Skip to main content
Log in

Optimizing Process Parameters of Screw Conveyor (Sugar Mill Boiler) Through Failure Mode and Effect Analysis (FMEA) and Taguchi Method

Journal of Failure Analysis and Prevention Aims and scope Submit manuscript

Abstract

This paper exhibits the failures of the boiler during the cogeneration process and provides solution to overcome the failures. The failures are frequently occurring in the screw conveyor of fuel-feeding system of the boiler and rarely occurring in the grate of the boiler. In this research work, three important statistical tools are employed to identify and further rectify the failures of the screw conveyor. The different techniques, viz., cause-and-effect diagram, failure mode and effect analysis (FMEA), and the Taguchi method have been applied. The cause-and-effect diagram, is the primary tool used to sort out all the possible root causes of the failures. The process parameters that cause the failures in the screw conveyor are identified by FMEA. Since the conventional FMEA has some limitations, fuzzy FMEA is employed. The most critical parameters selected by conventional FMEA and fuzzy FMEA are fuel type, fuel moisture, drum speed, and air flow. Finally, the selected process parameters are optimized by the Taguchi method to prevent the failures occurring in the screw conveyor. Among the various process parameters, the parameter, fuel type, significantly affects the performance of the screw conveyor.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9

Similar content being viewed by others

Abbreviations

R :

Number of tests in a trial

y i :

Response value of observation in the ith test

DOE:

Design of experiments

ν :

Degrees of freedom

ν A :

Degrees of freedom for factor A

k A :

Number of levels for factor A

ν required :

Total degrees of freedom required

ν LN :

Total degrees of freedom of the available orthogonal array

N :

Number of trials

ANOVA:

Analysis of variance

M :

Overall mean percentage defects

V Factor :

Variance of factor

SS:

Sum of square

V′:

Expected amount of variation

P :

Percent contribution

μ :

Mean

α :

Level of risk

ν e :

Degrees of freedom for the error

V e :

Error variance

F(α, 1, ν e):

F ratio required at the level of risk

η eff :

Effective number of replications

n :

Total number of experiments

CI:

Confidence interval

T :

Average values of defects at different levels

References

  1. A.M. Ghosh, M. Balakrishnan, Pilot demonstration of sugarcane juice ultrafiltration in an Indian sugar factory. J. Food Eng. 58, 143–150 (2003)

    Article  Google Scholar 

  2. M.P. Sharma, J.D. Sharma, Bagasse based co-generation system for Indian sugar mills. Renew. Energy 16, 1011–1014 (1999)

    Article  Google Scholar 

  3. M. Siddhartha Bhatt, N. Rajkumar, Mapping of combined heat and power systems in cane sugar industry. Appl. Therm. Eng. 21, 1707–1719 (2001)

    Article  Google Scholar 

  4. G.R. Lobley, W.L. Al-Otaibi, Understanding boiler tube failures. Saudi Aramco J. Technol. 7–11 (2008)

  5. A.C. Dunn, Y.Y. Du, Optimal load allocation of multiple fuel boilers. ISA Trans. 48, 190–195 (2009)

    Article  Google Scholar 

  6. A. Wienese, Boilers, boiler fuel and boiler efficiency. Proc. S. Afr. Sug. Technol. Ass. 75, 275–281 (2001)

  7. E. Bas, An investment plan for preventing child injuries using risk priority number of failure mode and effects analysis methodology and a multi-objective, multi-dimensional mixed 0–1 knapsack model. Reliab. Eng. Syst. Saf. 96, 748–756 (2011)

    Article  Google Scholar 

  8. T. Buksa, D. Pavletic, M. Sokovic, Shipbuilding pipeline production quality improvement. J. Achiev. Mater. Manuf. Eng. 40(2), 160–166 (2010)

    Google Scholar 

  9. M. Boldrin, A. De Lorenzi, A. Fiorentin, L. Grando, D. Marcuzzi, S. Peruzzo, N. Pomaro, W. Rigato, G. Serianni, Potential failure mode and effects analysis for the ITER NB injector. Fusion Eng. Des. 84, 466–469 (2009)

    Article  Google Scholar 

  10. A.C.F. Guimaraes, C.M.F. Lapa, Fuzzy inference to risk assessment on nuclear engineering systems. Appl. Soft Comput. 7, 17–28 (2007)

    Article  Google Scholar 

  11. A.C.F. Guimaraes, C.M.F. Lapa, M.D.L. Moreira, Fuzzy methodology applied to probabilistic safety assessment for digital system in nuclear power plants. Nucl. Eng. Des. 241, 3967–3976 (2011)

    Article  Google Scholar 

  12. M.K. Pınar, Y. Kumru, Fuzzy FMEA application to improve purchasing process in a public hospital. Appl. Soft Comput. 13, 721–733 (2013)

    Article  Google Scholar 

  13. S. Khanmohammadi, K. Rezaie, J. Jassbi, S. Tadayon, Development of failure occurrence model based on fuzzy inference system for control center of power system. Am. J Sci. Res. 38, 131–139 (2011)

    Google Scholar 

  14. S. Khanmohammadi, K. Rezaie, J. Jassbi, S. Tadayon, A model of the failure detection based on fuzzy inference system for the control center of a power system. Appl. Math. Sci. 6(36), 1747–1758 (2012)

    Google Scholar 

  15. S.K. Oraee, A. Yazdani-Chamzini, M.H. Basiri, Evaluating Underground Mining Hazards by Fuzzy FMEA (SME Annual Meeting, Denver, 2011)

    Google Scholar 

  16. M. Oudjene, L. Ben-Ayed, On the parametrical study of clinch joining of metallic sheets using the Taguchi method. Eng. Struct. 30, 1782–1788 (2008)

    Article  Google Scholar 

  17. U. Esme, Application of Taguchi method for the optimization of resistance spot welding process. The Arab. J. Eng. 34(2B), 519–528 (2009)

    Google Scholar 

  18. D. Bajic, S. Jozic, S. Podrug, Design of experiment’s application in the optimization of milling process. Metalurgija 49, 123–126 (2010)

    Google Scholar 

  19. A.H. Suhail, N. Ismail, S.V. Wong, N.A. Abdul Jalil, Optimization of cutting parameters based on surface roughness and assistance of work piece surface temperature in turning process. Am. J Eng Appl. Sci. 3, 102–108 (2010)

    Article  Google Scholar 

  20. T.-S. Li, S.-H. Chen, H.-L. Chen, Thermal-flow techniques for sub-35 nm contact-hole fabrication using Taguchi method in electron-beam lithography. Microelectron. Eng. 86, 2170–2175 (2009)

    Article  Google Scholar 

  21. S.H. Sadeghi, V. Moosavi, A. Karami, N. Behnia, Soil erosion assessment and prioritization of affecting factors at plot scale using the Taguchi method. J. Hydrol. 448–449, 174–180 (2012)

    Article  Google Scholar 

  22. C.-W. Hong, Using the Taguchi method for effective market segmentation. Expert Syst. Appl. 39, 5451–5459 (2012)

    Article  Google Scholar 

  23. I. Kotcioglu, A.C.M.N. Khalaji, Experimental investigation for optimization of design parameters in a rectangular duct with plate-fins heat exchanger by Taguchi Method. Appl. Therm. Eng. 50, 604–613 (2013)

    Article  Google Scholar 

  24. A. Hamdan, A.A.D. Sarhan, M. Hamdi, An optimization method of the machining parameters in high-speed machining of stainless steel using coated carbide tool for best surface finish. Int. J Adv. Manuf. Technol. 58, 81–91 (2012)

    Article  Google Scholar 

  25. C.N. Madu, Competing through maintenance strategies. Int. J. Qual. Reliab. Manag. 17(9), 937–948 (2000)

    Article  Google Scholar 

  26. B.S. Dhillon, Methods for performing human reliability and error analysis in health care. Int. J. Health. Qual. Assur. 16(6), 306–317 (2003)

    Article  Google Scholar 

  27. M. Sen, H.S. Shan, Analysis of Roundness error and surface roughness in the electro jet drilling process. Mater. Manuf. Process. 21, 1–9 (2006)

    Article  Google Scholar 

  28. Z. Zhang, X. Chu, Risk prioritization in failure mode and effects analysis under uncertainty. Expert Syst. Appl. 38, 206–214 (2011)

    Article  Google Scholar 

  29. N. Seliger, E. Wolfgang, G. Lefranc, H. Berg, T. Licht, Reliable electronics for automotive applications. Microelectron. Reliab. 42, 1596–1604 (2002)

    Article  Google Scholar 

  30. I.H. Afefy, Reliability-centered maintenance methodology and application: a case study. Sci. Res. Eng. 2, 863–873 (2010)

    Google Scholar 

  31. K.-H. Chang, Evaluate the orderings of risk for failure problems using a more general RPN methodology. Microelectron. Reliab. 49, 1586–1596 (2009)

    Article  Google Scholar 

  32. K. Ranjbar, Failure analysis of boiler cold and hot reheater tubes. Eng. Fail. Anal. 14, 620–625 (2007)

    Article  Google Scholar 

  33. K. Xu, L.C. Tang, M. Xie, S.L. Ho, M.L. Zhu, Fuzzy assessment of FMEA for engine systems. Reliab. Eng. Syst. Saf. 75, 17–29 (2002)

    Article  Google Scholar 

  34. M. Momeni, M.H. Moayed, A. Davoodi, Tuning DOS measuring parameters based on double-loop EPR in H2SO4 containing KSCN by Taguchi method. Corros. Sci. 52, 2653–2660 (2010)

    Article  Google Scholar 

  35. G.J. Tzou, C.C. Tsao, Y.C. Lin, Improvement in the thermal conductivity of aluminum substrate for the desktop PC Central Processing Unit (CPU) by the Taguchi method. Exp. Therm. Fluid Sci. 34, 706–710 (2010)

    Article  Google Scholar 

  36. S. Ebrahimiasl, W.M.Z.W. Yunus, A. Kassim, Z. Zainal, Prediction of grain size, thickness and absorbance of nanocrystalline tin oxide thin film by Taguchi robust design. Solid State Sci. 12, 1323–1327 (2010)

    Article  Google Scholar 

  37. F. Demir, B. Dönmez, Optimization of the dissolution of magnesite in citric acid solutions. Int. J. Miner. Process. 87, 60–64 (2008)

    Article  Google Scholar 

  38. H.K. Kansal, S. Singh, P. Kumar, Parametric optimization of powder mixed electrical discharge machining by response surface methodology. J. Mater. Process. Technol. 169, 427–436 (2005)

    Article  Google Scholar 

  39. H. Singh, Optimizing tool life of carbide inserts for turned parts using Taguchi’s design of experiments. in Approach Proceedings of the International Multi Conference of Engineers and Computer Scientists, Hong Kong, vol. II, IMECS 2008, 19–21 March 2008

  40. F.T.S. Chan, R. Bhagwat, S. Wadhwa, Flexibility performance: Taguchi’s method study of physical system and operating control parameters of FMS. Robot. Comput. Integr. Manuf. 23, 25–37 (2007)

    Article  Google Scholar 

  41. F. Mustaphaa, M. Mustapha, K. Noorsal, O. Mamat, P. Hussain, F. Ahmad, N. Muhamad, S.M. Haris, Preliminary study on the fabrication of aluminium foam through pressure assisted sintering dissolution process. J. Mater. Process. Technol. 210, 1598–1612 (2010)

    Article  Google Scholar 

  42. M. Altan, Reducing shrinkage in injection moldings via the Taguchi, ANOVA and neural network methods. Mater. Des. 31, 599–604 (2010)

    Article  Google Scholar 

  43. F.-J. Shiou, C.-C. Shiou, Surface finishing of hardened and tempered stainless tool steel using sequential ball grinding, ball burnishing and ball polishing processes on a machining centre. J. Mater. Process. Technol. 205, 249–258 (2008)

    Article  Google Scholar 

  44. Y.-T. Liu, W.-C. Chang, Y. Yamagata, A study on optimal compensation cutting for an aspheric surface using the Taguchi method. CIRP J. Manuf. Sci. Technol. 3, 40–48 (2010)

    Article  Google Scholar 

  45. J. Singaravelu, D. Jeyakumar, B. Nageswara Rao, Taguchi’s approach for reliability and safety assessments in the stage Separation process of a multistage launch vehicle. Reliab. Eng. Syst. Saf. 94, 1526–1541 (2009)

    Article  Google Scholar 

  46. A.K. Sahoo, M.K. Tiwari, A.R. Mileham, Six sigma based approach to optimize radial forging operation variables. J. Mater. Process. Technol. 202, 125–136 (2008)

    Article  Google Scholar 

  47. A.K. Lakshminarayanan, V. Balasubramanian, Process parameters optimisation for friction stir welding of RDE-40 aluminium alloy using Taguchi technique. Trans. Nonferrous Met. Soc. China 18(3), 548–554 (2008)

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to A. Mariajayaprakash.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Mariajayaprakash, A., Senthilvelan, T. Optimizing Process Parameters of Screw Conveyor (Sugar Mill Boiler) Through Failure Mode and Effect Analysis (FMEA) and Taguchi Method. J Fail. Anal. and Preven. 14, 772–783 (2014). https://doi.org/10.1007/s11668-014-9887-2

Download citation

  • Received:

  • Revised:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11668-014-9887-2

Keywords

Navigation