S.

No: Process/Product Function Potential Failure Mode

Low Cooling Tower

1 Improper Water flow distribution
Performance/capability

Low Cooling Tower

2 More number of CW Pump's running Condition
Performance/capability
 Low Cooling Tower
2 More number of CW Pump's running Condition
Performance/capability

Not Achieving Plant Load Factor

3 Low Cooling Tower Performance/capability
>90%

Low Liquid to Gas (L/G) ratio

Low Cooling Tower
4
Performance/capability
Loss in Efficeincy of fan
High APC

Low Cooling Tower

5 Damaged CT Fills
Performance/capability

Low Cooling Tower

6 Scale formation over Fills
Performance/capability

Low Cooling Tower

7 Damaged drift eliminators
Performance/capability

Low Cooling Tower

8 Scale formation in nozzle
Performance/capability

Low Cooling Tower

9 Low Blowdown
Performance/capability
 Low Cooling Tower
9 Low Blowdown
Performance/capability

Low Cooling Tower

10 High Relative Humidity
Performance/capability

Low Cooling Tower

11 Obstruction in air intake
Performance/capability

Low Cooling Tower

12 High Ambient Air Temperature
Performance/capability

Low Cooling Tower

13 Leakages in the CW Pipelines
Performance/capability
 GMR WARORA ENERGY LIMITED-2X
FMEA for "Cooling Tower Outlet Water Temperature

Severity
Potential Effect(s) of Failure
(S)

Non Availablity of water for atomisation in

Nozzles.

Heat transfer area of water droplet will

decrease.

Time Taken for heat transfer will decrease.

Low or No flow through fills will increase its

dryness leads to fouling in fills.

Cooling Water outlet temperature will

increase.

Low Water Flow through cooling tower

Low Water Pressure through cooling tower.

 Low Water Pressure through cooling tower.

High CT inlet water temperature

High air flow through CT

Air Ingress in CT fan through sealing doors and

gaps
Decrease in MTBF of Fans

Improper water flow

Reduction of CT performance

High evaporation loss through CT

Nozzle choking and Damages

Scale formation in Nozzles, Fills and Drift

eliminators
Decrease in Water consumption

Recirculation of water mist in air

Increase in power consumption of Fan

Low heat transfer between Water and Air

High Makeup Water Consumption

Low CW flow
High CW inlet water Temperature

Increase in running cooling fans & CW pump

numbers thereby increasing APC
 GMR WARORA ENERGY LIMITED-2X 300 MW
A for "Cooling Tower Outlet Water Temperature by 0.5 ⁰C by Mar-2024"

Occurence
Potential Cause(s)/ Mechanism(s) of Failure
(O)

Nozzle Choking/Damages
Duct damages
Algal formation in flow path.

Insuffient atomisation and improper distribution of

atomised water droplet over fills.
Nozzle Choke
Algal formation in flow path.
Damages in fills

Fills fouling

Nozzle Choke
Algal formation in flow path.
Damages in fills
Fills fouling
Nozzle Choke

Algal formation in flow path.

Damages in fills
Fills fouling
Improper CW pump impeller capacity

Leakages through CW water pipeline

All risers open condition

Water box choking
Hot water distribution duct/pipe damages
Nozzle choke and damages
Improper CW pump impeller capacity
Leakages through CW water pipeline

All risers open condition

Water box choking
Hot water distribution duct/pipe damages
Nozzle choke and damages

Low CW water flow in condensor

Leakages in CW pipeline
Water box choking
Water mist recirculation
High evaporation loss
High Fan Blade Angle >12 degrees
Improper sealing of doors and gaps
More No's of CT Fans running Condition
Faulty material
Nozzle chocking
Weathering due to ageing
Damaged nozzles
Improper chemical dosing
Low CW water flow
High air flow through cooling tower
Low Cycle of Concentration
Algal formation in flow path.
Faulty material
High Air velocity
Weathering due to ageing
High air flow through cooling tower
Improper chemical dosing
Low CW water flow
Static Nozzle's used
Low Cycle of Concentration
Algal formation in flow path.

Maintaining low cycle of Concentration

To reduce water consumption

High air flow through cooling tower

Wind direction, flow & velocity
High fan blade angle

Plantation blockages

CW pipeline blockage in air flow direction

Seasonal Changes of Weather & Climatic condition

Pipeline damages due to corrosion and rusting

0 MW
y 0.5 ⁰C by Mar-2024"
Recommended
Risk Priority Action(s)
Detection
Current Process Controls Number (Dated : )
(d)
(RPN)

Nozzle Cleaning & replacement during PM 0

Checking during PM 0
Maintaining Design Water parameter by
0
following water treatment procedure.
Only Static nozzle available for water
0
atomisation
Nozzle Cleaning & replacement 0
Fill's Cleaning during PM 0
Fill's Replacement as per Management
0
decision
Fill's Cleaning during PM 0
Maintaining Design Water parameter by
0
following water treatment procedure.
Nozzle Cleaning & replacement during PM 0
Fill's Cleaning during PM 0
Fill's Replacement as per Management
0
decision
Fill's Cleaning during PM 0
Nozzle Cleaning during PM 0
Fill's Cleaning during PM 0
Maintaining Design Water parameter by
0
following water treatment procedure.
Fill's Replacement as per Management
0
decision
Fill's Cleaning during PM 0
Flow measurnment avilable at DCS 0

Inspection during shutdown & unit running 0

Monitoring through Field checking 0

Monitoring through DCS 0
Checking during PM 0
Checking during PM 0
Flow measurnment avilable at DCS 0
Inspection during shutdown & unit running 0

Monitoring through Field checking 0

Monitoring through DCS 0
Checking during PM 0
Checking during PM 0
0
Flow measurnment avilable at DCS 0
Cannot able to identify leakages as pipeline is
0
laid underground.
Monitoring through DCS 0
Checking during PM 0
Checking during PM 0
Checking during PM 0
Checking during PM 0
Monitoring through DCS 0
Proper inspection during shutdown 0
Checking during PM 0
Checking during PM 0
Checking during PM 0
Monitoring of chemical parameters every 4
0
hours
Flow measurnment avilable at DCS 0
Blade angle checking during PM 0
Blowdown given and water properties
0
checking for every 4 hours.
Cleaning during PM 0
Proper inspection during shutdown 0
Blade angle checking during PM 0
Cleaning during PM 0
Blade angle checking during PM 0
Monitoring of chemical parameters every 4
0
hours
Flow measurnment avilable at DCS 0
Nil 0
Blowdown given and water properties
0
checking for every 4 hours.
Cleaning during PM 0

0
Blowdown given and water properties
checking for every 4 hours.
Blowdown given and water properties
checking for every 4 hours.
0

Checking during PM 0
Local round 0
Checking during PM 0
Clearing and levelling of areas around Cooling
0
Towers

Nil 0

0
Nil
0
Nil
Nil 0
Nil 0

0
Nil
0
0
0
0
0
0
0
0
0
 Action Results
Responsibility and
Target Completion (Dated)
Date Actions RPN=S*O
Sev Occ Det
Taken *D
S.No: Valid Causes

1 Nozzle Chocking

2 Nozzle Damaged

3 Hot Water Duct Damaged

4 Fills Damaged

5 Gap Between Fills And CT Cell Structure

6 Scale Formation Over Fills

7 Water Mist Recirculation

8 Improper Flow From Hot water Duct

9 Improper Water Flow Distribution

10 Fills Are Chocked

 1st Why? 2nd Why?

Debris Accumulation No Filtration System.

Corrosive Elements In Cooling Water Ineffective Water Quality Management

Due To Wear And Tear Abrasive Particles In The Water

Weathering Aging

Nozzle Missing Due To Chocking Nozzle Damaged

Damaged Hot Water Duct Weathering

Water Quality
Foreign Particle / CW Duct Rust Particles
Aging

Improper Stacking Of Ct Fills Civil Structure Not Proper

Uneven Size Of Ct Fills Ct Fills Prepared At Site Are Not Proper

Deviation In Chemical Parameter Maintained

Improper Chemical Dosing
& Recommended By OEM

Damaged Hot Water Duct

Low Water Flow Through Cooling Tower
CW Pump Impeller Issue

Damaged Due To Aging

Improper Drift Eliminator
Algae Formation

High Cooling Air Flow High Blade Angle

Hot Water Duct Damaged Weathering

 Hot Water Duct Damaged Weathering

Corrosive Elements In Cooling Water

Nozzle Damaged
Due To Wear And Tear

Nozzle Missing Due To Chocking Nozzle Damaged

Algae Formation Water Quality

Water Quality

Scale Formation Over Fills

Low Water Flow Through Cooling Tower

Hot Water Duct Damaged

Debris Accumulation
Nozzle Damaged
 3rd Why? 4th Why?
Damaged Duct Pieces Weathering/Aging

Aging
Foreign Particle / CW Duct Rust Particles
Water Quality

Algae Formation Water Quality

Water Quality
Scale Formation On Nozzle

Low Water Flow

Lack Of Monitoring And Adjustment Protocol

Inadequate/No Filtration System

Inadequate Maintenance

Aging Inadequate Maintenance

Water Hardness High Low Blowdown

Environmental Factor

Lack Of Monitoring And Poor Work

Lack Of Knowledge Or Negligence

Aging

Design Not Proper

Water Quality Improper Dosing

Air Flow Measurement Not Done

Aging Inadequate Maintenance

 Aging Inadequate Maintenance
Lack Of Monitoring And
Ineffective Water Quality Management
Adjustment Protocol
Inadequate/No Filtration
Abrasive Particles In The Water
System

Improper Chemical Dosing

Water Quality Not As Per OEM Improper Chemical Dosing

Damaged Hot Water Duct Aging

CW Pump Impeller Issue Design Not Proper

Weathering Aging

Ineffective Water Quality

Corrosive Elements In Cooling Water
Management

Abrasive Particles In The

Due To Wear And Tear
Water
 5th Why? 6th Why?
Environmental Factor Inadequate Maintenance

Water Hardness High Low Blowdown

Improper Dosing

Low Blowdown
Water Hardness High
Improper Dosing

Damaged Hot Water Duct Aging

To Be Implemented

To Be Implemented
Inadequate Maintenance To Be Implemented

Lack Of Monitoring And

Adjustment Protocol

Inadequate/No Filtration
To Be Implemented
System
 SEVERITY GUIDELINES FOR PROCESS FMEA
Effect Score
No 2
Slight 4
Moderate 6
Major 8
Extreme 10

OCCURRENCE GUIDELINES FOR PROCESS FMEA

Effect Score
Almost never 2
Probably 4
Certainly 6
High 8
Extremely High 10

DETECTABILITY GUIDELINES FOR PROCESS FMEA

Effect Score
Easily 2
Moderately 4
Hardly 6
Very Hardly 8
Almost impossible 10
 SEVERITY GUIDELINES FOR PROCESS FMEA
Criteria
No affect on Cooling Tower performance
Slight effect on Cooling Tower Performance
Moderate affect on Cooling Tower Performance
Major effect on Cooling Tower Performance
Extreme effect on Cooling Tower Performance

OCCURRENCE GUIDELINES FOR PROCESS FMEA

Criteria
History shows no occurance.
< 5nos of incidences Yearly.
< 5nos of incidences Monthly.
> 5nos of incidences Monthly.
Problems observed on daily basis

DETECTABILITY GUIDELINES FOR PROCESS FMEA

Criteria
Its very easy to detect.
Proven method available for detection.
Analysis required for detection.
Tests or prototype's required for detection
No known techniques available.
 GM
FMEA for "Re

Severity
S.No Product or Process Failure Mode Failure Affect

Oil Leakages from 8

Manifold connector
8

Oil Leakages from

8
Manifold hose
1 Wagon tippler Oil Leakages
8
Damage of Hoses
8

8
Hydraulic Pipe line
puncture
8

7
Idler Damages Coal spillages
7

Skirt rubber Damages Coal spillages 7

7
2 Stacker reclaimer
tripping of entire
Feedback faults downstream system on 8
process trip

Tripping of particular
motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

3 Grizzly Feeder Body Crack Equipment outage 9

8
Chute Puncture Coal spillages
8
4 Flap Gates
Actuator shaft damage Bush Damage 7
 8
Skirt Pad Damages Coal spillages
8

Tripping of particular
motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

5 BCN-4
Delay in starting of
system and delay in
Circuit Breaker fault 9
rack unloading and
bunkering

Motor high vibration,

bearing housing
Motor bearing damage 9
damage, in few cases
motor winding burnt

8
Skirt Pad Damages Coal spillages
8

Tripping of particular
motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

6 BCN-6
Delay in starting of
system and delay in
Circuit Breaker fault 9
rack unloading and
bunkering

Motor high vibration,

bearing housing
Motor bearing damage 9
damage, in few cases
motor winding burnt

Joint patch Opening Equipment outage 8

Tripping of particular
7 BCN-2 motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

Joint patch Opening Equipment outage 8

Tripping of particular
8 BCN-3 motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

Air leakage form

Air leakage form Gland 6
system
 8
Classifier Belt Looseness Current Hunting
8

8
Coal Leakages/ Pipe
Coal Pipe Leakages
Thinning
8

Foreign Material Stuck Abnormal sound 5

9 Coal Mills Damper not Operating/

Gate & Damper 8
jamming

Grinding elements gap Decreasing of Coal Mill

9
increased performance

Oil Leakages from

Oil Leakages from seal 8
pump

Reject gate not

Reject gate not operate 8
available

Mill Reject MRHS system not 9

10 MRHS Overload
Handling System available

Soot blower Not

Guide Roller Damage 9
available

Soot blower Steam

Poppet Valve Defect 8
11 Soot Blowers leakages

Steam Leakages from Pipe Steam leakages 6

Valve/NRV Passing Valve Not available 8

Higher Aux Power 1

Valve operating problem 5

Air leakage

Valve internals damage 6

Higher Aux Power 1

8
Ash leakage Fugitive Ash Emission
8

AHP Ash Conveying

12
System
 Ash leakage

Evacuation Delayed 8
AHP Ash Conveying Higher Aux Power 5
12
System Choking
Joints looseness 5

7
Valve operating problem Valve internals damage
4

7
Valve feedback issue Valve internals damage
3

Ash Spillage 5
Duct leakage
Bearing damages 4
Ash Spillage 4
gland leakage
Bearing damages 4

HMDC internals damage 7

HMDC abnormal sound
Poor Availability 5

HMDC internals damage 7

HMDC misalignment
Poor Availability 5
7
7
HMDC paddle worn out Unavailability of HMDC
7
8

7
HMDC shaft worn out Unavailability of HMDC 7

7
13 Bottom Ash Silo 8

Fugitive Ash Emission 5

HMDC spray problem
Oil contamination Bearing damages 6
Oil leakage Bearing damages 2
Unloading Delayed 3
valve op problem
Valve internals damage 3

Unloading Delayed 3
Valve passing
Valve internals damage 3

6
Water pump vibration Unavailability of pump
6
Delay in ash Evacuation 4
level transmitter problem
Unavailability of 5
Motor abnormal sound
equipment 5
SOV issue Valve inoperative 4

Motor Abnormal sound delay in ash unloading 7

 Higher Aux Power 1

Valve operating problem 5

Air leakage

Valve internals damage 6

8
Ash emission/leakage Delay in ash Evacuation 8
8
calibration issue Evacuation Delayed 5
5
Fugitive Ash Emission
gland leakage 5
Evacuation Delayed 3
MHV problem
Valve internals damage 3

RSV operation problem Evacuation Delayed

8
14 Buffer Hopper
Evacuation Delayed 3
Segregating valve passing
Valve internals damage 5

Fugitive Ash Emission 7

Segregating valve coupling
gasket leakage
Valve internals damage 3

8
Vacuum Drop Delay in ash Evacuation
8

logic issue Evacuation Delayed 9

8
pulse jet not working Evacuation Delayed 5
8
8
8
Ash emission/leakage Delay in ash Evacuation
8
8
Evacuation Delayed 8

ESP Ash Vacuum Valve internals damage 8

15 MHV problem
system
Valve internals damage 8

Higher Aux Power 2

Chokage
Joints looseness 5
Evacuation Delayed 7
Vacuum Drop
Higher Aux Power 2
Oil contamination Bearing damages 6
7
Bearing damages
Oil leakage 7
Higher Aux Power 1

Air leakage
 Valve operating problem 5
Air leakage

Valve internals damage 6

8
Ash emission/leakage Fugitive Ash Emission 8
5

Chokage Delay in ash unloading 5

Delay in ash unloading 3

dome valve problem
Valve internals damage 3

HMDC internals damage 7

HMDC abnormal sound
Poor Availability 5
7
16 Fly Ash Silo System Unavailability of HMDC
8
9
7

HMDC shaft worn out Unavailability of HMDC 5

8
Unavailability of Silo
Silo blower abnormal sound
Blower 7
4
8
Unavailability of Silo
Silo blower vibration 7
Blower
4
3
TC operating problem Unloading Delayed
3

Overload trip delay in ash evacuation 7

Motor Abnormal sound delay in ash unloading 7

Duct leakage Ash Spillage 5

7
Roller abnormality Unavailability of Mac belt 7
7
Poor Availability 7
Spill chain link worn out
17 Mac Belt Ash Spillage 4
Poor Availability 7
Spill chain sprocket issue Ash Spillage 2
Misalignment 5
8
wing clit damage Unavailability of Mac belt
 wing clit damage Unavailability of Mac belt 8
8
8
Primary crusher ZSS Evacuation Delayed
3
8
Unavailability of Post 8
Roller abnormality
cooler 8
8
Ash Spillage 5
Duct leakage
Roller Damage 5
Unavailability of Post 8
belt misalignment
cooler belt 8
8
8
O chain link/clamp issue Unavailability of O-chain
18 Post Cooler 8
8
9
Post cooler belt worn out Evacuation Delayed 9
9
Post cooler Mesh damage Evacuation Delayed 9
4
Pre-crusher operating problem Evacuation Delayed
4
8
Tooth worn out Evacuation Delayed 8
8

tripping of entire BA
Motor abnormal sound 9
system
 GMR WARORA ENERGY LIMITED-2X 300 MW
FMEA for "Reduction in number of Defects by 30% by Dec-2021"
RPN Threshold

Occurrence

Detection

RPN
Causes Controls

Providing protection against big size of

Hit by big size coal/Stone 8 7 448
coal

improper fitment 6 Fit-up and alignment check 6 288

Preventing coal heaps coming in contact

Hose rubbing with coal heap 7 7 392
with hose

Protection of hoses against coming in

Impact of coal/Stones on hoses 7 7 392
contact with hose
Inspection of Condition of hoses ,
Aging of Hoses 5 6 240
Orientation change as per wear pattern

Rusting of pipe 7 Protective coating to be provided 6 336

Poor Housekeeping 6 Daily housekeeping to be maintained 7 336

High tension on idler 8 Relocating the installation zone 7 392

improper fitment 7 revisiting maintenance procedure 5 245

material quality issue 6 material hardness as per requirement 6 252

uneven Coal flow path 8 Centralizing coal flow on belt 7 392

Even profile of skirt rubber to be
improper fitment 5 7 245
maintained

Ensuring proper tightness and healthiness

due to improper contact at feeder
5 of terminal block during preventive 7 280
terminal block contacts
maintenance

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

stoppage of system to avoid partial

Partial loading 8 7 504
loading
Wall thickness reduced 7 Strengthening the deck wall 7 441
Cleaning of equipment after every
Chokage inside equipment 6 6 324
operation
Higher stroke setting 7 Stroke value to be minimized 7 441
Running of equipment with deviation Regular communication with Coal
8 8 576
on coal size & quality Sourcing
Reduced thickness of plates 7 Replacement of wear plates 7 392
Quality of work 7 Inspection of Chute thickness 7 392
Setting of limit switch based on site
Feedback for ON/OFF issue 7 8 392
operation
 Replacement of skirt pad with skirt
Gape Between Skirt pad and belt 7 7 392
rubber
Belt sway 8 Channelizing coal flow to centre 8 512

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

Due to ageing and more number of Checking of VCB's required in frequent

7 7 441
operations intervals

high number of operations, dust Bearing replacement to take up at

7 7 441
accumulation frequent intervals

Replacement of skirt pad with skirt

Gape Between Skirt pad and belt 7 7 392
rubber
Belt sway 8 Channelizing coal flow to centre 8 512

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

Due to ageing and more number of Checking of VCB's required in frequent

7 7 441
operations intervals

high number of operations, dust Bearing replacement to take up at

7 7 441
accumulation frequent intervals

Joint weak 7 re-joining of belt 7 392

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

Joint weak 7 re-joining of belt 7 392

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

Aging of gland 5 Gland replacement 6 180

Looseness of belt 7 7 392
Belt inspection in regular interval
Belt damage 7 6 336

Erosion of coal pipe body 7 Permanent Patching 7 392

Ceramic Lining damage 7 Bend to repair or replace 7 392

Comes with coal 4 Regular monitoring of foreign material 6 120

Looseness of bolt 7 Addition locking nut required 6 336

Grinding elements wear/tear 7 Roller setting to check in regular interval 7 441

Shaft seal Aging / Damages 8 Oil Seal inspection in regular interval 7 448

Pneumatic gate internal seal

4 Life of internal seal to ensure 6 192
damages

Parallel operation of reject gate for Parallel operation of reject gate for
8 6 432
two or more coal mill should be avoided

Elongation of Bucket elevator Chain 8 Chain shortening of BE in regular interval 6 432

Foreign material comes in DCC Regular monitoring of foreign material

4 6 216
chamber during bunkering

Guide Roller Worn-out/aging 6 Guide Roller to check in regular interval 7 378

Poppet Valve seat and disk Worn- Poppet valve service required in regular
7 7 392
out/aging interval

Pipe line thickness to check in regular

Pipe line thinning /aging 5 6 180
interval

Valve seat and disk Worn-out/aging 7 valve service required in regular interval 6 336

improper fitment 3 Field supervision 5 15

Mishandling of fittings 3 Field supervision 5 75

Ageing of fitment 4 Monitoring SCADA parameters 2 48

improper fitment 3 Field supervision 5 15

Improper alignment 8 Field supervision 5 320
Ash erosion 4 Field supervision 5 160
Ageing 2 Field supervision 5 80
Operation issues 3 Field supervision 5 75
Weather Conditions 3 Monitoring SCADA parameters 2 30

Cylinder passing 3 Field supervision 5 105

Bolt looseness 3 Field supervision 5 60

Cylinder passing 3 Field supervision 5 105

Limit switch problem 3 Maintenance Supervision 8 72

Thinning of plates 5 Field supervision 5 125

abnormal flow 4 Thickness measurement 4 64
improper fitment 5 Field supervision 5 100
Poor Monitoring 5 Maintenance Supervision 8 160

Foreign material 4 Field supervision 5 140

Looseness of paddle 4 Maintenance Supervision 8 160

Foreign material 4 Field supervision 5 140

Looseness of paddle 4 Maintenance Supervision 8 160

Foreign material 6 Field supervision 5 210
one or more paddle is missing 5 Field supervision 5 175
Looseness of paddle 5 Maintenance Supervision 8 280
Poor Quality Material 5 MOC checking 5 200

Foreign material 6 Field supervision 5 210

Improper alignment 6 Maintenance Supervision 8 336

Improper tightness of gland 5 Maintenance Supervision 8 280
Equipment run with Paddle in removed
8 Field supervision 5 280
condition
Poor Quality Material 5 MOC checking 5 200

Operation issues 2 Field supervision 5 50

Ash leakages 4 Maintenance Supervision 8 192

Seal damage 4 Field supervision 5 40
Cylinder passing 3 Field supervision 5 45

improper fitment 3 Maintenance Supervision 8 72

Cylinder passing 3 Field supervision 5 45

improper fitment 3 Maintenance Supervision 8 72

Alignment problem 5 Maintenance Supervision 8 240

Bearing damages 2 Maintenance Supervision 8 96
ash accumulation on sensor 3 Monitoring SCADA parameters 3 36

Alignment issue 3 Maintenance Supervision 8 120

Bearing damage 3 Field supervision 5 75
SOV looseness 2 Maintenance Supervision 8 64

replacement of bearing to take place

due to bearing failure 7 6 294
based of number of running hours
improper fitment 3 Field supervision 5 15

Mishandling of fittings 3 Field supervision 5 75

Ageing of fitment 4 Monitoring SCADA parameters 2 48

Bag filter damage 7 Maintenance Supervision 8 448

Fluidising line damage 8 Field supervision 5 320
Equalizing line bend leakage 8 Field supervision 5 320
Ageing 2 Monitoring SCADA parameters 2 20
Gland follower damage 4 Maintenance Supervision 8 160
Bolt looseness 4 Maintenance Supervision 8 160
Poor Monitoring 3 Monitoring SCADA parameters 4 36

Foreign material 3 Maintenance Supervision 8 72

Due to aging effect 5 Maintenance Supervision 8 120

Improper alignment 5 Maintenance Supervision 8 320

improper fitment 3 Maintenance Supervision 8 72

Limit switch problem 5 Maintenance Supervision 8 200

improper fitment 5 Field supervision 5 175

Poor Quality Material 3 Maintenance Supervision 8 72

Misalignment 5 Maintenance Supervision 8 320

Material code not prepared/available with
Poor Quality Material 4 5 160
proper MOC
Equalizing line bend leakage 8 Field supervision 5 320

Erosion of Seat & Disc of equalizing valve 8 Maintenance Supervision 8 512

System hanging 6 Monitoring SCADA parameters 3 162

Card issue 2 Field supervision 5 80
Union looseness 5 Field supervision 5 125
SOV problem 3 Monitoring SCADA parameters 4 96
Improper alignment 6 Field supervision 5 240
Ageing 4 Field supervision 5 160
Square plate thread damage 8 Field supervision 5 320
Ash erosion 5 Maintenance Supervision 8 320
Poor Monitoring 3 Field supervision 4 96

Improper gland tightening 6 Maintenance Supervision 8 384

Poor Quality Material 2 Maintenance Supervision 8 128

Operation issues 3 Field supervision 5 30

Weather Conditions 3 Monitoring SCADA parameters 2 30
Alignment issue 4 Field supervision 5 140
Operation issues 3 Monitoring SCADA parameters 2 12
Ash leakages 2 Maintenance Supervision 8 96
View glass damage 5 Field supervision 5 175
Seal damage 5 Field supervision 5 175
improper fitment 3 Field supervision 5 15
Mishandling of fittings 3 Field supervision 5 75

Ageing of fitment 4 Monitoring SCADA parameters 2 48

Improper alignment 8 Field supervision 5 320

Gland leakage 8 Field supervision 5 320
Ash erosion 4 Maintenance Supervision 8 160

Improper fluidising 3 Field supervision 5 75

Foreign material at suction 2 Maintenance Supervision 8 80

Moisture ingress 3 Maintenance Supervision 8 120

Seal damage 3 Maintenance Supervision 8 72

improper fitment 3 Maintenance Supervision 8 72

Foreign material 4 Field supervision 5 140

Looseness of paddle 3 Maintenance Supervision 8 120

one or more paddle is missing 3 Field supervision 5 105
Poor Quality Material 5 MOC checking 5 200
Foreign material 3 Field supervision 5 135
Improper alignment 5 Maintenance Supervision 8 280
Improper tightness of gland 5 Maintenance Supervision 8 200
Equipment run with Paddle in removed
5 Field supervision 5 200
condition
Poor Quality Material 5 MOC checking 5 200

Bearing damage 7 Maintenance Supervision 8 448

Pulley minus 3 Field supervision 5 105

V-Belt loose 5 Field supervision 5 100
Bearing damage 7 Maintenance Supervision 8 448
Pulley minus 3 Field supervision 5 105
V-Belt loose 5 Field supervision 5 100
Rope misalignment 3 Maintenance Supervision 8 72
Limit switch problem 3 Maintenance Supervision 8 72

due to one phase open which results checking of motor lead terminals during
in unbalance current, due to over 7 preventive maintenance, ensuring silo 6 294
loading in motor dampers position

replacement of bearing to take place

due to bearing failure 7 6 294
based of number of running hours

Thinning of plates 5 Field supervision 5 125

Bearing damage 3 Maintenance Supervision 8 168

Process Overload 2 Field supervision 5 70

Worn Out parts 4 Field supervision 5 140
Ageing 3 Field supervision 5 105
More fine ash 4 Field supervision 5 80
Ageing 2 Field supervision 5 70
Process Overload 2 Field supervision 5 20
Worn Out parts 8 Field supervision 5 200
Roller damage 2 Field supervision 5 80
Foreign material/Clinkers 4 Field supervision 5 160
Process Overload 3 Field supervision 5 120
Chain/sprocket broken 2 ZSS trip 1 16
Foreign material 3 ZSS trip 5 45
High Ash Spillage 8 Field supervision 5 320
Belt mis-alignment 4 Field supervision 5 160
Damage of wing clit/ mesh 7 Field supervision 5 280
Damage of bearing 5 Field supervision 5 200
Thinning of plates 5 Field supervision 5 125
Ageing 5 Field supervision 5 125
More fine ash 9 Field supervision 5 360
Cylinder passing 1 Field supervision 5 40
Link Broken 8 Field supervision 5 320
Clamp Broken 8 Field supervision 5 320
Sprocket worn out 4 Field supervision 5 160
Overload 8 ZSS trip 3 192
Wing plate/clit damage 8 Field supervision 5 360
Pan plate damage 5 Field supervision 5 225
Ageing 3 Field supervision 5 135
Ageing 3 Field supervision 5 135
ash accumulation at guide plate 5 Field supervision 5 100
Process Overload 5 Field supervision 5 100
Ageing 2 Field supervision 5 80
Ash quality 2 Field supervision 5 80
Foreign material 2 Field supervision 5 80

Oil ingress into motor from gear box

9 Gear box gasket healthiness to ensure 6 486
end
W
y Dec-2021"
180 Date 11/15/2021

Probability of

Probability of

Probability of
Occurrence

Detection
Severity
Responsibility& Target/

RPN
Action/ Plan
Complete date
 Total Failure Failure Modes with Failure Modes
S.No Significant Equipments Types Modes RPN >= 180 Before with RPN >= 180
Correction After Correction
1 Wagon Tippler 7 7 0
2 Stacker reclaimer 7 7 0
3 Grizzly Feeder 5 5 0
4 Flap Gates 3 3 0
5 BCN 4 5 5 0 12
6 BCN 6 5 5 0 10
7 BCN 2 2 2 0 8 7 7
8 BCN 3 2 2 0 6
9 Coal Mills 10 9 0 4
10 Mill Reject Handling System 3 3 0 2
11 Soot Blowers 4 4 0 0 0
0
12 AHP Ash Conveying System 13 1 0 r er
le
13 Bottom Ash Silo 31 11 0 i pp l a im
T F
on ec zl y
14 Buffer Hopper 25 8 0
ag e rr i z
15 ESP Ash Vacuum system 11 4 0 W ac
k Gr
St
16 Fly Ash Silo System 33 11 0
17 Mac Belt 12 1 0
18 Post Cooler 24 10 0
202 98 0 Failure
 Chart Title
12 11 11
10
10 9
8
8 7 7
6 5 5 5
4 4
4 3 3
2 2
2 1 1
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0
le
r er er es 4 6 2 3 il l
s m er
s m Si
lo er m m lt er
i pp im e ed at CN BCN BCN BCN l M s te w s te h o pp s te s te c Be ool
a G B y o y y y C
T
ec
l F
ap a S Bl S As H s S a t
on rr z zl y Fl Co i ng ot i ng m ffer um ilo M os
ag e i l o y o u u S P
ac
k Gr nd S ve tt B c
V a y As
h
W
St Ha on Bo h
ct C s F l
je h A
Re As SP
l P E
il AH
M

Failure Modes with RPN >= 180 Before Correction Failure Modes with RPN >= 180 After Correction
1
10

1
0 0 0
m lt le
r
c Be oo
a C
M st
Po

ction
 GM
FMEA for "Re

Severity
S.No Product or Process Failure Mode Failure Affect

8
Oil Leakages from
Manifold connector
8

Oil Leakages from

8
Manifold hose
1 Wagon tippler Oil Leakages
8
Damage of Hoses
8

8
Hydraulic Pipe line
puncture
8

7
Idler Damages Coal spillages
7

Skirt rubber Damages Coal spillages 7

7
2 Stacker reclaimer

tripping of entire
Feedback faults downstream system on 8
process trip

Tripping of particular
motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

3 Grizzly Feeder Body Crack Equipment outage 9

9
3 Grizzly Feeder Body Crack Equipment outage

8
Chute Puncture Coal spillages
4 Flap Gates 8

Actuator shaft damage Bush Damage 7

8
Skirt Pad Damages Coal spillages
8

Tripping of particular
motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

5 BCN 4
Delay in starting of
system and delay in
Circuit Breaker fault 9
rack unloading and
bunkering

Motor high vibration,

bearing housing
Motor bearing damage 9
damage, in few cases
motor winding burnt

8
Skirt Pad Damages Coal spillages
8

Tripping of particular
motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

6 BCN 6
Delay in starting of
system and delay in
Circuit Breaker fault 9
rack unloading and
bunkering

Motor high vibration,

bearing housing
Motor bearing damage 9
damage, in few cases
motor winding burnt

Joint patch Opening Equipment outage 8

7 BCN-2
7 BCN-2
Tripping of particular
motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

Joint patch Opening Equipment outage 8

8 BCN-3
Tripping of particular
motor and process trip
Thruster brake not operating 8
of entire downstream
equipment's

Air leakage form

Air leakage form Gland 6
system

8
Classifier Belt Looseness Current Hunting
8

8
Coal Leakages/ Pipe
Coal Pipe Leakages
Thinning
8

Foreign Material Stuck Abnormal sound 5

9 Coal Mills
Damper not Operating/
Gate & Damper 8
jamming

Grinding elements gap Decreasing of Coal Mill

9
increased performance

Oil Leakages from

Oil Leakages from seal 8
pump

Reject gate not

Reject gate not operate 8
available

Mill Reject MRHS system not

10 MRHS Overload 9
Handling System available
 Mill Reject MRHS system not
10 MRHS Overload
Handling System available

Soot blower Not

Guide Roller Damage 9
available

Soot blower Steam

Poppet Valve Defect 8
11 Soot Blowers leakages

Steam Leakages from Pipe Steam leakages 6

Valve/NRV Passing Valve Not available 8

Higher Aux Power 1

Valve operating problem 5

Air leakage

Valve internals damage 6

Higher Aux Power 1

8
Ash leakage Fugitive Ash Emission

AHP Ash Conveying 8

12
System Evacuation Delayed 8
Higher Aux Power 5
Choking
Joints looseness 5

7
Valve operating problem Valve internals damage
4

7
Valve feedback issue Valve internals damage
3

Ash Spillage 5
Duct leakage
Bearing damages 4
Ash Spillage 4
gland leakage
Bearing damages 4

HMDC internals damage 7

HMDC abnormal sound
Poor Availability 5

HMDC internals damage 7

HMDC misalignment
Poor Availability 5

HMDC paddle worn out Unavailability of HMDC 7

 HMDC paddle worn out Unavailability of HMDC

7
HMDC shaft worn out Unavailability of HMDC

13 Bottom Ash Silo 7

Fugitive Ash Emission 5

HMDC spray problem
Oil contamination Bearing damages 6

Oil leakage Bearing damages 2

Unloading Delayed 3
valve op problem
Valve internals damage 3

Unloading Delayed 3
Valve passing
Valve internals damage 3

6
Water pump vibration Unavailability of pump
6
Delay in ash Evacuation 4
level transmitter problem
Unavailability of 5
Motor abnormal sound
equipment 5
SOV issue Valve inoperative 4

Motor Abnormal sound delay in ash unloading 7

Higher Aux Power 1

Valve operating problem 5

Air leakage

Valve internals damage 6

8
Ash emission/leakage Delay in ash Evacuation

calibration issue Evacuation Delayed 5

5
Fugitive Ash Emission
gland leakage
 Fugitive Ash Emission
gland leakage 5
Evacuation Delayed 3
MHV problem
Valve internals damage 3

RSV operation problem Evacuation Delayed

14 Buffer Hopper 8

Evacuation Delayed 3
Segregating valve passing
Valve internals damage 5

Fugitive Ash Emission 7

Segregating valve coupling
gasket leakage
Valve internals damage 3

Vacuum Drop Delay in ash Evacuation

8

logic issue Evacuation Delayed 9

8
pulse jet not working Evacuation Delayed 5
8

Ash emission/leakage Delay in ash Evacuation

ESP Ash Vacuum

15 8
system

Evacuation Delayed 8

Valve internals damage 8

MHV problem

Valve internals damage 8

Higher Aux Power 2

Chokage
Joints looseness 5
Evacuation Delayed 7
Vacuum Drop
Higher Aux Power 2
Oil contamination Bearing damages 6
7
Bearing damages
Oil leakage
 Bearing damages
Oil leakage 7
Higher Aux Power 1

Valve operating problem 5

Air leakage

Valve internals damage 6

Ash emission/leakage Fugitive Ash Emission

8

Chokage Delay in ash unloading 5

Delay in ash unloading 3

dome valve problem
Valve internals damage 3

HMDC internals damage 7

HMDC abnormal sound
Poor Availability 5
7

Unavailability of HMDC
8

16 Fly Ash Silo System 9

HMDC shaft worn out Unavailability of HMDC

8

8
Unavailability of Silo
Silo blower abnormal sound
Blower 7
4

8
Unavailability of Silo
Silo blower vibration
Blower

7
 Unavailability of Silo
Silo blower vibration
Blower

4
3
TC operating problem Unloading Delayed
3

Overload trip delay in ash evacuation 7

Motor Abnormal sound delay in ash unloading 7

Duct leakage Ash Spillage 5

7
Roller abnormality Unavailability of Mac belt 7
7
Poor Availability 7
Spill chain link worn out
Ash Spillage 4
17 Mac Belt Poor Availability 7
Ash Spillage 2
Spill chain sprocket issue
Misalignment 5

8
wing clit damage Unavailability of Mac belt 8
8
8
Primary crusher ZSS Evacuation Delayed
3

Unavailability of Post
Roller abnormality
cooler 8

Ash Spillage 5
Duct leakage
Roller Damage 5

Unavailability of Post 8
belt misalignment
cooler belt

18 Post Cooler
O chain link/clamp issue Unavailability of O-chain
18 Post Cooler
8
O chain link/clamp issue Unavailability of O-chain
8

Post cooler belt worn out Evacuation Delayed

9
Post cooler Mesh damage Evacuation Delayed 9
4
Pre-crusher operating problem Evacuation Delayed
4
8
Tooth worn out Evacuation Delayed 8
8

tripping of entire BA
Motor abnormal sound 9
system
 GMR WARORA ENERGY LIMITED-2X 300 MW
FMEA for "Reduction in number of Defects by 30% by Dec-2021"
RPN Threshold

Occurrence

Detection

RPN
Causes Controls

Providing protection against big size of

Hit by big size coal/Stone 8 7 448
coal

improper fitment 6 Fit-up and alignment check 6 288

Preventing coal heaps coming in contact

Hose rubbing with coal heap 7 7 392
with hose

Protection of hoses against coming in

Impact of coal/Stones on hoses 7 7 392
contact with hose
Inspection of Condition of hoses ,
Aging of Hoses 5 6 240
Orientation change as per wear pattern

Rusting of pipe 7 Protective coating to be provided 6 336

Poor Housekeeping 6 Daily housekeeping to be maintained 7 336

High tension on idler 8 Relocating the installation zone 7 392

improper fitment 7 revisiting maintenance procedure 5 245

material quality issue 6 material hardness as per requirement 6 252

uneven Coal flow path 8 Centralizing coal flow on belt 7 392

Even profile of skirt rubber to be

improper fitment 5 7 245
maintained

Ensuring proper tightness and healthiness

due to improper contact at feeder
5 of terminal block during preventive 7 280
terminal block contacts
maintenance

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

stoppage of system to avoid partial

Partial loading 8 7 504
loading

Wall thickness reduced 7 Strengthening the deck wall 7 441

Cleaning of equipment after every

Chokage inside equipment 6 6 324
operation

Higher stroke setting 7 Stroke value to be minimized 7 441

Running of equipment with deviation Regular communication with Coal
8 8 576
on coal size & quality Sourcing

Reduced thickness of plates 7 Replacement of wear plates 7 392

Quality of work 7 Inspection of Chute thickness 7 392

Setting of limit switch based on site

Feedback for ON/OFF issue 7 8 392
operation

Replacement of skirt pad with skirt

Gape Between Skirt pad and belt 7 7 392
rubber

Belt sway 8 Channelizing coal flow to centre 8 512

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

Due to ageing and more number of Checking of VCB's required in frequent

7 7 441
operations intervals

high number of operations, dust Bearing replacement to take up at

7 7 441
accumulation frequent intervals

Replacement of skirt pad with skirt

Gape Between Skirt pad and belt 7 7 392
rubber

Belt sway 8 Channelizing coal flow to centre 8 512

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

Due to ageing and more number of Checking of VCB's required in frequent

7 7 441
operations intervals

high number of operations, dust Bearing replacement to take up at

7 7 441
accumulation frequent intervals

Joint weak 7 re-joining of belt 7 392

due to coal dust accumulation and
Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

Joint weak 7 re-joining of belt 7 392

due to coal dust accumulation and

Overhauling of thruster brakes in
oil become slurry due to fine coal 5 6 240
frequent intervals
dust

Aging of gland 5 Gland replacement 6 180

Looseness of belt 7 7 392

Belt inspection in regular interval
Belt damage 7 6 336

Erosion of coal pipe body 7 Permanent Patching 7 392

Ceramic Lining damage 7 Bend to repair or replace 7 392

Comes with coal 4 Regular monitoring of foreign material 6 120

Looseness of bolt 7 Addition locking nut required 6 336

Grinding elements wear/tear 7 Roller setting to check in regular interval 7 441

Shaft seal Aging / Damages 8 Oil Seal inspection in regular interval 7 448

Pneumatic gate internal seal

4 Life of internal seal to ensure 6 192
damages

Parallel operation of reject gate for Parallel operation of reject gate for
8 6 432
two or more coal mill should be avoided

Elongation of Bucket elevator Chain 8 Chain shortening of BE in regular interval 6 432

Foreign material comes in DCC Regular monitoring of foreign material
4 6 216
chamber during bunkering

Guide Roller Worn-out/aging 6 Guide Roller to check in regular interval 7 378

Poppet Valve seat and disk Worn- Poppet valve service required in regular
7 7 392
out/aging interval

Pipe line thickness to check in regular

Pipe line thinning /aging 5 6 180
interval

Valve seat and disk Worn-out/aging 7 valve service required in regular interval 6 336

improper fitment 3 Field supervision 5 15

Mishandling of fittings 3 Field supervision 5 75

Ageing of fitment 4 Monitoring SCADA parameters 2 48

improper fitment 3 Field supervision 5 15

Improper alignment 8 Field supervision 5 320

Ash erosion 4 Field supervision 5 160

Ageing 2 Field supervision 5 80
Operation issues 3 Field supervision 5 75
Weather Conditions 3 Monitoring SCADA parameters 2 30

Cylinder passing 3 Field supervision 5 105

Bolt looseness 3 Field supervision 5 60

Cylinder passing 3 Field supervision 5 105

Limit switch problem 3 Maintenance Supervision 8 72

Thinning of plates 5 Field supervision 5 125

abnormal flow 4 Thickness measurement 4 64
improper fitment 5 Field supervision 5 100
Poor Monitoring 5 Maintenance Supervision 8 160

Foreign material 4 Field supervision 5 140

Looseness of paddle 4 Maintenance Supervision 8 160

Foreign material 4 Field supervision 5 140

Looseness of paddle 4 Maintenance Supervision 8 160

Foreign material 6 Field supervision 5 210

one or more paddle is missing 5 Field supervision 5 175

Looseness of paddle 5 Maintenance Supervision 8 280

Poor Quality Material 5 MOC checking 5 200

Foreign material 6 Field supervision 5 210

Improper alignment 6 Maintenance Supervision 8 336

Improper tightness of gland 5 Maintenance Supervision 8 280

Equipment run with Paddle in removed

8 Field supervision 5 280
condition

Poor Quality Material 5 MOC checking 5 200

Operation issues 2 Field supervision 5 50

Ash leakages 4 Maintenance Supervision 8 192

Seal damage 4 Field supervision 5 40

Cylinder passing 3 Field supervision 5 45

improper fitment 3 Maintenance Supervision 8 72

Cylinder passing 3 Field supervision 5 45

improper fitment 3 Maintenance Supervision 8 72

Alignment problem 5 Maintenance Supervision 8 240

Bearing damages 2 Maintenance Supervision 8 96

ash accumulation on sensor 3 Monitoring SCADA parameters 3 36

Alignment issue 3 Maintenance Supervision 8

Bearing damage 3 Field supervision 5 75
SOV looseness 2 Maintenance Supervision 8 64

replacement of bearing to take place

due to bearing failure 7 6 294
based of number of running hours

improper fitment 3 Field supervision 5 15

Mishandling of fittings 3 Field supervision 5 75

Ageing of fitment 4 Monitoring SCADA parameters 2 48

Bag filter damage 7 Maintenance Supervision 8 448

Fluidising line damage 8 Field supervision 5 320

Equalizing line bend leakage 8 Field supervision 5 320

Ageing 2 Monitoring SCADA parameters 2 20

Gland follower damage 4 Maintenance Supervision 8 160
Bolt looseness 4 Maintenance Supervision 8 160
Poor Monitoring 3 Monitoring SCADA parameters 4 36

Foreign material 3 Maintenance Supervision 8 72

Due to aging effect 5 Maintenance Supervision 8 120

Improper alignment 5 Maintenance Supervision 8 320

improper fitment 3 Maintenance Supervision 8 72

Limit switch problem 5 Maintenance Supervision 8 200

improper fitment 5 Field supervision 5 175

Poor Quality Material 3 Maintenance Supervision 8 72

Misalignment 5 Maintenance Supervision 8 320

Material code not prepared/available with

Poor Quality Material 4 5 160
proper MOC

Equalizing line bend leakage 8 Field supervision 5 320

Erosion of Seat & Disc of equalizing valve 8 Maintenance Supervision 8 512

System hanging 6 Monitoring SCADA parameters 3 162

Card issue 2 Field supervision 5 80
Union looseness 5 Field supervision 5 125
SOV problem 3 Monitoring SCADA parameters 4 96

Improper alignment 6 Field supervision 5 240

Ageing 4 Field supervision 5 160

Square plate thread damage 8 Field supervision 5 320

Ash erosion 5 Maintenance Supervision 8 320

Poor Monitoring 3 Field supervision 4 96

Improper gland tightening 6 Maintenance Supervision 8 384

Poor Quality Material 2 Maintenance Supervision 8 128

Operation issues 3 Field supervision 5 30

Weather Conditions 3 Monitoring SCADA parameters 2 30
Alignment issue 4 Field supervision 5 140
Operation issues 3 Monitoring SCADA parameters 2 12
Ash leakages 2 Maintenance Supervision 8 96
View glass damage 5 Field supervision 5 175
Seal damage 5 Field supervision 5 175
improper fitment 3 Field supervision 5 15

Mishandling of fittings 3 Field supervision 5 75

Ageing of fitment 4 Monitoring SCADA parameters 2 48

Improper alignment 8 Field supervision 5 320

Gland leakage 8 Field supervision 5 320

Ash erosion 4 Maintenance Supervision 8 160

Improper fluidising 3 Field supervision 5 75

Foreign material at suction 2 Maintenance Supervision 8 80

Moisture ingress 3 Maintenance Supervision 8 120

Seal damage 3 Maintenance Supervision 8 72

improper fitment 3 Maintenance Supervision 8 72

Foreign material 4 Field supervision 5 140

Looseness of paddle 3 Maintenance Supervision 8 120

one or more paddle is missing 3 Field supervision 5 105

Poor Quality Material 5 MOC checking 5 200

Foreign material 3 Field supervision 5 135

Improper alignment 5 Maintenance Supervision 8 280

Improper tightness of gland 5 Maintenance Supervision 8 200

Equipment run with Paddle in removed

5 Field supervision 5 200
condition

Poor Quality Material 5 MOC checking 5 200

Bearing damage 7 Maintenance Supervision 8 448

Pulley minus 3 Field supervision 5 105

V-Belt loose 5 Field supervision 5 100

Bearing damage 7 Maintenance Supervision 8 448

Pulley minus 3 Field supervision 5 105

V-Belt loose 5 Field supervision 5 100
Rope misalignment 3 Maintenance Supervision 8 72
Limit switch problem 3 Maintenance Supervision 8 72

due to one phase open which results checking of motor lead terminals during
in unbalance current, due to over 7 preventive maintenance, ensuring silo 6 294
loading in motor dampers position

replacement of bearing to take place

due to bearing failure 7 6 294
based of number of running hours

Thinning of plates 5 Field supervision 5 125

Bearing damage 3 Maintenance Supervision 8 168

Process Overload 2 Field supervision 5 70

Worn Out parts 4 Field supervision 5 140
Ageing 3 Field supervision 5 105
More fine ash 4 Field supervision 5 80
Ageing 2 Field supervision 5 70
Process Overload 2 Field supervision 5 20

Worn Out parts 8 Field supervision 5 200

Roller damage 2 Field supervision 5 80

Foreign material/Clinkers 4 Field supervision 5 160
Process Overload 3 Field supervision 5 120
Chain/sprocket broken 2 ZSS trip 1 16
Foreign material 3 ZSS trip 5 45

High Ash Spillage 8 Field supervision 5 320

Belt mis-alignment 4 Field supervision 5 160

Damage of wing clit/ mesh 7 Field supervision 5 280

Damage of bearing 5 Field supervision 5 200

Thinning of plates 5 Field supervision 5 125

Ageing 5 Field supervision 5 125

More fine ash 9 Field supervision 5 360

Cylinder passing 1 Field supervision 5 40

Link Broken 8 Field supervision 5 320

Clamp Broken 8 Field supervision 5 320

Sprocket worn out 4 Field supervision 5 160

Overload 8 ZSS trip 3 192

Wing plate/clit damage 8 Field supervision 5 360

Pan plate damage 5 Field supervision 5 225

Ageing 3 Field supervision 5 135

Ageing 3 Field supervision 5 135
ash accumulation at guide plate 5 Field supervision 5 100
Process Overload 5 Field supervision 5 100
Ageing 2 Field supervision 5 80
Ash quality 2 Field supervision 5 80
Foreign material 2 Field supervision 5 80

Oil ingress into motor from gear box

9 Gear box gasket healthiness to ensure 6 486
end
W
y Dec-2021"
180 Date 12/20/2022

Probability of

Probability of

Probability of
Occurrence

Detection
Severity
Responsibility& Target/

RPN
Action/ Plan
Complete date

1. Canopy provided.
Pamesh Agrawal ,
2. Bolted arrangement done for quick 4 3 6 72
15-02-2022
replacement

Pamesh Agrawal ,
Training to staff 4 3 6 72
15-02-2022

Pamesh Agrawal ,
Guard to be provided 3 3 7 63
21-12-2021

Protective layer on hoses to be Pamesh Agrawal ,

4 4 6 96
provided 21-12-2021
Replacement to be done as per Pamesh Agrawal ,
3 3 7 63
condition during PM activity 21-12-2021
Rusted pipes to be replaced and Pamesh Agrawal ,
4 3 6 72
painting to be done 15-02-2022
Pamesh Agrawal ,
Area ownership allocation under 5S 3 3 7 63
21-12-2021
Pamesh Agrawal ,
Sifting Location of Idler 4 3 7 84
10-02-2022

Pamesh Agrawal ,
Training to staff 4 3 6 72
15-02-2022

Nature of failure and tracking to be Pamesh Agrawal ,

3 3 7 63
done 21-12-2021

Deflector plate location to be Pamesh Agrawal , 01-

3 3 6 54
relocated 12-2021

Pamesh Agrawal ,
Training to staff 4 3 6 72
15-02-2022

same to be incorporate in preventive

Tarak
maintenance checklist and ensure the 3 3 7 63
04.12.2021
same during preventive maintenance

Thruster brake overhauling to do Tarak

3 3 6 54
during frequent intervals 15.02.2022

Pamesh Agrawal , 20-

SOP to be revised 4 3 7 84
02-2022

stiffeners and support plates to be Pamesh Agrawal , 15-

3 4 6 72
provided to prevent cracks 01-2022

Cross verification SCE for proper Pamesh Agrawal , 20-

4 3 7 84
cleaning 02-2022

Stroke measurement value to be Pamesh Agrawal , 15-

4 4 7 112
minimized 12-2021
Communicating to Coal sourcing during Pamesh Agrawal , 20-
4 3 7 84
deviation in coal quality 02-2022

Replacement of wear plates/Mother Pamesh Agrawal , 31-

3 4 6 72
plates 03-2022

Based on thickness survey work to be Pamesh Agrawal , 31-

4 4 7 112
executed 03-2022

Pamesh Agrawal , 21-

Timer based tripping to be done 4 3 6 72
11-2021

Pamesh Agrawal , 15-

Change from Pad to skirt rubber 3 3 6 54
02-2022

Pamesh Agrawal , 10-

deflector plate for control feeding 3 4 7 84
01-2022

Thruster brake overhauling to do Tarak

3 3 6 54
during frequent intervals 15.02.2022

VCB's maintenance to take up monthly Tarak

4 4 5 80
once 10.12.2021

Tarak
Bearing replacement to take up 3 3 5 45
15.12.2021

Pamesh Agrawal , 15-

Change from Pad to skirt rubber 3 3 6 54
02-2022

Pamesh Agrawal , 10-

deflector plate for control feeding 3 4 7 84
01-2022

Thruster brake overhauling to do Tarak

3 3 6 54
during frequent intervals 15.02.2022

VCB's maintenance to take up monthly Tarak

4 4 5 80
once 10.12.2021

Tarak
Bearing replacement to take up 3 3 5 45
15.12.2021

Belt condition to analyse and

Pamesh Agrawal ,
replacement/re-joint activity to be 4 4 7 112
15-01-2022
done
Thruster brake overhauling to do Tarak
3 3 6 54
during frequent intervals 15.02.2022

Belt condition to analyse and

Pamesh Agrawal ,
replacement/re-joint activity to be 4 4 7 112
15-01-2022
done

Thruster brake overhauling to do Tarak

3 3 6 54
during frequent intervals 15.02.2022

Inspection and replacement of gland in Abhishak Kumar Tiwari

5 4 4 80
monthly schedule PM - 15.12.2021

Abhishak Kumar Tiwari

5 4 4 80
Belt tension and healthiness monitoring - 15.12.2021
incorporated in monthly schedule PM Abhishak Kumar Tiwari
5 4 4 80
- 15.12.2021

Permanent Patching in schedule PM as Abhishak Kumar Tiwari

5 5 4 100
per list generated in SAP system - 15.12.2021

Abhishak Kumar Tiwari

Bend to repair or replace in AOH/COH 5 4 3 60
- 15.12.2021

Addition locking nut to check during Abhishak Kumar Tiwari

5 4 4 80
monthly PM - 15.12.2021

Grinding element gap inspection , wear

Abhishak Kumar Tiwari
rate pattern monitoring, roller setting 5 4 4 80
- 15.12.2021
Inspection in monthly schedule PM

Visual Inspection of oil pump seal in

monthly schedule PM, if any leakages Abhishak Kumar Tiwari
5 5 4 100
observed from drain point seal - 15.12.2021
replacement to be done preventively

Inspection of oil pump in monthly Abhishak Kumar Tiwari

5 5 4 100
schedule PM - 15.12.2021

Remote operation of reject gate is

Abhishak Kumar Tiwari
preferable to avoid manual error 6 5 4 120
- 15.12.2021
during night hours

Chain shortening inspection in every Abhishak Kumar Tiwari

6 5 4 120
Opportunities/monthly schedule PM - 15.12.2021
Regular monitoring of foreign material Abhishak Kumar Tiwari
5 5 4 100
during bunkering - 15.12.2021

Guide Roller to check in every

Abhishak Kumar Tiwari
operation and raised the defect in SAP 6 5 4 120
- 15.12.2021
System

Poppet valve to check in every

Abhishak Kumar Tiwari
operation and raised the defect in SAP 6 5 4 120
- 15.12.2021
System

Pipe line thickness to check in regular Abhishak Kumar Tiwari

4 4 4 64
interval - 15.12.2021
valve service required in regular Abhishak Kumar Tiwari
5 5 4 100
interval - 15.12.2021

Training to the fitter, Monitoring from

Balakrishnan
Supervisor at the end of alignment. Work to
Rajamanickam- 8 3 6 144
be carried out by preparing list of pipe line
15.12.2021
where alignment is out.

Net provision for suction of HMDC to avoid

Vishal Pahune-15.12.2021 8 2 6 96
entry of foreign material

Net provision for suction of HMDC to avoid

Vishal Pahune-15.12.2021 9 3 6 162
entry of foreign material
MOC to be check on every receipt of lot.
Alternate development to be explore. Every Vishal Pahune-15.12.2021 8 2 5 80
month twice checking to be carried out.

Net provision for suction of HMDC to avoid

Vishal Pahune-15.12.2021 8 2 6 96
entry of foreign material
After alignment maintenance supervisor
has to witness. Regarding material
Vishal Pahune-15.12.2021 7 3 8 168
manufacturing defect communication to be
done.

Training to the fitter to avoid damage to the

Vishal Pahune-15.12.2021 5 3 8 120
shaft by replacing the gland on time.

Training to B.A Silo unloader for monitoring

during the shift and put of defect Dhiraj Gautam-15.12.2021 5 4 6 120
immediately

MOC to be check on every receipt of lot.

Alternate development to be explore. Every Vishal Pahune-15.12.2021 8 2 5 80
month twice checking to be carried out.

Ash leakages to be attended on priority by

Vishal Pahune-15.12.2021 6 2 8 96
preparing list

Balakrishnan
Training for proper alignment for technician
Rajamanickam- 6 3 8 144
to be take up
15.12.2021

Tarak
Replacement of bearings to take place 6 3 5 90
15.12.2021

Thrust on bag to be analyse from Buffer

Ramesh Rajamanickam 5 4 8 160
hopper trend.
Fluidising pad inspection to be carried out if
any ash collection found inside fluidising Vishal Pahune-15.12.2021 6 4 6 144
pipe line.
Balakrishnan
Replacement bend from CI to Ceramic Rajamanickam- 5 5 6 150
15.12.2021
 Balakrishnan
Cylinder shifting to be avoid by making all
Rajamanickam- 6 3 8 144
cylinder ready
15.12.2021
RSV inspection schedule to be prepared for
Vishal Pahune, 15.12.2021 6 3 8 144
routine inspection

Limit switch to be commissioned for Ashish Malhotra-

5 3 8 120
identification 15.12.2021

RSV inspection schedule to be prepared for

Vishal Pahune-15.12.2021 6 3 8 144
routine inspection

Balakrishnan
Replacement bend from CI to Ceramic Rajamanickam- 5 5 6 150
15.12.2021
Balakrishnan
Replacement form current combined valve
Rajamanickam- 5 3 8 120
to other type of valve to be explore
15.12.2021

Training to the fitter, Monitoring from

Balakrishnan
Supervisor at the end of alignment. Work to
Rajamanickam- 8 3 6 144
be carried out by preparing list of pipe line
15.12.2021
where alignment is out.

Modification of current square plate which

is having thread damage to removable type
Vishal Pahune-15.12.2021 3 4 6 72
square plate which enables proper
tightening of square plate

Balakrishnan
Pipe thickens to be checked & accordingly
Rajamanickam- 6 3 8 144
pipe replacement to be plan
15.12.2021

Particular ESP 1st row hopper MHV gland to

Vishal Pahune-15.12.2021 4 3 8 96
be replaced on six month basis.
Drive to be taken for resolving the Balakrishnan
alignment issue particular at piping above Rajamanickam- 4 4 6 96
F.A Silo-2 15.12.2021

In TC-2A Rotary feeder opening to be

reduce so that MIV can be open to full to
avoid damage of MIV & thus reduce ash Vishal Pahune-15.12.2021 4 4 6 96
emission. Depends upon its result, other TC
to be taken up.

MOC to be check on every receipt of lot.

Alternate development to be explore. Every Vishal Pahune-15.12.2021 8 2 5 80
month twice checking to be carried out.

Alignment of shaft with dial gauge to be

Vishal Pahune-15.12.2021 7 3 8 168
check

Training to the fitter to avoid damage to the

Vishal Pahune-15.12.2021 5 3 8 120
shaft by replacing the gland on time.

Training to F.A Silo unloader for monitoring

during the shift and put of defect Dhiraj Gautam-15.12.2021 5 4 6 120
immediately

MOC to be check on every receipt of lot.

Alternate development to be explore. Every Vishal Pahune-15.12.2021 8 2 5 80
month twice checking to be carried out.
Belt alignment on every PM, Lobe setting
with new method as suggested by OEM(By Balakrishnan
matching axis of bottom shaft with top Rajamanickam- 6 3 8 144
shaft timing gear to avoid touching of lobe 15.12.2021
shaft in running)

Belt alignment on every PM, Lobe setting

with new method as suggested by OEM for Balakrishnan
vacuum pump(By matching axis of bottom Rajamanickam- 6 3 8 144
shaft with top shaft timing gear to avoid 15.12.2021
touching of lobe shaft in running)
 Tarak
Ensure healthiness of motor internal leads 7 4 6 168
20.12.2021

Tarak
Replacement of bearings to take place 6 3 5 90
15.12.2021

During shutdown wear out scrapper plate

to be build by welding plate from used Post Vishal Pahune-15.12.2021 5 4 5 100
cooler pan plate.

1. Dry fog nozzle installation at discharge of

O-Chain & Primary crusher.
2. Use of Mac belt include portion water Vishal Pahune-15.12.2021 6 4 6 144
spray by optimising as per requirement till
new belt replacement

Dry fog nozzle to be installed to avoid ash Ramesh Rajamanickam-

4 3 5 60
accumulation at post cooler tail end 15.12.2021

Till new belt replacement way for reduction

Vishal Pahune-15.12.2021 8 3 5 120
of ash collection at tail end to be explore

1. Dry fog nozzle installation at discharge of

O-Chain & Primary crusher.
2. Use of Mac belt include portion water Vishal Pahune-15.12.2021 6 4 6 144
spray by optimising as per requirement till
new belt replacement

Reduction of ash load by preparing parallel

Vishal Pahune-15.12.2021 6 4 5 120
duct at O-Chain inclined portion
Reduction of ash load by preparing parallel
Vishal Pahune-15.12.2021 6 4 5 120
duct at O-Chain inclined portion

Reduction of ash load by preparing parallel

8 4 3 96
duct at O-Chain inclined portion

1. Dry fog nozzle installation at discharge of

O-Chain & Primary crusher.
2. Use of Mac belt include portion water Vishal Pahune-15.12.2021 6 4 6 144
spray by optimising as per requirement till
new belt replacement.

1. Dry fog nozzle installation at discharge of

O-Chain & Primary crusher.
2. Use of Mac belt include portion water Vishal Pahune-15.12.2021 9 3 5 135
spray by optimising as per requirement till
new belt replacement.

Healthiness of gear box gasket to check 4 4 3 48