FMEA Boiler Tube
FMEA Boiler Tube
FMEA Boiler Tube
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Risk Analysis of Water Tubes in Boiler using FEMA Risk Analysis of Water
Tubes in Boiler using FEMA Risk Analysis of Water Tubes in Boiler using FEMA
Risk Analysis of Water Tubes i...
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Abstract
Failure Mode and Effects Analysis (FMEA) technique is used 2. FMEA and Methodology of FMEA
to identify potential failure modes for a product or process
before the problem occur, to assess the risk associated with
those failure modes and identify and carrying out measures to (Chin kwai-Sang, Wang Ying-Ming, 2009) Failure
address the most serious concerns. The Failure Modes and Mode and Effects Analysis (FMEA) technique is used to
Effects Analysis (FMEA) method has been used to study the identify potential failure modes for a product or process
reliability of many different power generation systems. This before the problem occur, to assess the risk associated
paper now applies that method to a water tubes (WT) in with those failure modes and identify and carrying out
boilers. The aim of this study was to reduce the breakdown and measures to address the most serious concerns. The
specific power consumption for continuous power generation purpose of FMEA is to analyze the design characteristics
in the plant. In this study we work on the “Failure mode and
effect analysis” technique in plant. Comparison is made
relative to the planned manufacturing process to ensure
between the quantitative results of an FMEA and reliability that the resultant product meets customer needs and
field data from real water tube systems. These results are expectations. When potential failure modes are
discussed to establish relationships which are useful for future identified, corrective action can be taken eliminate or
water tube designs. continually reduce the potential for occurrences. The
Keywords: Failure Mode and Effect Analysis, Reliability FMEA approach also documents rationale for a
Analysis, Risk Analysis of water tubes in boiler. particular manufacturing process. It uses occurrence and
detection probabilities in conjunction with a severity
1. Introduction criteria develop a Risk Priority Number (RPN) for
ranking corrective action considerations (Chin and
With rapidly growing Indian economy demand for Wang, 2009).
electricity is increasing day by day. Although FMEA is needed to identify potential failure modes that
government has put most efforts to meet out this demand may adversely affect safely, government regulations
by building new plants but still gap between demand and compliance or customer satisfaction and the rate of
supply is not shorting. Government has also taken severity of their effects, the purpose of FMEA is
initiatives by setting benchmark parameters for running
power plant to follow these parameters to improve plant a) To identify critical characteristics and
efficiency. In India more than 75% of electricity is based significant characteristics.
on coal so it draws a lot of attention to improve b) To concentrate engineers focus on eliminating
efficiency of thermal power plant as there is a large product and process defects and prevent
scope of saving energy in thermal power plant. problem from occurrence.
Suratgarh Super Thermal Power Plant is one of the c) To identify potential design deficiencies before
power plant s in Rajasthan with capacity 1500 MW. It is releasing hardware for production.
bitumen coal based plant. Thermal plant runs over d) To identify potential process deficiencies before
Rankine cycle which consist boilers, turbines, production begins.
condensers and feed pumps. Water tube is a part of e) To rank order potential design & process
boiler. For continuous generation of electricity, power deficiencies for prioritizing corrective actions.
plant engineers keep attention on how to minimize plant
breakdown by reducing failure modes. More power Failure mode and effect analysis (FMEA) is an
consumption and failure modes in water tubes are big engineering technique used to eliminate potential
problems for power plant engineers. There are number failures, problems and errors in the system and
of failure mode due to corrosion, erosion, misalignment determine their effects on the operation of the product. It
of tubes, leakage of water, high pressure and temperature could be a design, manufacturing process and services of
etc. This require correct operation and routinely and products before it reaches to the customers. The analysis
timely maintenance for running continuously. of the evolution may take two courses of action. First
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International Journal of Engineering Sciences Paradigms and Researches (IJESPR)
(Vol. 12, Issue 01) and (Publishing Month: March 2014)
(An Indexed, Referred and Impact Factor Journal)
ISSN (Online): 2319-6564
www.ijesonline.com
using historical data, there may be analysis of similar process engineer is expected as a representative from all
data for similar products and/or services, warranty data, the affected activities. Team members will various the
customer complaints and any other appropriate concept, product and process design matures. For
information available to define failure. Secondly proprietary designs suppliers are responsible. FMEA
inferential statistics, mathematical modeling and stimulates the interchange of ideas between the function
simulations, concurrent engineering and reliability affected and thus promote a team approach.
engineering may be used to identify and define the
failure. Using the FMEA does not mean that one Types of FMEAs based on nature of application, and can
approach is better than the other or that one is more be classified into three basic types of
accurate than the other. Both can be efficient, accurate FMEA:
and correct if used properly and appropriately.
Any FMEA conducted properly and appropriately will a) Process FMEA
provide the practitioner with useful information that can b) Design FMEA
reduce risk (work) load in the lad system, design,
process and service. This is because it is logical and a
c) Concept FMEA
progressive potential failure analysis method (technique)
that allows the task to be performed more effectively. FMEA conduct as the steps given below:
FMEA is one of the most important early preventive
actions is system, design, process or service, which will a) Detect a failure mode.
prevent failure and errors occurring and reaching to the b) Find the severity number for the failure mode.
customer. c) Find the probability of occurrence for the
Conducting FMEA is a team approach. To conduct failure mode.
FMEA, it is recommended to cross functional team of d) Detection for the failure mode.
knowledgeable individual with expertise and design, e) Calculate the risk priority number for the
manufacturing, assembly, service and quality. The different failure modes.
responsible team of product or manufacturing/ assembly f) Recommended action for the failure modes.
engineer leads the FMEA tool. The responsible design or
In Fig. 1 Risk Priority Number (RPN) shows the risk important part in the choice of an action against failure
associated with potential problems identified during a modes. They are more threshold values in the evaluation
Failure Mode and Effects Analysis (FMEA). The basic of these actions. The failure modes that have the highest
RPN method and then examines some additional and RPN should be given the highest priority for corrective
alternative ways to use RPN ratings to evaluate the risk action. RPN = Severity (S) * Occurrences (O) *
associated with a product or process design and to Detection (D). We apply process FMEA on water tubes,
prioritize problems for corrective action. RPNs because process FMEA used to assess any processes and
calculated at the level of the potential causes of failure mostly involves manufacturing area process. For
(Severity x Occurrence x Detection). RPN do not play an effective process FMEA, a team of expertise is
IJESPR
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International Journal of Engineering Sciences Paradigms and Researches (IJESPR)
(Vol. 12, Issue 01) and (Publishing Month: March 2014)
(An Indexed, Referred and Impact Factor Journal)
ISSN (Online): 2319-6564
www.ijesonline.com
Figure 2: Boiler tube failures 2005-09 Figure 3: Tube failure types 2005-09
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International Journal of Engineering Sciences Paradigms and Researches (IJESPR)
(Vol. 12, Issue 01) and (Publishing Month: March 2014)
(An Indexed, Referred and Impact Factor Journal)
ISSN (Online): 2319-6564
www.ijesonline.com
a. Due to producing of wrong or excess quantity of air (i)Boiler Operation: The boiler under consideration
fuel mixture the temperature of tube suddenly here is of the water tube natural circulation type. The
increase. feed water enters the boiler steam drum from the
b. Due to failure of feed water pump and presences of economizer or from the feed water heater. For reducing
impurities in the circulating water in tubes occurs the tube failure there are following recommended action
the corrosion and other problems in water tubes. to be taken.
c. Due to effect of corrosion tubes have leakages the
water and due to this leakage affected the other sub a. At the time of working condition alignment of the
components. tube, excess steam temperature and pressure to be
d. Misalignment and setting of the water tubes is the check in routine maintenance.
major problem due to this vibration and sound effect b. Controlling the flow velocity in the riser tube is to
of generated. be sufficient; due to some abnormality excess steam
build up in the risers occurs the tubes may over heat
and the excess stress in the tube.
c. During the operation if the corrosion effect in tube
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International Journal of Engineering Sciences Paradigms and Researches (IJESPR)
(Vol. 12, Issue 01) and (Publishing Month: March 2014)
(An Indexed, Referred and Impact Factor Journal)
ISSN (Online): 2319-6564
www.ijesonline.com
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IJESPR
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International Journal of Engineering Sciences Paradigms and Researches (IJESPR)
(Vol. 12, Issue 01) and (Publishing Month: March 2014)
(An Indexed, Referred and Impact Factor Journal)
ISSN (Online): 2319-6564
www.ijesonline.com
Atul Kumar is pursuing PhD from Suresh Gyan Vihar University, Jaipur. He has a number of
publications in some journals of well repute. His research area is machining of aluminum metal
matrix composite. He has more than 15 years of experience in industry and in teaching
mechanical engineering and guiding projects at Graduate and Post-Graduate levels.
Vikrant Sharma is Assistant Professor in Mechanical Engineering Department at the Mody Institute
of Technology & Science, Lakshmangarh (Rajasthan). He did his B.E. from Pune University in
Production Engineering and M.Tech from MNIT Jaipur in Manufacturing System Engineering. He
has more than 6 years of experience in teaching. He is associate Member of the Institution of
Engineers (India). Vikrant Sharma is the author of the two books entitled Advanced Workshop
Technology and CNC Machine & Automation (in Hindi) published by Vardhan Publishers Jaipur.
He has also published two papers in national level conference.
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