Process Step / Potential Failure

Potential Failure Mode Potential Causes Current Controls/Tactics

Input Effects
What are the existing
What is the What is the impact on
controls and procedures
process step and In what ways does the the Key Output What causes the Key Input to go
(inspection and test) that
input under Key Input go wrong? Variables (Customer wrong?
prevent either the cause or
investigation? Requirements)?
the Failure Mode?

Overheating(Bearings) Bearing Failure/Seizure Mal-Lubrication Bearing Greasing

Overheating(Windings) Winding Failure Inactive Cooling fan Winding cleaning

Drive Motor Communication loss Mill unable to run Instrumentation error Inspection/Servicing
Bad Bearings
High Vibration Defect Bearing Failure/Seizure Conditioning,Misalignment and Vibration Analysis
Soft Foot
Coupling Greasing/Vibration
Overheating Coupling failure/seizure Mal-Lubrication
Analysis
Drive Couplings
Vibration Coupling failure/seizure Misalignment Vibration Analysis

Bad Bearings
High Vibration Defect Bearings/Gears Failure Conditioning,Misalignment and Vibration Analysis
Gearbox Soft Foot
Mal-Lubrication and Inactive
Overheating Bearings/Gears Failure Cooling fans and Oil analysis
cooling
Bad Bearings
High Vibration Defect Bearings/Gears Failure Conditioning,Misalignment and Vibration Analysis
Pinion Gear Soft Foot
Mal-Lubrication and Inactive
Overheating Bearings/Gears Failure Cooling fans and Oil analysis
cooling

Girth Gear High Vibration Defect Bearings/Gears Failure Misalignment and Looseness Vibration Analysis

Mal-Lubrication/Faulty grease Level sensor

Overheating Gears Failure
system inspection/Servicing
Contaminated Oil and Bad
High Vibration Defect Bearings Failure Vibration Analysis
Trunnion Bearings Bearings Condition
Overheating Bearings Failure Inactive cooling/Faulty Radiator Cooling fans and Oil analysis
Mill Shell Leakage Spilllage Worn Liners Inspection and Replacement
Blockage Spilllage Conveyor overloading Operational Monitoring
Feed Spout Tank sedimentation/Low flow(Raw
Gland Water stoppage Seal tear Pump inspection/tank desilting
water pumping)
Filter clogg Oil Contamination Dirt/Water Ingress Filtration System/Oil analysis
Lube System High Vibration
Overheating Defect/Bad Bearings Inactive cooling/Faulty Radiator Cooling fans
Condition
Panel Wear/Tear Oversize pulp(feed) Aging/Operational impacts Inspection and Replacement
Trommel Inspection ,retightening and
Bolt break Trommel Tear Design Error/Looseness
Replacement
 Actions Recommended

What are the actions for

reducing the occurrence of
the cause, or improving
detection?

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections
OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

OEM Annual Inspections

 Technical Element Potential Failure Potential Failure
Entity Number Potential Causes
/Component Mode Effects

What is the impact on

What is the process
What is the unique ID In what ways does the the Key Output What causes the Key
step and input under
of technical element? Key Input go wrong? Variables (Customer Input to go wrong?
investigation?
Requirements)?

Overheating(Bearings) Bearing Failure/Seizure Mal-Lubrication

Overheating(Windings) Winding Failure Inactive Cooling fan

12-ML-02 Drive Motor Communication loss Mill unable to run Instrumentation error

Bad Bearings
High Vibration Defect Bearing Failure/Seizure Conditioning,Misalignment
and Soft Foot

Overheating Coupling failure/seizure Mal-Lubrication

12-ML-02 Drive Couplings
Vibration Coupling failure/seizure Misalignment

Bad Bearings
High Vibration Defect Bearings/Gears Failure Conditioning,Misalignment
12-ML-02 Gearbox and Soft Foot
Overheating Bearings/Gears Failure Mal-Lubrication
Bad Bearings
High Vibration Defect Bearings/Gears Failure Conditioning,Misalignment
12-ML-02 Pinion Gear and Soft Foot
Overheating Bearings/Gears Failure Inactive cooling
Misalignment and
High Vibration Defect Bearings/Gears Failure
Looseness
12-ML-02 Girth Gear
Mal-Lubrication/Faulty
Overheating Gears Failure
grease system
Contaminated Oil and Bad
High Vibration Defect Bearings Failure
12-ML-02 Trunnion Bearings Bearings Condition
Overheating Bearings Failure Mal-Lubrication

12-ML-02 Mill Shell Spilllage Worn Liners

Leakage
Blockage Spilllage Conveyor overloading
12-ML-02 Feed Spout Tank sedimentation/Low
Gland Water stoppage Seal tear
flow(Raw water pumping)

Filter clogg Oil Contamination Dirt/Water Ingress

12-ML-02 Lube System High Vibration
Inactive cooling/Faulty
Overheating Defect/Bad Bearings
Radiator
Condition

Panel Wear/Tear Oversize pulp(feed) Aging/Operational impacts

12-ML-02 Trommel
Bolt break Trommel Tear Design Error/Looseness
Current Maintenance Current Component Failure
MTBF MTTR
Strategy Controls/Tactics Frequency
What are the existing
controls and
procedures
Run-to-failure/ What is the failure Expected per Actual per Expected per Actual per
(inspection and test)
Preventive/ Predictive rate week week week week
that prevent either the
cause or the Failure
Mode?

Preventive Bearing Greasing 3years

Preventive Winding cleaning >3years

Preventive Inspection/Servicing Quarterly 150 152 1.5 0.5

Predictive Vibration Analysis 3years

Preventive Coupling Greasing >3years

150 152 1.5 0.5
Predictive Vibration Analysis >3years

Predictive Vibration Analysis >3years

150 152 1.5 0.5
Predictive Oil analysis >3years

Predictive Vibration Analysis >3years

150 152 1.5 0.5
Preventive Cooling fans cleaning >3years

Predictive Vibration Analysis >3years

150 152 1.5 0.5
Level sensor
Preventive >3years
inspection/Servicing

Predictive Vibration Analysis >3years

150 152 1.5 0.5
Predictive Oil analysis >3years
Inspection and
Preventive Bi-Yearly 150 152 1.5 0.5
Replacement
Predictive Operational Monitoring Monthly
Pump inspection/tank 150 152 1.5 0.5
Preventive Yearly
desilting

Preventive Filtration System Weekly

150 152 1.5 0.5
Preventive Cooling fans cleaning Weekly

Inspection and
Preventive Quarterly
Replacement
150 152 1.5 0.5
Inspection ,retightening
Preventive Quarterly
and Replacement
 Contributing Factors to Actions
Availability Identified Gaps/Challenges
Gaps/Challenges Recommended

What are the identified Any identified

Expected per Actual per
current maintenance contributing factors to
week week
shortfalls/gaps/challenges? gaps?

NA NA NA

NA NA NA

91% 91% Backup of all Stratix

Programming Update Start up challenges
Switches quarterly

NA NA NA

NA NA NA
91% 91%
NA NA NA

NA NA NA
91% 91%
NA NA NA

NA NA NA
91% 91%
NA NA NA

NA NA NA
91% 91%
Greasing system replacement Defective Proximity Replace Proximity
plan sensor sensor quarterly

NA NA NA
91% 91%
NA NA NA

91% 91% NA NA NA

Non-optimal Design Poor Design Redesign spout liners

91% 91%
NA NA NA

Feed Spout Non-optimal Design Contamination ingress Redesign spout liners

91% 91%
NA NA NA

NA NA NA
91% 91%
Non-optimal Design Broken bolts Redesign anchorage
Run-to-failure
Preventive
Predictive
Weekly
Monthly
Quarterly
Bi-Yearly
Yearly
3years
>3years