Failure Mode and Effect Analysis (FMEA) for Enhancing Reliability

of Water Tube Boiler in Thermal Power Plant

Kapil Dev Sharma*1 and Shobhit Srivastava2
1. Assistant Professor, Faculty of Engineering and Technology, Gurukul Kangri Vishwavidyalaya, Haridwar, Uttrakhand. e-mail : kapilshiva999@gmail.com
2. Assistant Professor, Faculty of Engineering and Technology, Gurukul Kangri Vishwavidyalaya, Haridwar, Uttrakhand e-mail : shobhit.srivastava27@gmail.com

Publication Info Abstract

Failure mode and effect analysis is one of the QS-9000 quality system
Article history :
requirement supplements, with a wide applicability in all industrial fields. FMEA
Received : 12th Oct. 2016 is the inductive failure analysis instruments which can be defined as a methodical
Accepted : 24th Nov. 2016 group of activities intended to recognize and evaluate the potential failure
DOI : 10.18090/samriddhi.v8i2.7139 modes of a product/ process and its effects with an aim to identify actions
which could eliminate or reduce the chance of the potential failure before the
problem occur.

Keywords : The purpose of this paper is to evaluate the FMEA research and application in
the Thermal Power Plant Industry. The research will highlight the application
Water Tube Boiler, FMEA, RPN,
of FMEA method to water tubes (WT) in boilers with an aim to find-out all the
Reliability, Thermal Power Plant.
major and primary causes of boiler failure and reduce the breakdown for
continuous power generation in the plant.
Failure Mode and Effect Analysis technique is applied on most critical or serious
parts (components) of the plant which having highest Risk Priority Number
*Corresponding author :
(RPN). Comparison is made between the quantitative results of FMEA and
Kapil Dev Sharma
reliability field data from real tube systems. These results are discussed to
e-mail : kapilshiva999@gmail.com
establish relationships which are useful for future water tube designs.

1. INTRODUCTION how to minimize plant breakdown by reducing

T he demand for electricity is increasing day by

day with rapidly change in worlds economy in
failure modes. In the boiler, there are the many
small components. If one of them fails, whole
process of boiler stops working. It is big problem
every country similar to India. Although, the for Power Plant Engineers. There are a number of
government has put its efforts to meet out this failure modes due to breakdown in the Power
demand by building new Power Plants but still Plant.
gaps between demand and supply is very large. In
FMEA discipline was developed in the United
India, more than 75% of electricity is based on
States Military. Military Procedure MIL-P-1629,
coal, so it draws a lot of attention to improve
titled Procedures for Performing a Failure Mode,
efficiency of Thermal Power Plant as there is a
Effects and Criticality Analysis, dated November
large scope of saving energy in Thermal Power
9, 1949. FMEA is a Formal Design Methodology
Plant. For continuous generation of electricity in
in the 1960s by the aerospace industry, with
Thermal Power Plant, engineers keep attention on
obvious reliability and safety requirements. In the
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Failure Mode and Effect Analysis (FMEA) for Enhancing Reliability of Water Tube Boiler in Thermal Power Plant

late 1970s, the Ford Motor Company introduced 2. BASIC CONCEPTS OF FMEA
FMEA to the automotive industry for safety and The main purpose for performing FMEA is to
regulatory considerations. They also used it to prevent the possibility that a new design, process
improve production and design. FMEA has been or system fails to achieve, totally or in part the
adopted in many places, such as: Aerospace, proposed requirements, under certain conditions
Military, Automobile, Electricity, Mechanical, and such as defined purpose and imposed limits.
Semi-conductor industries. Most current FMEA Through FMEA, the client requirements are
methods use the risk priority number (RPN) value evaluated and products and processes are developed
to evaluate the risk of failure.
in a manner that minimizes the risks of the
The ability to improve continually is desirable. occurrence of potential failure modes, with an
In recent years, the reliabilities of Power Plants emphasis on insuring the safety and health of the
have become increasingly important issues in the personnel and the security of the systems. Another
most developed and developing countries. Reliability, purpose of the FMEA is to develop, evaluate and
Availability, Maintainability and Supportability enhance the design development and testing
(RAMS), as well as risk analysis, have become methodologies to achieve the elimination of
big issues in the power industries. Major causes failures and thus obtain world-class competitive
of customer dissatisfaction often results from the products. The main advantages of using FMEA
unexpected failures, which have led to an unanticipated methods are: Reduction of Costs, with a critical
costs in the Thermal Power-Station. However, with
impact on warranty returns; Reduction of the Time
proper integration of RAMS and risk analysis in
needed from the project phase to the market launch
each maintenance process in the Thermal Power-
and Improvement of the Quality and Reliability
Station, the frequency of failures can be reduced
of the products, while increasing the safety of their
and their consequences can be diminished.
operation. The ultimate goal for attaining these
Failures are prioritized according to how benefits is the increase of customer satisfaction,
serious their consequences may be occur and how which assures the growth of the organization's
easily they can be detected. FMEA is used during competitively and the improvement of the image
the design stage with an aim to avoid future on the market.
failures. Later, it is used for process control, before
3. FMEA PROCESS STEPS
and during on-going operation of the process.
Ideally, FMEA begins during the earliest The description of the FMEA process steps are:
conceptual stages of design and continues 1. Establishment of FMEA team.
throughout the life of a product or service. The
2. Describing the product/process/system which
outcome of FMEA development is actions to
wants to be analyzed.
prevent or reduce the severity or likelihood of
3. Creating a Block Diagram of the product or
failures, starting with the highest-priority. FMEA
process which shows major components or
determines the risk priorities of failure modes through
the risk priority number (RPN), which is the product process as blocks connected together by lines
of the occurrence (O), severity (S) and detection (D) indicate how the components or steps are co-
of a failure. (RPN = O * S * D) related.

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 Kapil Dev Sharma and Shobhit Srivastava

4. List of potential failure modes, causing of There are some major components in the plant
failures in the system. failure in the following years. Table1. Shows that
5. Assign Severity, Occurrence and Detection boiler is the most critical and serious component
rankings to each failure mode. in a power plant because it can fail many times
6. Calculate RPN (Risk Priority Number) by using during years as compared to the other components.
mathematical formula (RPN= Severity X So, the team is focused on the boiler to find out all
Occurrence X Detection.) basic failure modes of it.

7. Develop an Action Plan and define who will For finding out all the Basic Failure Modes and
do what by when. causes of failure of boiler, use "Cause and Effect
Diagram" or "Fishbone Diagram". After finding
8. Take actions those are identified by the FMEA
all Basic Failure Modes of boiler, calculate Risk
team.
Priority Number of each failure mode and find out
9. Calculate the resulting RPN after implementation
the component in boiler more serious and having
of actions.
the highest RPN.
10. Compare RPN before and after implementation
Calculate RPN by using mathematical formula
of actions and Re-evaluating each of the
(RPN= Severity X Occurrence X Detection). On
potential failures once improvements have been
the basis of above analysis for RPN, it is seen that
made. Determine the impact of the improvements
boiler tube failure has the highest Risk Priority
using FMEA.
Number (315) amongst all other failure modes.
So, the first priority is given to the boiler tube
for reduction in the failures of a boiler. Boiler tube
plays the most important role for shuting down of
a power plant.

Table-1: Major Component's failure in SSTPS

Year 2007 2008 2009 2010

Boiler 34 62 68 70
Feed water pump 15 12 16 15

Circulating water 12 15 16 20
pump
Electrical system 10 12 13 15
Emissions control 14 20 38 40
Fig.1: FMEA Process Steps
system
C & I System 15 0 12 10
4. FMEA IN THERMAL POWER PLANT Turbine 25 32 44 45
Suratgarh Super Thermal Power Plant (SSTPS) Others 48 25 22 20
is First Super Thermal Power Station of Rajasthan.
The total planned installed capacity is 1500 MW.

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 Failure Mode and Effect Analysis (FMEA) for Enhancing Reliability of Water Tube Boiler in Thermal Power Plant

5. RECOMMENDED ACTIONS
80
70
60 There are some actions suggested by the FMEA
50
40
30 2007
team to reduce the failures of Water Tube:
20
2008
10
0 2009
If a major failure occurs, unit shuts down for 3
to 4 days that affects power generation.
p

s
r

e
2010
p

er
ile

um

in
m

te
ste

th
te

rb
Bo

ys
pu
rp

O
ys

Tu
sy

IS
e

er

ls
t

al

&
wa

at

ro
ric

At the time of working, alignment of the tube,

C
w

nt
ed

ct
g

co
Ele
in
Fe

ns
at
ul

io
rc

iss

excess steam temperature and pressure is to be

Ci

Em

Fig.2: Major Component's Failure in SSTPS checked in routine.

The boiler here is a Water Tube Natural circulation
type.
Controlling the flow velocity in the raised tube
is to be sufficient. Due to some abnormality,
excess steam builds up in the raised tube
causing over heating and exerting excessive
stress in the tube.
During the operation if the corrosion affects in
Fig.3: "Cause and Effect Diagram" for boiler to find out
cause of Failures and their effects tube in a small area, take necessary action by
the Boiler Maintenance Department.
If there is any doubt in the leakage of Water
Table-2: RPN number before implementation of FMEA
Potential failure Potential effect of failure Potential causes of failure Severity Occurrence Detection RPN Tube, the setting of the tubes need to be
mode (S) (O) (D)
Flow air fuel ratio 1. The unit had shut down due 1. Air flow below 30 %
to bad proportion of air fuel
5 3 5 75
examined.
mixture
2.bed combustion 2.grain size of coal
3.dust in fuel increases
Corrosion effect 1. Boiler tube material becomes 1. creep failure 5 6 8 240
If temperature of the tubes rises excessively,
weak.
2. Cooling of tube wall reduce 2. corrosion is associated with
so temperature increases austenitic super heater materials
inform quickly to the Control Room.
3.boiler pressure increases

4. Welded joint goes weak.

3. It is usually with the coal
firing also with the oil firing. Use innovative preventive techniques to reduce
Temperature of 1. Plant efficiency reduce 1.changing the plant load 7 6 5 210
super heater and re-2. failure of super heater and re-
heater heater tubes
2. excess of air fuel mixture the failures.
3. failure of turbine blades 3. bed combustion
Loss of fuel (coal) 1. Steam not produces in proper
manner.
1. proper air fuel mixture in
furnace
5 4 4 80
Extensive inspection of pressure load to be
2. Abnormal combustion of fuel 2. quality of fuel

3. less air flow measured where the pressure rises.

Flame failure 1.combustion does not take 1.scanner not works proper 6 3 3 54

Shielding tube at critical zone to reduce the

place
2. steam not produced properly 2.DC and AC fan not works
proper
3.reheater not works proper

Boiler tube 1.water leakage

4. moisture in coal
1.corrosion 9 7 5 315
erosion and corrosion.
2.cooling process stops 2.scale formation
3.unit had shut down 3. High pressure and
temperature Improve maintenance of Flue Gas part.
4.water level not maintained 4. extremely combustion
5. Inside and outside damage
the tubes
6.highly impurities in feed water

7. Creep failure
Expert analysis of the tube failure.
8. Rupture
9. Poor water circulation
Tube alignment
and setting
1. vibration arrestors get
deformed
1. tubes come out of connectors 7 5 5 175 6. RELIABILITY ANALYSIS
2. boiler tube had damaged 2. vibration increases and tube
failed
Incomplete
combustion
1. proper steam does not supply 1.insufficient air supply in
furnace
6 5 5 150 In the plant due to major failure of Water Tube,
2. air fuel losses 2. fuel bed in poor condition
3. boiler tube wall damaged 3. cooling of furnace at low
ratings
plant unit (5th) had been shut down many times.
Water level of
drum
1.safety valve does not work
steam comes at outside of boiler
1. failure of boiler feed pump 6 7 4 168
Here reliability analysis and MTTF (Mean Time
due to leakage
2. steam pressure excess
3. boiler may be damaged
2. water tubes corrosion
3. failure of feed valve To Failure) is done, to know the failure of tube
4. failure of water level
indicator
maintenance duration and working duration of

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 Kapil Dev Sharma and Shobhit Srivastava

boiler between two failures. Table 3 shows last

Table-5: Hypothesis Test by using Mann's test
three years data of Water Tube failure from 14- S. ti lnt i Mi lnti+1 - lnti (lnti+1 - lnti)/Mi
12-2008 to 20-01-2011. No.
1 1345 7.204 1.113 0.134 0.12
2 1538 7.338 0.525 0.294 0.56
Table-3: Failure Time of Water Tube in Boiler
3 2063 7.632 0.551 0.022 0.04
S. Date of Time of Time of Time of Time duration Working time
No. failure breakdown hand over repair of Maintenance duration (Hrs.)
4 2110 7.654 0.267 0.079 0.295
after repair (Hrs.) 5 2283 7.733 0.216 0.075 0.347
1 14-12-08 10 A.M. 17-12-08 6 A.M 69 2,462
6 2462 7.808 0.183 0.016 0.087
2 28-03-09 4 P.M. 01-04-09 5 A.M 99 2,501
3 10-07-09 12 P.M. 14-08-09 2 P.M 78 3,678 7 2501 7.824 0.16 0.037 0.231
4 13-11-09 9 A.M. 15-11-09 7 A.M 44 2,283 8 2595 7.861 0.142 0.349 2.458
5 10-03-10 2 P.M. 13-03-10 11 A.M 73 2,063
9 3678 8.21
6 05-05-10 8 A.M. 06-05-10 12 P.M 37 1,345
7 21-08-10 11 A.M. 24-08-10 9 P.M 43 2,595
8 17-11-10 10 A.M. 19-11-10 6 P.M 42 2,110
9 20-01-11 4 P.M 23-01-11 7 A.M 63 1,538 Above eqn. compared with the
a Y bX
Reliability for each working duration by using
n n
Rank Adjustment Method (RAM) and MTTF as
b
i 1
Xi, Yi X i 1Yi
n 2
shown in Table 4. For example Reliability R (t) i 1
Xi 2 n. X
for 21101hrs. i=4, n=9
33.21 7.6958 4.667 2.769
i 0.3 b= 3.3894
R (t) 1 = 0.6063 533.72 9 59.225 0.695
n 0.4
Apply the Weibull least square method And, a Y b.X - 0.5185 (3.3840*7.6958) =
26.632 Find out scale parameter () for find MTTF
X = 69.263, Y -4.667, XY =-30.210,
(Mean Time to Failure), so

=59.225,
X =7.6958, a
X2 X 9 Scale parameter e

Y 2 = 2584.889 hrs. = 2,585 hrs.

Y 9 = -0.5185, X = 533.72
1
So slop factor in weibull distribution or Shape MTTF 1 , Gammafuncation
parameter m=b=

For straight line y = bx +a, 1

= 2,585, 1 = 2,585
3.3894
Table-4: Analysis for Mean Time To Failure (MTTF)
S. Working hours R
i 0.3
X=ln (t) 1 X*Y X
2 Here (1.2950) =0.92877 (From the gamma
No. in ascending (t) 1 Y= In In
order (t)
n 0.4 R (t ) function table)
1 1345 0.9255 7.204 -2.558 -18.43 51.89
= 2,585 = 2,326.50hrs. = 96.9375days
2 1538 0.8191 7.338 -1.611 -11.82 53.85
3 2063 0.7127 7.631 -1.082 -8.256 58.23 =97 days
4 2110 0.6063 7.654 -0.6923 -5.298 58.58
5 2283 0.5 7.733 -0.3665 -2.834 59.8 From the Weibull least square method, MTTF
6 2462 0.3936 7.808 -0.0699 -0.546 60.96 is 97 days. But, here we consider the Manns test
7 2501 0.2872 7.824 0.2212 1.7306 61.21
for verifying the Weibull distribution in satisfying
8 2595 0.1808 7.861 0.5367 4.219 61.8
9 3678 0.0744 8.21 0.9548 7.813 67.41 the failure of the Water Tube. Now, we apply the
Manns test.
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Failure Mode and Effect Analysis (FMEA) for Enhancing Reliability of Water Tube Boiler in Thermal Power Plant

In the last three years of failure data 36 failures denominator. Since M <Fcrit 0.05,9,9, so H0 is accepted.
occursed out of 36 failure in which 9 times of the Where (Fcrit 0.05,9,9, = 3.18, from the F distribution
major failure had in the water tube. Due to these table).
failures, unit had to be shut down. For these failures 8. RESULT
MTTF is 97 days. Table.6 Shows the Comparison of RPN before
Manns Test Shows - and after implementation of FMEA.
n = 36;
Table-6: Comparison of RPN
r = 9; and the confidence level for the failures
Occurrence Severity Detection RPN
is 95 %, so
Old RPN 7 9 5 3 15
= 0.05 New RPN 6 9 5 2 70
r 9
K1 = K2 = = 4.5 4
2 2
From the above table, after implementing
r 1
K 1 i k 1 [(ln ti 1 ln ti ) / M i ] FMEA on Water Tube, calculated RPN is to be
M 1
k1
K 2 i 1[ (ln ti 1 ln t i ) / M i ] reduced and recommended action is to be taken
resulting in the reduction of the occurrence of the
Where Mi= Zi+1- Zi, and failure modes and severity in the Water Tube.

i 0.5 In reliability analysis of the Water Tube, major

Zi ln ln(1 )
n 0.25 failure of the Water Tube was taken in the last three
years. After calculating MTTF by the Weibulls
1 0. 5
So Z1 = In In1 = -4.276 Least Square Method its counts 2,324.00 hours or
36 0.25
97 days.
2 0. 5
Z2 = In In1 = -3.163 After applying the Manns test on failure data,
36 .25
that tests the applicability of failure data in
So on
Weibulls Least Square Method. The results
9 0. 5 showed that the hypothesis is accepted.
Z9 = In In1 = -1.319
36 0.25
It has been seen that there are many critical
And M1 = Z2- Z1 = -3.163 -- (-4.276) = 1.113
failure modes in the boiler, but, only the Water
So on .. Tube failures are considered because Water Tube
M8 = 0.142 is a most critical and serious part of a boiler. These
From the above calculation, we can find the failures affected the boiler performance and power
following values for M: generation. It is concluded the Risk Priority
Numerator = 12.492 and Denominator = 4.0.6, Number (RPN) of the boiler tube is reduced by
12.492 some recommendations.
M= = 3.070 using the above eqn. with
4.06
degree of freedom for both the numerator and

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 Kapil Dev Sharma and Shobhit Srivastava

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