Rcfa Report Template For Mechanical Equipment 4e6x37

Report No.

Root Cause Failure Analysis Report A) What Are The Details Of The Event/Failure? Failure Report Title (May be based on the work order title)

Date Of Event/Failure Equipment Tag No Tag Description Equipment Type Equipment Vendor Equipment Serial No CMMS Work Order No Work Order Opened (date) Work Order Closed (date)

_____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ _____________________________ ________________________________

NOTE: Complete only relevant sections. If certain sections are not considered relevant, you must state why it is not relevant. Incomplete reporting is unacceptable.

B) Function

What does ‘it’ do?

Very often there is a lack of clarity on, what the equipment should actually do, what the performance standards are for the equipment (e.g. to pump 350cu meter/hour of crude at 40bar). This lack of clarity can make the process of failure analysis very difficult. Consider what the normal operational performance standard is for this equipment in its normal operating mode. It is necessary to know the normal parameters first, as a reference/datum. In this section record the entire key data regarding the equipment’s primary function. 1

What is the operating context for this equipment you have worked on? (State the primary function and the performance, throughput, in a specified time, i.e. pressure, temperature, etc?)

If relevant, please describe secondary functions.

2

• • • • •

•

State what the standard primary function performance standard is, i.e., it is the datum for comparison, and who has set this performance standard? Work - What is expected? Cycles/Load Etc. Time - How long for? Duration Throughput - At what rate? Output quantity & quality. At what quality? Safety & risk compliance Standard set by (whom)

__________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________ __________________________________________________

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C) Functional Failure

How has ‘it’ not done what it should?

In what way has this piece of equipment been deemed to have failed to fulfil its function? Provide a brief statement of the ‘problem’ or failure that Maintenance was asked to investigate/resolve. [This may be the key point from the maintenance work order.]

3

What change or deviation was observed from the normal operating condition? Compared to the function details previously in Q1 & Q2, e.g. was deterioration, slow down, increases noted, etc? State how? By how much? Over what time frame, etc?

4

Please describe what changed/deviated below, e.g. reduced by x% in time t.

What was the sequence of events that lead up to this failure? Can this be ed with hardcopy documentation such as logs/trends/journals? (Via SER/DCS/RMPIS/Other_________ ) Consider all aspects. ‰ Yes? ‰ No? If Yes please attach the logs/trends/journals to this report.

5

The attached documentation demonstrates/proves that: _______________ and then subsequently

D) Failure Effect

What happened?

6

State in words briefly what happened when the failure occurred? Consider the effect on the equipment, system, and plant.

7

How serious was the failure in of downtime, secondary damage?

(More detailed consequences analysis, see Section H)

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E) Action to Restore Function 8

State clearly what exactly has been done physically to overcome this functional failure? Explain beneath:3

9

Action Code Cleaned Repaired Reset Refurbished in situ Overhauled Recalibrated Adjustment Other, specify

If the item was replaced please state the condition of the fitted item: 3

10

Description

Action Code Replaced with new item Replaced with refurbished item Refurbished and then replaced Replaced with modified item Other

Where are the primary failed components now? Lost/Discarded Available for review (tagged and stored) Refurbished and reinstalled A) Good as new B) Better than old Refurbished and returned to store Returned to vendor Other, explain ________________________

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‰ ‰ ‰ ‰ ‰ ‰ ‰

Has this equipment been returned to as good as new condition and function? ‰ Yes? ‰ No? If Yes how did you , test and confirm that the equipment meets the required performance standards following the response?

Note: Attach test sheets, start-up/ acceptance logs to validate. If you have indicated No:

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• • • •

By how much was it degraded? _____________% Is this considered a temporary repair? or Is this considered a modification temporary or otherwise?

‰ Yes? ‰ No? ‰ Yes? ‰ No?

If a temporary repair has been made, what is required and when?

Requirement _________________ Due date: _______________________ Consequence if due date missed ______________________________________________________________ Follow on MWO Number _______________________________________ Page 3 of 11

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How long will the equipment run now ? ______________________________. Until what next datum? _________________________________________. When? ____________________________.

F) Change Control 14

If you have performed a modification that alters the original fit, form or function, (this includes the substitution of components, different manufacturers, in house made) then this may significantly change its life. These changes must be tracked. Please explain technically the reason, purpose and who authorised this modification, • •

•

Reason [s] Purpose Authority To Modify Is

_____________________________________________________ _____________________________________________________ _____________________________________________________

(Letter No., Engineering Package No, etc)

15

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Detail what effect this modification will have on the function and performance of the equipment/component?

Please indicate what updates are needed as a result of this repair? When permanent changes are made it is very important that all the records, documentation and are also updated so that the maintenance remains valid. that Maintenance is mandated to maintain and not modify – without review/approval and disciplined change management.

The following must be re-validated: • Equipment Master Record in CMMS • Material Spare Parts details, stocking, specifications • Drawings & documentation (to be red lined and returned to design agencies to formally update corporate documentation records) ƒ equipment and tools, updated, provisioned ƒ Standard Job Plan (PM or corrective) ƒ Standard Operating Procedure’s ƒ Start-Up/Acceptance Forms Modified Provide details as necessary in the box below

Any items with No – State Why!

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‰ Yes? ‰ No? ‰ Yes? ‰ No? ‰ Yes? ‰ Yes? ‰ Yes? ‰ Yes? ‰ Yes?

‰ No? ‰ No? ‰ No? ‰ No? ‰ No?

G Failure Mode/Cause 17

What are the initial recorded CMMS Failure Codes for the work that was conducted? ƒ ƒ ƒ ƒ ƒ ƒ

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Failure Failure Code Problem Problem Code Cause Description Cause Code

_________________ _________________ _________________ _________________ _________________ _________________

What do you think happened? What can you prove, and how? Consider also your comments in section C. State clearly in words in the box below

-Initially _______________________________________________________________________________________ -Subsequently _________________________________________________________________________________

Please expand and your conclusion(s): -

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What was the failed component(s) and its mode of failure, e.g., Oil Filter Blocked?

20

Has this failure occurred on similar equipment or a group of equipment? ‰ Yes? ‰ No? If YES, – how often? _______________ in _________________duration.

21

Have you conducted a five-why or other technique to arrive at the Root Cause? ‰ Yes? ‰ No?

Be aware that the initial reported cause is rarely the root cause codes and a further level of detailed, analysis and comparison is necessary to arrive at the real root cause. If YES - What were the findings from this kind of techniques?

Please list the possible Root Cause of failure into the table below. NOTE if further investigation is ongoing or required do not complete this section until the investigation is complete.

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Root Cause Maintenance Related Skills (Competency Deficiency Of Craftsmen) Incorrect Tooling or Equipment Utilised Improper Previous Repair (Rework Issue) Improper Alignment or Field Installation None Standard or Original Materials, Parts Used Original Design or Selection In Question Operational Related Mal-operation. (Improper Operation/Sequence/Etc) Improper Start-up or Shutdown Equipment Overloaded, Operated Too Hard or Too Slow Operating Context/Condition has Changed Since Design Lubrication Issue (Insufficient/Incorrect/Contaminated) Other, explain E.g., design related E.g., purchasing related

Yes

No

You must say what it may be and what it is not; i.e. a Y or N is required for each. No omissions allowed. 22

State what you consider are the real Root Causes.

23

Evaluate the Reliability of this failure?

Based upon the initially reported fault codes, the historical data that has been gathered, the evidence of this event/failure and the basic causes of failure from the table above, from a maintenance perspective would you say this failure is:a) b) c)

Considered ‘normal’ due to appropriate wear & tear. Considered abnormal & unusual. Considered chronic or repetitive. If you indicated Yes to either of the last two questions above. I.e. [abnormal/unusual or chronic/repetitive] What is the historical frequency (number of occurrences)? ___________ Attach the through the relevant CMMS Reports.

d)

‰ Yes? ‰ No? ‰ Yes? ‰ No? ‰ Yes? ‰ No? Please compare these to Nos.1&2 (on Page 1 to define the deviation in performance

Considered unacceptably costly. ‰ Yes? ‰ No? Please financially with the relevant CMMS report that considers lifetime maintenance costs incurred for this asset. What is the ‘normal’ unit cost per work/time/throughput for this equipment for a comparator? <x> ____ $’s per ________ _____

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H) Consequences of Failure 24

Does it matter? How much?

State the consequences of this failure in of safety, environment, production, and costs?

Safety: Was there an actual safety loss associated with this event /failure? (This refers to a quantifiable safety loss that was sustained.) ‰ Yes? ‰ No? If Yes - then how can this actual safety loss be quantified in financial ? Indicate the value of this safety loss in the box provided 24a

<X $’s> for ___________________________

24b

Environmental: Was there an actual environmental loss associated with this event/failure? (This refers to a quantifiable environmental loss that was sustained.) ‰ Yes? ‰ No?

If Yes – then how can this actual safety loss be quantified in financial ? Indicate the value of this environmental loss in the box provided. <X $’s> for ___________________________

As this was an actual safety and/or environmental loss, has this been documented separately, accompanied with the near miss or preliminary incident reportage and channelled through to population of, e.g., HAZOP databases? ‰ Yes? ‰ No? If Yes, - record the transmittal reference to Safety & Environmental Department ______________________ If No, - why not?

24c

Production: - Was there an actual production loss associated with this failure/event? Note. This refers to a quantifiable loss that was sustained that was not recovered by increasing throughput through the plant/unit/equipment once the failure/event was dealt with. ‰ Yes? ‰ No?

If Yes, - then how can this actual production loss be quantified in financial ? Indicate the value of this loss in the box provided. (You may need to discuss this with a performance-monitoring engineer.) <X $’s> for ___________________________ of <product> for

24d

Maintenance: When maintenance responded to this event/failure. (It is important to understand if this was a completely unbudgeted/unplanned response.)

Was this a breakdown response? ‰ Yes? ‰ No? Did this occur out of hours and require call out/overtime? ‰ Yes? ‰ No? Were all the costs directly apportioned to this failure/event? ‰ Yes? ‰ No? If No, - then what other work (opportunistically) was conducted whilst the event/failure was being dealt with? What were the total maintenance costs associated with the response to this event/failure? Total Labour Materials Other

_________________ _________________ _________________ _________________

Hr’s

What was the total downtime of the equipment?

Hr’s

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What was the total maintenance time within this total downtime? Where is the balance of the downtime to be attributed to if the maintenance downtime is less than 50% of the total?

24e

Non Operational/Other

Did this event/failure result in other non operational cost other than the direct costs of response/repair? Perhaps taxes, penalties, logistics etc. ‰ Yes? ‰ No? If Yes what were these costs by type and cost? •

_____$’s For _______<what>

•

25

Determine the Total Financial Cost Of This Event/Failure. (Add together numbers 24a –24e.) ______

$’s

I) Preventive Action 26

What should (could), be done to prevent this failure from re-occurring? (Brief statement only)

<Why> ------------------------------------------------------------------------------------------------------------------------------------------------ ------------------------------------------------------------------------------------------------------------------------------------------------- ---------------------------------------------------------------------------------------------------------------------------------------------

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1. 2. 3. 4. 5.

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Define the tasks or ideas that your work group should do to resolve this issue?

_______________________________________________________________________________________ _______________________________________________________________________________________ _______________________________________________________________________________________ ________________________________________________________________________________________ Approximate Cost?_______________ ROI v/s cost @ Number 25 = x:1 in y period

Have you any other suggestions that would prevent a re-occurrence? (Perhaps outside of your control.) My suggestion is to _____________ because _________________. This needs to be ________________, By ____________________________________.

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Do you consider your suggestions to be: An in-house maintenance activity(s) A outsourced specialist maintenance activity A redefined operations activity (s). A modification or enhancement.

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‰ Yes? ‰ Yes? ‰ Yes? ‰ Yes?

‰ No? ‰ No? ‰ No? ‰ No?

J) Maintenance Strategy Review Would checking the equipment at different intervals have been sufficient to detect the failure before it occurred? How would it then become detectable and preventable? Please explain.

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We should check ___________________ by _______________ at ____________ . This would then make _______________________ <what> detectable & preventable because ______________________________________________________________________________________ <why>

Should we consider a scheduled overhaul / strip down for this equipment? Would the timely replacement of a component have retained the original system resistance to failure as a whole? Please expand/ below.

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- Wear pattern ____________________________ - characteristic _____________________

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Is this equipment currently in the preventative maintenance (PM) programme? ‰ Yes? ‰ No?

If NO - What are the reasons why it should be included in the PM program ? What specific individual failure modes would be targeted and how, in the revised preventative maintenance checks?

It should be included in the preventative maintenance program because ____________________________. We would target ________________________________ failure mode(s) with _________________________________ activities/tasks________________________________ using __________________________ techniques.

If YES - Why didn’t the current preventative measures avoid this current failure? The equipment is in the PM program and the current PM activities did not prevent this current failure because _____________________________________________________________________________________________ _____________________________________________________________________________________________ My /evidence for this conclusion is ___________________________________________________________

If YES - What was the date of the last PM?__________ Type/Code Used ___________ Have the PM’s been conducted on time/schedule in the last year? ‰ Yes? ‰ No? (Please attach the proof that the scheduled PM’s have been completed on schedule and completed. Do you still believe a review of the preventative maintenance -content/frequency is warranted? ‰ Yes? ‰ No? 33

Is this equipment currently included in the predictive maintenance program? ‰ Yes? ‰ No?

If YES, should or could the failure have been predicted? Explain _______________________________________________________________________________

If NO, should condition monitoring be considered? Explain _______________________________________________________________________________

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K) Design out.

Do we need to change ‘it’?

What should be done if no suitable preventative task can be found? Is there an inherent systemic or equipment ‘problem’ that can only be resolved by a redesign action?

34

A design out initiative needs to be considered here because _____________________________________________. This is able, as ________________ is unacceptable in accordance with________________________________________________standard/regulation/required performance standard. The consequences (in cost, danger ) of not making this change are ________________________

L) Status/Conclusion 35

What needs to be done, by whom & by when?

What tangible & able actions are recommended?

Category

Yes

Inconclusive Need to Send Failed Components For Analysis Maintenance Costs Are Unacceptable – Consult Vendor/TSD Design Change Is Necessary Review Materials Of Construction Change Revise Preventative Maintenance Content/Frequency Revise Predictive Maintenance Content/Frequency Review/Revise Operating Procedures Training Is Required Improve, Prove Different Tools/Test Equipment Corrosion/Erosion Issue. Refer To TSD Inspection Other, specify

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No

Next Action To

Due Date.

Scratchpad - Anything To Add or Record? 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Team Leader/Title/Department

Name:_______________________ Title:_________________________ Department:___________________

Team /Discipline/Dept

Name

Discipline

Department

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

___________________________

Date Report Closed Out: _____/______/______

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