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Process Step Potential Effect (s) of Failure Potential Cause (s)/ Criticality Analysis
Potential Failure Mode
Function Local System Plant Mechanism(s) of Failure Sev Occur Detect RPN
Failed to open Low Effect Low Effect No Effect Valve failure 3 1 2 6
Check Valve Remain open Low Effect Low Effect No Effect Valve failure 3 1 2 6
Crack valve Low Effect Low Effect No Effect Valve failure 3 2 2 12
Incorrect burner sequence Boiler trip Steam system trip Production stooping Bearing failure 6 1 2 12
Too much fuel being fired Boiler trip Steam system trip Production stooping Valve failure 6 2 2 24
Boiler low
Too much excess air Steam system trip Lower production 2
Combustion room performance Valve failure 2 2 8
Faulty flam detector Boiler trip Steam system trip Production stooping Sensor failure 6 1 3 18
Combustion air very low flow Boiler trip Steam system trip Lower production Valve failure 3 2 2 12
Combustion gas pass failure Boiler trip Steam system trip Lower production Sensor failure 5 2 3 30
Over maximum permissible working
Boiler trip Steam system trip Lower production 1
pressure Tank failure 1 1 1
Low water level Boiler trip Steam system trip Lower production Tank failure 1 2 1 15
Control
Extra water level Boiler trip Steam system trip Lower production Pipe failure 2 1 1 15
Power Failure Boiler trip Steam system trip Production stooping Tank failure 5 1 4 1
Water treatment Boiler trip Steam system trip Lower production Enviroment effect 3 1 1 20
Forced draft fan Noise in motor Boiler trip Steam system trip Lower production Motor failure 5 1 2 23
Low effect on
Air filter Dirt on sureface Low effect No effect 1
boiler Air filter failure 3 1 27