ActivityYearly Cost to PerformRisk Matrix Rating After Controls OperatingL, M, H, EProof that Actions are Completed1Pump SetP-45ACirculation PumpPower SupplyH1) Power outage1) Power provider outage1) Complete shutdown of operation1) Request notification of planned outages from Power Provider1)Install Uninterruptible Power Supplies on all process control computersL1. Final draft specifications to be reviewed by Electrical Maintenance Supervisor before issueTransmission lineE2) Transmission wire loss1) Transmission line damage1) Complete shutdown1) Preventive Maintenance round to inspect poles every 2 years1) Transmission pole condition standardRepair wires1) Install PM work order in CMMS for 2 yearly visual inspect1) No lose of power transmission lines2 Yr$2,0002) Electrical transmission line standard2) Write and distribute Transmission Pole condition standard3) Write and distribute Transmission Line standard3) Pole damage1) Vehicle impact1) Damage to pole1) Bollards around transmission poles1) Safe speed limits on-siteReplace pole on failure1) Install bollards1) No loss of power poles from impact2) Pole fall causes complete shutdown2) Develop bollard standardTransformerH1) Transformer failure1) Oil degrades from contamination1) De-rate transformer1) Annual transformer oil analysis1) Transformer oil quality standardReplace if cannot return to as-new condition standards1) Install PM work order in CMMS for annual oil sample analysis2) Develop Transformer oil quality standard1) Transformers always available for operation1 Yr$1,000L2) Lightning strike1) Electrical overload1) Complete process line shutdown1) Install lightning protection1) Lightning protection standardReplace if cannot return to as-new condition standards1) Electrical engineer is to specify required lightning protection for components in electrical specifications1) No loss of process control2) Process computer burn-out2) Install power surge protection and UPS to key computers2) Estimate costs and request capital funds to install lightning protection2) No damage from lightning strikes2Switch Board1) Loss of switchboard1) FireDowntime, SafetyReplace2) Liquid ingressDowntimeRepair damage to as-new standards3) ImpactDowntimeRepair damage to as-new standards3Panel ConnectionE1) Damage to bus bar connection1) Loose cable clamp boltsDowntime, SafetyRepair damage to as-new standards2) Poor cable crimpingDowntime, SafetyRepair damage to as-new standards4Drive RackH1) Internal drive damage1) Dust from ProductDowntimeReplace with new2) Poor assemblyDowntime, Rate LossRepair damage to as-new standards3) Rusted into placeDowntimeReplace with new5Motor StarterE1) Motor starter failure1) OverloadDowntime1Prevent overload and short circuit effectsReplace with new1) Electrical engineer is to specify required load ratings for components and short circuit current withstand rating in switchboard specification. (Note that adequate withstand ratings ensure only that the equipment will not fail catastrophically; damage to the contactor or overload relay may still occur, and they must be inspected following any motor or circuit fault that causes the protective device to operate.)1) Final draft specification to be reviewed by Electrical Maintenance Supervisor before issue2) Short circuitDowntime, SafetyReplace with new

&C&AFor the mitigation to be acceptable, the mitigation actions must 'sustantially' reduce the level of stress or the chance of stress. 'Substantially' implies a clear and unquestionable change between one state and another

Maintenance TasksID NoProcess LineEquip DescEquip Tag NoMain Assy / PartsMaint TypeFreqCarry Spare PartsLikely ProblemsCondition Monitoring Test to UseSummary of MaintenanceMaintenance ActivityCommentsBM, TBM, CBM, Design-Out, Precision1Digestion circuitCirculating pumpP-45AbearingTBM2Y1 pairBearing failure due to liquor ingressOil analysisBased on TBM for bearing. Neighbouring parts replaced at same time.Control oil level and look for shaft seal leakmechanical sealTBM2Y1Wear from product crossing seals or water hammer pressure spikesVisual observationIn case of occurred following trouble, deal with CBM each time.Check the delivery pressure/flow rate and quality of mechanical seal waterV beltCBM2Y1 setBecomes a bad situation because of belt wear, or leak from mechanical sealTension testerInspect and deal on CBM each time.impeller, casingCBM2Y1 impellerKeep spare pump (A&B is same specification)P-45Bspare pumpTBM2Y12heat exchangerE-60BbodyTBM1Y1Pin hole occurs in shell caused by erosion/corrosion around bracketUltrasonic ThicknessOverhaul and inspection (legal check)Check the every point with a thickness measurement (only outside casing), pressure test , visual check. Hot pressure test after start and visually confirm no leakagegasket1Low temperature side.Replace gasketScaling at high temperature side.Keep the spare pump in operating condition3heat exchangerE-60CbodyTBM1Y1Scaling at low temperature side. (process side)Ultrasonic ThicknessOverhaul and inspection (legal check)Check the every point with a thickness measurement (only outside casing), pressure test , visual check. Hot pressure test after start and visually confirm no leakagegasket1Replace gasket4pressure vesselZ-62bodyTBM1Y0Scaling by productUltrasonic ThicknessOverhaul and inspection (legal check)Check the every point with a thickness measurement (only outside casing), pressure test , visual check. Hot pressure test after start and visually confirm no leakage5drain tankD-61bodyTBM1Y0Corrosion caused by flashing at drain inlet nozzle.Overhaul and inspection (legal check)Check the every point with a thickness measurement (only outside casing), pressure test , visual check. Hot pressure test after start and visually confirm no leakageProtected with insert pipe.6manual valveY-valvebodyBM02Blocked drained valve (especialy high temperature liquor)Visual observationDeal as a breakdown. Keep spare valve7Steel pipelow temp side (Slurry)pipeBM00Pinhole occur caused by erosion/corrosion when we usedDeal as a breakdownInspection the fixing pointChanged to stainless steel material (SS316L) if it occurred at welded part of flange or elbow.gasket3Carbon Steel (Type 380). Ensure the welding bead/elbow bead faces counter flow.Check thickness of weld8high temp side (Liquor)pipeBM00Blockage caused by scaling.Deal as a breakdowngasket3

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Condition Monitoring TestsKindPositionCondition Monitoring Diagnostic MethodPurposePurpose for MonitoringRotating MachineryBearingWear debris analysisEarly detection of parts wearPrevent parts failureOil AnalysisEarly detection of oil problemsIndicate condition of oilVibration measurementEarly detection of abnormalities by controlling the trend.High level of production riskStator CoilInsulation diagnosisDetection of repair time.High voltage MOHeat ExchangerTube (SS, CU)Eddy currentPrevention of trouble by detecting faults.Much production loss if heat exchanger failsTube (CS)Wall thickness measurement and extreme-value analysis using the ultrasonic immersion test methodEstimate of residual life. Decision of renewal time.Steel pipe heat exchangers are known to failTube SheetColour check (Dye Penetrant)Prevention of trouble by detecting faults.Each timeStatic EquipmentMain body, NozzleWall thickness measurement,Early detection of troubles by controlling the trend. Decision of repair time. Detecting faults. Prevention of trouble, etc.Legal inspectionPT, MT, UT, RT,Each timeGL pinhole inspectionEach timePipingMain body, NozzleWall thickness measurementEarly detection of troubles by controlling the trend.Legal inspectionCablesInsulationInsulation measurementEarly detection of troubles by controlling the trend.High voltage cableHot line diagnosisTransformerInsulation oilAnalysis of gas in the oil.Early detection of troubles by controlling the trend.Special high voltage transformerWithstand voltage, acid valueEarly detection of troubles by controlling the trend.Distribution transformerBatteryBatteryCapacity testDecision of renewal time by prediction of life.Storage battery

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Long-Term ImprovementM = Major parts renewed or repaired, A = Auxiliary parts renewed or inspected, R = Repair plan, I = Inspection plan, T = TroubleItem NoEquipment ID and TypeEquipment HistoryInspectionRenewal94959697989900010203Specification, Current ConditionPartsCycleCycle1E-20 dryerInstallation: 10/85Bearing - Part No 17E4321901010During Operation5 yrM/ In October replaced with the backup Cyclo reducer.M/ On May 13, periodic service O/H - Each bearing, timing gear and sprocket was replaced - Seal consumable parts were replaced. (The sleeves were in good condition.)R/ In May, a periodical O/H was carried out on the whole unit. - Arrangements were made for a timing gear.New XYZ Seal design fitted: 3/93Rotary joint - Part No 17E4321901110During OperationAfter an IncidentM/ On May 11, the southeast RJ and the flexible tube were replaced.M/ On June 7, the northwest RJ was replaced.M/ On September 17, the north-east rotary joint was renewed.M/ The north-west RJ was renewed.T/ A/ On April 19, the northeast RJ was replaced. T/ M/ On December 30, the northwest RJ and leaking flexible tube were replaced.Previous O/H: 3/93Flexible tubeDuring OperationAfter an IncidentT/ Called on September 8. The RJ flexible tube on the east side of the exit was leaking and was replaced. The flange packing on the west side of the entrance was leaking and was replaced.Duty - 20 Ton/DTiming gearAt rest5 yrT/ A/ On May 29, the chain became loose and the tension was adjusted. The worn timing gear will be replaced later.T/ M/ On April 20, since the timing gear was worn, it was replaced and the drive chain was replaced. (Deflection of the shafts: East shaft 0,6, West shaft 0, 1) T/ On August 28, the tension of the loose chain was adjusted.R/ Arrangements were made for a timing gear.11 KW cyclo driveWingAt restWhen requiredT/ On July 13, a leak from the SS on the back edge of the collar on the east and northwest shafts and the SUS lining surface was repaired. (What was the cause? Leaks shouldnt occur here.)Revs - 10 RPMWing liningAt restWhen requiredM/ On March 5, the overflow side shaft and a steam leak from the lining were repaired. After machining, they were repaired by TIG welding.Pressure - 10K SteamXYZ sealDuring Operation5 yrT/ On February 5, the blowdown on the northwest XYZ seal was inspected. (The air valve was closed and no air was coming in. After clearing a blockage in the pipe, operations continued.)R/ Arrangements were made for consumable parts for the XYZ seal.

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Reliability GrowthReliability Growth Cause Analysis (RGCA)Business Process:Department:Date of Analysis:Equipment Number:Equipment Name:Equipment Criticality Rating:Step 1Step 2Step 3Step 4Step 5Step / Item / Part Description:Procedure Description:Process Description:Part Number:Effect of Step/Item/Part failure?Failure of Step/Item/Part causes system failure (Y/N)?Total DAFT Cost Savings Possible ($/yr):Risks and ControlsFailure Mode 1:Freq of Cause 1:Time to Repair 1:DAFT Cost:Causes of Stress/Overload:Causes of Fatigue/Degradation:Current Risk Matrix Rating:Controls to Prevent Cause:Est failures prevented after risk controls in use (/yr):New Risk Matrix Rating:DAFT Cost savings with higher reliability:Failure Mode 2:Freq of Cause 2:Time to Repair 2:DAFT Cost:Causes of Stress/Overload:Causes of Fatigue/Degradation:Current Risk Matrix Rating:Controls to Prevent Cause 2:Est failures prevented after risk controls in use (/yr):New Risk Matrix Rating:DAFT Cost savings with higher reliability:Failure Mode 3:Freq of Cause 3:Time to Repair 3:DAFT Cost:Causes of Fatigue/Degradation:Current Risk Matrix Rating:Controls to Prevent Cause 3:Est failures prevented after risk controls in use (/yr):New Risk Matrix Rating:DAFT Cost savings with higher reliability:Failure Mode 4:DAFT Cost Savings ($/yr):

- What failures are possible?- What are the full busines-wide costs (DAFT Costs)?- What causes stress in the item/part/step?- What causes fatigue to the item/part/step?___________________

- What can be done to reduce chance of failure?- What frequency of failure reduction is possible?- What savings result from improved reliability?

Risk MatrixLikelihood of Equipment Failure Event per YearDAFT Cost per Event$30$100$300$1,000$3,000$10,000$30,000$100,000$300,000$1,000,000$3,000,000$10,000,000$30,000,000$100,000,000$300,000,000$1,000,000,000Event Count per YearTime ScaleDescriptor ScaleHistoric DescriptionC1C2C3C4C5C6C7C8C9C10C11C12C13C14C15C161.522.533.544.555.566.777.588.59100Twice per weekL132HHHHEEEEEEEEEEEE30Once per fortnightL121.5MMMMHEEEEEEEEEEE10Once per monthCertainL111LLLLMHEEEEEEEEEE3Once per quarterL100.5LLMHEEEEEEEEE1Once per yearAlmost CertainEvent will occur on an annual basisL90LLMHEEEEEEEE0.3Once every 3 yearsLikelyEven has occurred several times or more in a lifetime careerL8-0.5LLMHEEEEEEE0.1Once per 10 yearsPossibleEvent might occur once in a lifetime careerL7-1LLMHEEEEEE0.03Once per 30 yearsUnlikelyEvent does occur somewhere from time to timeL6-1.5LLMHEEEEE0.01Once per 100 yearsRareHeard of something like it occurring elsewhereL5-2LLMHEEEE0.003Once every 300 yearsL4-2.5LLMHEEE0.001Once every 1,000 yearsVery RareNever heard of this happeningL3-3LLMHEE0.0003Once every 3,000 yearsL2-3.5LLMHE0.0001Once every 10,000 yearsAlmost IncredibleTheoretically possible but not expected to occurL1-4LLMHNote:Risk Level1) Risk Boundary is set at 'LOW' LevelRed = Extreme2) Based on HB436:2004-Risk ManagementAmber = High3) Identify 'Black Swan' events as B-S (A 'Black Swan' event is one that people say 'will not happen' because it has not yet happened)Yellow = Medium4) DAFT Cost (Defect and Failure True Cost) is the total business-wide cost from the eventGreen = LowBlue = Accepted