Wear / Seize Prob abilit y 2 D-2 EBC Proposed Task Task Duration(Hr) Consequence 1 1 1 1 D D-1 1 1 1 1 D D-1 1 1 1 1 D D-1 LEVEL 2 1 1 1 1 D D-1 LEVEL 2 1 1 1 1 D D-1 Task Responsibility TA (YES / NO) Maintenance Level Daily Operation No LEVEL 1 No LEVEL 2 No LEVEL 1 No No No of Pax C1 C2 C3 Shift Shift Task Remarks Check for abnormal sound / vibration / operating parameter Periodic Condition Maintenance (Vibration, Temperature & Noise) Pump failure will cause insignificant impact on production due to redundancy Bearing spalling 1 Task Frequency Task Type Mitigated risk Failure Effect Probability Normal wear and tear Detection Mechanism Asset Reputatio n Failure Cause People Environm ent Description of Failure Mode Unmitigated risk Failure Modes Asset Reputatio n Component People Environm ent Consequence Functional Failure 1 1 D Perform offline vibration collection and analysis 1 1 2 1 D 1 1 2 1 D CNM 1 1 Bearing Bi Weekly 1M 3M Mechanical Rotating - CBM Shift Shift Daily Operation C2 - Moderate (D3) C1 - Major ( D4) For all To Check for oil level and condition Lack of Lubrication Casual Observation Breakage Coupling Bearings have reduced operability or seized. External influence (high vibration, misallignment, Coupling failure due to Maintenance error Clearance/Alignmen excessive misalignment t failure Overload Membrane Fatigue Corrosion Off Spec Product Condition monitoring Periodic condition monitoring Inspection Off-design service Condition monitoring Production inteference Erosion Errosion of impeller surface by foreign Condition monitoring material causes flow angle to deviate and may Off-design service induce fatigue crack and impeller rupture if left undetected Impeller Pump totally fail to deliver medium; pump seizure Fatigue Fatigue crack from stress in runner Off-design service blade/vane due to frequent start/stop of the pump or excessive Pump failure will cause insignificant impact on production due to redundancy Pump failure will cause insignificant impact on production due to redundancy Pump failure will cause insignificant impact on production due to redundancy Pump failure will cause insignificant impact on production due to redundancy Pump failure will cause insignificant impact on production due to redundancy Pump failure will cause insignificant impact on production due to redundancy Inspection Pump failure will cause insignificant impact on production due to redundancy EBC 1 1 2 1 D D-2 CNM 1 1 2 1 D D-2 CNM 1 1 2 1 D D-2 SCH 1 1 2 1 D D-2 CNM 1 1 2 1 D D-2 EBC 1 1 2 1 D 1 1 2 1 D Pump failure will cause insignificant impact on production due to redundancy Production inteference D-2 CNM D-2 Deformation Breakage Shaft High Vibration Fatigue deformation from misalignment, shaft Off-design service imbalance and other dynamic phenomena Shaft damage by foreign object ingestion due to inadequate flushing of pump suction line or fatigue crack from operating under stress outside envelope Overload / High vibration/ Fatigue Production inteference Pump failure will cause insignificant impact on production due to redundancy Production inteference Pump failure will cause insignificant impact on production due to redundancy Production inteference Pump failure will cause insignificant impact on production due to redundancy Production inteference Pump failure will cause insignificant impact on production due to redundancy Check coupling element/disk condition. Replace if necessary. Perform offline vibration collection and analysis 1 1 1 1 1 1 1 1 Bi Weekly Bi Weekly Process parameter monitoring Check for abnormal sound / vibration / operating parameter Mechanical Rotating - CBM Mechanical Rotating - CBM 1M 3M 1M 3M 6M 6M 6M AMT Rotating No LEVEL 2 1 1 1 1 D D-1 Bi Weekly 1M 3M Mechanical Rotating - CBM No LEVEL 2 1 1 1 1 D D-1 Shift Shift Daily Operation No LEVEL 1 1 1 1 1 D D-1 1 1 Bi Weekly 1M 3M Mechanical Rotating - CBM No LEVEL 1 1 1 1 1 D D-1 1 1 Bi Weekly 1M 3M Mechanical Rotating - CBM No LEVEL 2 1 1 1 1 D D-1 Operation No LEVEL 1 1 1 1 1 D D-1 No LEVEL 2 1 1 1 1 D D-1 TA Level 3 Perform offline vibration collection and analysis Process parameter monitoring EBC 1 1 2 1 D 1 1 2 1 D CNM D-2 1 1 2 1 D 1 1 2 1 D CNM EBC D-2 CNM EBC 1 1 2 1 D 1 1 2 1 D CNM EBC 1 1 2 1 D EBC D-2 D-2 1 Periodic condition monitoring Perform offline vibration collection and analysis CNM SCH Clearance/Alignmen Impeller clearance failure t failure Perform offline vibration collection and analysis 1 2 1 D 1M 3M Inspection during pump overhaul 1 1 Check for abnormal sound / vibration / operating parameter Perform offline vibration collection and analysis 1 1 TA Condition Condition Based Based Mechanical Rotating Mechanical Rotating 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 6M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 Process parameter monitoring Check for abnormal sound / vibration / operating parameter Perform offline vibration collection and analysis Check for abnormal sound / vibration / operating parameter Verify Pump operating as per pump curve CNM Pump failure will cause insignificant impact on production due to redundancy Check for abnormal sound / vibration / operating parameter Perform offline vibration collection and analysis CNM Perform offline vibration collection and analysis Perform offline vibration collection and analysis Check for abnormal sound / vibration / operating parameter Erosion Fatigue crack from Off-design service errosion/corrosion attack Condition monitoring Pump failure will cause insignificant impact on production due to redundancy 1 1 2 1 D CNM D-2 1 1 2 1 D Verify Pump Flow is Above Minimum Flow Verify Switch Setting & Valve Arrangement Correct For Auto Start Function CNM Perform offline vibration collection and analysis Check for abnormal sound / vibration / operating parameter 1 1 2 1 D CNM 1 1 2 1 D CNM Check packing boxes, bearings (bearing housing), or pump casing for overheating Wear ( Follow above) Bearing spalling Expected wear and tear Condition monitoring Pump failure will cause insignificant impact on production due to redundancy Bearings Overheating Coupling Lube oil degradation Coupling failure due to Clearance/Alignmen excessive misalignment t failure and compression/ expansion stress contamination Maintenance error Casual Observation / Oil Pump failure will cause insignificant impact on sampling analysis production due to redundancy Condition monitoring Pump failure will cause insignificant impact on production due to redundancy D-2 Perform offline vibration collection and analysis Clean Sight Glass, Constant Level Oiler, Water Collector - if applicable 1 1 2 1 D 1 1 2 1 D SCH CNM D-2 Flush bearing housing, replace oil in bearing housings and lube oil filter (if required) per manufacturer's recommendations Check packing boxes, bearings (bearing housing), or pump casing for overheating Clean Sight Glass, Constant Level Oiler, Water Collector - if applicable 1 1 2 1 D SCH Flush bearing housing, replace oil in bearing housings and lube oil filter (if required) per manufacturer's recommendations EBC 1 1 2 1 D CNM To Check for oil level and condition (colour) Perform offline vibration collection and analysis 1 1 2 1 D 1 1 2 1 D D-2 4 2 Force feed . TA 6M 6M 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 SCH Check coupling and bolting condition and alignment. Rectify if necessary 1Y Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 SCH Check coupling element/disk condition. Replace if necessary. 1Y Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 6M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 Process parameter monitoring Casing Leakage Casing Leaks Due To Gasket Degradation, sealing surface wear or corrosion that leads to premature external or internal casing leaks External influence Casual Observation Pump failure will cause insignificant impact on production due to redundancy Cavitation Bubble formed from pressure drop below liquid vapor pressure implodes and trigger shockwaves causing Errosion of impeller Off-design service Pump failure will cause insignificant impact on production due to redundancy Erosion Impeller ( use same as above) Open surface by foreign Off-design service material causes flow angle to deviate and may induce fatigue crack Condition monitoring Condition monitoring Pump failure will cause insignificant impact on production due to redundancy 1 2 2 1 D D-2 EBC 1 1 2 1 D 1 1 2 1 D CNM 1 1 2 1 D CNM 1 1 2 1 D CNM D-2 D-2 CNM Check for abnormal sound / vibration / operating parameter Perform offline vibration collection and analysis Check for abnormal sound / vibration / operating parameter Perform offline vibration collection and analysis same as above) Fatigue Pump delivering process medium at reduced efficiency; high vibration Fatigue crack from stress in runner blade/vane due to frequent start/stop of the pump or excessive Operating error Clearance/Alignmen Impeller clearance failure Maintenance error t failure Material wear on seal faces, springs or O-rings Mechanical seal Wear & Tear Condition monitoring Condition monitoring Casual Observation Pump failure will cause insignificant impact on production due to redundancy Pump failure will cause insignificant impact on production due to redundancy Seal flush cooler fouling Clogged Condition monitoring 1 2 1 D 1 1 2 1 D 1 1 2 1 D Potential reduced or no pumping capability, Process Impact Periodic condition monitoring Potential reduced or no pumping capability, Process Impact Periodic condition monitoring Periodic condition monitoring Potential reduced or no pumping capability, Process Impact Potential reduced or no pumping capability, Process Impact CNM D-2 CNM CNM D-2 1 1 2 1 D CNM 1 1 2 1 D EBC 1 1 2 1 D Pump failure will cause insignificant impact on production due to redundancy Leakage Loss of seal flush flow which cause damage to the seal faces 1 D-2 1 1 2 1 D 1 1 2 1 D 1 1 2 1 D Misalignment SCH Regularly inspect seal flush tubing by disassembling, include seal detection piping Deformation Shaft ( follow above) Breakage Fatigue deformation from misalignment, shaft Maintenance error imbalance and other dynamic phenomena Shaft damage by foreign object ingestion due to inadequate flushing of pump suction line or fatigue crack from operating under stress outside envelope Condition monitoring Pump failure will cause insignificant impact on production due to redundancy CNM CNM 1 2 1 D 1 1 2 1 D 1 1 2 1 CNM D-2 D CNM SCH 4 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 6M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 6M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 Mechanical Rotating No LEVEL 2 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1Y Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 3M Mechanical Rotating No LEVEL 2 1 1 1 1 D D-1 1M Operation No LEVEL 1 1 1 1 1 D D-1 2 Condition Condition Condition Base Base Base Inspect seal flushing line orifice condition. Rectify if necessary SCH CNM EBC 1 Check for leakage Verify Level, Pressure, quality and outlet temperature of buffer fluid/flushing fluid is OK. Monitor seal flush temperature on gauge, listen for abnormal noise Regularly inspect seal flush cooler and tubing including orifice. SCH High Vibration Check for abnormal sound / vibration / operating parameter Perform offline vibration collection and analysis Replace Buffer Fluid SCH D-2 Check for abnormal sound / vibration / operating parameter Perform offline vibration collection and analysis Monitor Seal flush temperature Clean and unclogged seal flushing and cooling water line Perform offline vibration collection and analysis 4 2 6M 6M 1Y Bi Weekly 1M 3M Perform offline vibration collection and analysis Check for abnormal sound / vibration / operating parameter Perform offline vibration collection and analysis Check coupling and bolting condition and alignment. Rectify if necessary Check for abnormal sound / vibration / operating parameter Operating error Condition monitoring Pump failure will cause insignificant impact on production due to redundancy 1 1 2 1 D CNM Verify Pump Flow is Above Minimum Flow D-2 Verify Switch Setting & Valve Arrangement Correct For Auto Start Function 1 1 2 1 D CNM Perform offline vibration collection and analysis Check for abnormal sound / vibration / operating parameter Erosion Pump suction (strainer) / discharge Open Blockage/plugged Fatigue crack from errosion/corrosion attact Blockage due to debris or inadvertently closed suction valve Off-design service Off-design service Condition monitoring Pump failure will cause insignificant impact on production due to redundancy Pump failure will cause insignificant impact on Production inteference production due to redundancy 1 1 2 1 D CNM Verify Pump Flow is Above Minimum Flow D-2 Verify Switch Setting & Valve Arrangement Correct For Auto Start Function 1 1 2 1 D 1 2 2 1 D CNM D-2 EBC Perform offline vibration collection and analysis Process parameter monitoring ie:. PDI across strainer, pump discharge pressure, discharge flow.
