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RCM CENTRIFUGAL PUMP C3

The document outlines various failure modes and their corresponding detection mechanisms, consequences, and proposed maintenance tasks for different components, primarily focusing on pumps and bearings. It categorizes risks based on their frequency and severity, detailing the impact of potential failures on production and the redundancy measures in place. The maintenance tasks are structured by type, frequency, and responsibility, aimed at mitigating risks associated with equipment failure.
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0% found this document useful (0 votes)
14 views2 pages

RCM CENTRIFUGAL PUMP C3

The document outlines various failure modes and their corresponding detection mechanisms, consequences, and proposed maintenance tasks for different components, primarily focusing on pumps and bearings. It categorizes risks based on their frequency and severity, detailing the impact of potential failures on production and the redundancy measures in place. The maintenance tasks are structured by type, frequency, and responsibility, aimed at mitigating risks associated with equipment failure.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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abilit

Prob

Mitigated risk
Task Frequency

Unmitigated
y
Consequence Consequence

Probability
Functional Description of Failure Failure Task Task TA Maintenance

risk
Environm

Environm
Reputatio

Reputatio
Component Failure Modes Detection Mechanism Failure Effect Task Type Proposed Task No of Pax Task Remarks

Asset
Failure Mode Cause Duration(Hr) Responsibility (YES / NO) Level

People

People
ent
C1 C2 C3

Asset
ent
n

n
Check for abnormal sound / vibration / operating
Periodic Condition parameter
Maintenance (Vibration, 1 1 2 1 D D-2 EBC Shift Shift Daily Operation No LEVEL 1 1 1 1 1 D D-1
Normal wear and Temperature & Noise)
tear
Pump failure will cause insignificant impact on Perform offline vibration collection and analysis C2 - Moderate (D3)
Wear / Seize Bearing spalling Bi Mechanical
production due to redundancy 1 1 2 1 D CNM 1 1 1M 3M No LEVEL 2 C1 - Major ( D4) 1 1 1 1 D D-1
Bearing Weekly Rotating - CBM
For all
To Check for oil level and condition
Lack of Lubrication Casual Observation 1 1 2 1 D D-2 EBC Shift Shift Daily Operation No LEVEL 1 1 1 1 1 D D-1

External influence
Bearings have reduced Pump failure will cause insignificant impact on
Breakage (high vibration, Condition monitoring Perform offline vibration collection and analysis Bi Mechanical
operability or seized. production due to redundancy 1 1 2 1 D D-2 CNM 1 1 1M 3M No LEVEL 2 1 1 1 1 D D-1
misallignment, Weekly Rotating - CBM
Coupling failure due to Periodic condition Pump failure will cause insignificant impact on Perform offline vibration collection and analysis Bi Mechanical
Maintenance error 1 1 2 1 D D-2 CNM 1 1 1M 3M No LEVEL 2 1 1 1 1 D D-1
Clearance/Alignmen excessive misalignment monitoring production due to redundancy Weekly Rotating - CBM
Coupling
t failure Pump failure will cause insignificant impact on Check coupling element/disk condition. Replace if
Overload Membrane Fatigue Inspection 1 1 2 1 D D-2 SCH 1 1 6M 6M 6M AMT Rotating No LEVEL 2 1 1 1 1 D D-1
production due to redundancy necessary.
Pump failure will cause insignificant impact on Perform offline vibration collection and analysis Bi Mechanical
Corrosion Off Spec Product Off-design service Condition monitoring 1 1 2 1 D D-2 CNM 1 1 1M 3M No LEVEL 2 1 1 1 1 D D-1
production due to redundancy Weekly Rotating - CBM
Pump failure will cause insignificant impact on Process parameter monitoring
Production inteference 1 1 2 1 D D-2 EBC Shift Shift Daily Operation No LEVEL 1 1 1 1 1 D D-1
production due to redundancy
Errosion of impeller
Check for abnormal sound / vibration / operating
surface by foreign Bi Mechanical
Condition monitoring 1 1 2 1 D CNM parameter 1 1 1M 3M No LEVEL 1 1 1 1 1 D D-1
material causes flow Weekly Rotating - CBM
Pump failure will cause insignificant impact on
Erosion angle to deviate and may Off-design service D-2 Perform offline vibration collection and analysis
production due to redundancy
induce fatigue crack and Bi Mechanical
1 1 2 1 D CNM 1 1 1M 3M No LEVEL 2 1 1 1 1 D D-1
impeller rupture if left Weekly Rotating - CBM
undetected
Process parameter monitoring
Pump failure will cause insignificant impact on
Impeller Production inteference EBC
production due to redundancy
Fatigue crack from
Pump totally Check for abnormal sound / vibration / operating
stress in runner 1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
fail to deliver Pump failure will cause insignificant impact on parameter
Fatigue blade/vane due to Off-design service Inspection D-2
medium; production due to redundancy Perform offline vibration collection and analysis Mechanical
frequent start/stop of the 1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
pump seizure Rotating
pump or excessive
Inspection during pump overhaul 1 1 Condition Condition Mechanical
SCH TA TA Level 3
Based Based Rotating
Check for abnormal sound / vibration / operating
1 1 2 1 D EBC 1M Operation No LEVEL 1 1 1 1 1 D D-1
Clearance/Alignmen Pump failure will cause insignificant impact on parameter
Impeller clearance failure High Vibration Production inteference D-2
t failure production due to redundancy Perform offline vibration collection and analysis 1 1 Mechanical
1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Rotating
Pump failure will cause insignificant impact on Process parameter monitoring
Production inteference EBC
production due to redundancy
Check for abnormal sound / vibration / operating
Fatigue deformation from 1 1 2 1 D EBC 1M Operation No LEVEL 1 1 1 1 1 D D-1
parameter
misalignment, shaft Pump failure will cause insignificant impact on
Deformation Off-design service Production inteference D-2 Perform offline vibration collection and analysis
imbalance and other production due to redundancy Mechanical
dynamic phenomena 1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Rotating
Shaft damage by foreign Check for abnormal sound / vibration / operating
object ingestion due to parameter
Pump failure will cause insignificant impact on
inadequate flushing of Production inteference 1 1 2 1 D EBC 1M Operation No LEVEL 1 1 1 1 1 D D-1
Overload / High production due to redundancy
Breakage pump suction line or D-2 Verify Pump operating as per pump curve
vibration/ Fatigue
fatigue crack from
operating under stress Perform offline vibration collection and analysis Mechanical
1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
outside envelope Rotating
Shaft Perform offline vibration collection and analysis
Periodic condition Pump failure will cause insignificant impact on
CNM
monitoring production due to redundancy
Check for abnormal sound / vibration / operating
parameter

1 1 2 1 D CNM Verify Pump Flow is Above Minimum Flow 1M Operation No LEVEL 1 1 1 1 1 D D-1
Fatigue crack from Pump failure will cause insignificant impact on
Erosion Off-design service Condition monitoring D-2
errosion/corrosion attack production due to redundancy Verify Switch Setting & Valve Arrangement Correct
For Auto Start Function
Perform offline vibration collection and analysis Mechanical
1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Rotating
Check for abnormal sound / vibration / operating
parameter
1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
Check packing boxes, bearings (bearing housing),
or pump casing for overheating
Perform offline vibration collection and analysis Mechanical
Wear ( Follow Expected wear and Pump failure will cause insignificant impact on 1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Bearing spalling Condition monitoring D-2 Rotating
above) tear production due to redundancy
Clean Sight Glass, Constant Level Oiler, Water
Collector - if applicable
Mechanical
1 1 2 1 D SCH Flush bearing housing, replace oil in bearing 6M No LEVEL 2 1 1 1 1 D D-1
Bearings Rotating
housings and lube oil filter (if required) per
manufacturer's recommendations
Check packing boxes, bearings (bearing housing),
1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
or pump casing for overheating
Clean Sight Glass, Constant Level Oiler, Water 4 2 Force
Casual Observation / Oil Pump failure will cause insignificant impact on Collector - if applicable feed . TA
Overheating Lube oil degradation contamination D-2
sampling analysis production due to redundancy Mechanical
1 1 2 1 D SCH Flush bearing housing, replace oil in bearing 6M 6M No LEVEL 2 1 1 1 1 D D-1
Rotating
housings and lube oil filter (if required) per
manufacturer's recommendations
EBC To Check for oil level and condition (colour)
Perform offline vibration collection and analysis Mechanical
1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Rotating
Coupling failure due to Check coupling and bolting condition and alignment.
Mechanical
Clearance/Alignmen excessive misalignment Pump failure will cause insignificant impact on 1 1 2 1 D SCH Rectify if necessary 1Y No LEVEL 2 1 1 1 1 D D-1
Coupling Maintenance error Condition monitoring D-2 Rotating
t failure and compression/ production due to redundancy
expansion stress Check coupling element/disk condition. Replace if
Mechanical
1 1 2 1 D SCH necessary. 1Y No LEVEL 2 1 1 1 1 D D-1
Rotating

Process parameter monitoring


Casing Leaks Due To
Gasket Degradation,
sealing surface wear or Pump failure will cause insignificant impact on Mechanical
Casing Leakage External influence Casual Observation 1 2 2 1 D D-2 EBC 6M No LEVEL 2 1 1 1 1 D D-1
corrosion that leads to production due to redundancy Rotating
premature external or
internal casing leaks
Bubble formed from
Check for abnormal sound / vibration / operating
pressure drop below 1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
Pump failure will cause insignificant impact on parameter
Cavitation liquid vapor pressure Off-design service Condition monitoring D-2
production due to redundancy Perform offline vibration collection and analysis Mechanical
implodes and trigger 1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Rotating
shockwaves causing
Errosion of impeller
Check for abnormal sound / vibration / operating
surface by foreign 1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
Pump failure will cause insignificant impact on parameter
Erosion material causes flow Off-design service Condition monitoring D-2
production due to redundancy Perform offline vibration collection and analysis Mechanical
angle to deviate and may 1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Impeller ( use Rotating
induce fatigue crack
same as above)

Open
same as above) Fatigue crack from
Check for abnormal sound / vibration / operating
stress in runner 1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
Pump failure will cause insignificant impact on parameter
Fatigue blade/vane due to Operating error Condition monitoring D-2
production due to redundancy Perform offline vibration collection and analysis Mechanical
frequent start/stop of the 1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Pump Rotating
pump or excessive
delivering Check for abnormal sound / vibration / operating
1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
process Clearance/Alignmen Pump failure will cause insignificant impact on parameter
Impeller clearance failure Maintenance error Condition monitoring D-2
medium at t failure production due to redundancy Perform offline vibration collection and analysis Mechanical
1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
reduced Rotating
efficiency; Check for leakage
high vibration 1 1 2 1 D EBC Verify Level, Pressure, quality and outlet 1M Operation No LEVEL 1 1 1 1 1 D D-1
temperature of buffer fluid/flushing fluid is OK.
Material wear on seal Pump failure will cause insignificant impact on
Wear & Tear Casual Observation D-2 Replace Buffer Fluid 4 2 Condition Condition Condition
faces, springs or O-rings production due to redundancy
Base Base Base Mechanical
1 1 2 1 D SCH Inspect seal flushing line orifice condition. Rectify if No LEVEL 2 1 1 1 1 D D-1
Rotating
necessary
Mechanical seal Leakage Monitor seal flush temperature on gauge, listen for
1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
abnormal noise
Regularly inspect seal flush cooler and tubing
Mechanical
Seal flush cooler Potential reduced or no pumping capability, 1 1 2 1 D SCH including orifice. 6M No LEVEL 2 1 1 1 1 D D-1
Loss of seal flush flow Condition monitoring D-2 Rotating
fouling Process Impact
which cause damage to
Regularly inspect seal flush tubing by
the seal faces Mechanical
1 1 2 1 D SCH disassembling, include seal detection piping 6M No LEVEL 2 1 1 1 1 D D-1
Rotating

Clogged Periodic condition Potential reduced or no pumping capability, Monitor Seal flush temperature
EBC
monitoring Process Impact
Clean and unclogged seal flushing and cooling 4 2 Mechanical
SCH 6M 6M 1Y No LEVEL 2
water line Rotating
Periodic condition Potential reduced or no pumping capability, Perform offline vibration collection and analysis Bi
High Vibration CNM 1M 3M
monitoring Process Impact Weekly
Periodic condition Potential reduced or no pumping capability, Perform offline vibration collection and analysis
Misalignment CNM
monitoring Process Impact
Check for abnormal sound / vibration / operating
1 1 2 1 D CNM 1M Operation No LEVEL 1 1 1 1 1 D D-1
parameter
Fatigue deformation from
Perform offline vibration collection and analysis Mechanical
misalignment, shaft Pump failure will cause insignificant impact on 1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Deformation Maintenance error Condition monitoring D-2 Rotating
imbalance and other production due to redundancy
Check coupling and bolting condition and alignment.
dynamic phenomena Mechanical
1 1 2 1 D SCH Rectify if necessary 1Y No LEVEL 2 1 1 1 1 D D-1
Rotating

Check for abnormal sound / vibration / operating


Shaft damage by foreign parameter
object ingestion due to
inadequate flushing of 1 1 2 1 D CNM Verify Pump Flow is Above Minimum Flow 1M Operation No LEVEL 1 1 1 1 1 D D-1
Pump failure will cause insignificant impact on
Breakage pump suction line or Operating error Condition monitoring D-2
Shaft ( follow production due to redundancy Verify Switch Setting & Valve Arrangement Correct
fatigue crack from
above) For Auto Start Function
operating under stress
outside envelope Perform offline vibration collection and analysis Mechanical
1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Rotating
Check for abnormal sound / vibration / operating
parameter

1 1 2 1 D CNM Verify Pump Flow is Above Minimum Flow 1M Operation No LEVEL 1 1 1 1 1 D D-1
Fatigue crack from Pump failure will cause insignificant impact on
Erosion Off-design service Condition monitoring D-2
errosion/corrosion attact production due to redundancy Verify Switch Setting & Valve Arrangement Correct
For Auto Start Function
Perform offline vibration collection and analysis Mechanical
1 1 2 1 D CNM 3M No LEVEL 2 1 1 1 1 D D-1
Rotating
Pump suction Blockage due to debris Process parameter monitoring ie:. PDI across
Pump failure will cause insignificant impact on
(strainer) / Blockage/plugged or inadvertently closed 1 2 2 1 D D-2 EBC strainer, pump discharge pressure, discharge flow. 1M Operation No LEVEL 1 1 1 1 1 D D-1
Off-design service Production inteference production due to redundancy
discharge suction valve

Open

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