Skip to main content
SpringerLink
Log in

Failure Modes Effects and Criticality Analysis and Fault Tree Analysis Case Study of Waste Heat Recovery Plant in a Cement Factory, United Arab Emirates

  • Case History---Peer-Reviewed
  • Published:
Journal of Failure Analysis and Prevention Aims and scope Submit manuscript

Abstract

This article reports a case study of the application of FMECA and FTA methods to inform the design of effective maintenance program for a waste heat recovery power plant in the hot arid climate of the United Arab Emirates. It illustrates the strengths and weaknesses of these approaches through a case study report of a live plant in a cement factory. The article highlights the implications and importance of plant-specific contextual factors in conducting quality FMECA and FTA.

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

Access this article

Log in via an institution

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

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2

Similar content being viewed by others

Abbreviations

FMECA:

Failure modes effects and criticality analysis

FTA:

Fault tree analysis

WHRPP:

Waste heat recovery power plant

MTBF:

Mean time before failure

MTTR:

Mean time to repair

PPM:

Project portfolio management

RPN:

Risk priority number

ALARP:

As low as reasonably practicable

Fr:

Failure rate

Sr:

Severity ranking

Rc:

Risk class

AC:

Alternating current

DC:

Direct current

T-G:

Turbine generator

References

  1. S. Foon, M. Terziovski, The impact of operations and maintenance practices on power plant performance. J. Manuf. Technol. Manag. 25(8), 1148–1173 (2014)

    Article  Google Scholar 

  2. H. Iqbal, S. Tesfamariam, H. Haider, R. Sadiq, Inspection and maintenance of oil & gas pipelines: a review of policies. Struct. Infrastruct. Eng. 13(6), 794–815 (2017)

    Article  Google Scholar 

  3. M. Braglia, M. Frosolini, Fuzzy criticality assessment model for failure modes and effects analysis. Int. J. Qual. Reliab. Manag. 20(4), 503–524 (2003)

    Article  Google Scholar 

  4. G.P. Putraa, H.H. Purbab, Failure mode and effect analysis on power plant boiler. J. Optim. Ind. Eng. 11(2), 1–6 (2018)

    Google Scholar 

  5. A. Hassan, A. Siadat, J. Dantan, P. Martin, Conceptual process planning—an improvement approach using QFD, FMEA, and ABC methods. Robot. Comput.-Integr. Manuf. 26, 392–401 (2010)

    Article  Google Scholar 

  6. T. Tereshchenko, N. Nord, Uncertainty of the allocation factors of heat and electricity production of combined cycle power plant. Appl. Therm. Eng. 76, 410–422 (2015)

    Article  Google Scholar 

  7. H.T. Sheng, Y.H. Shin, Failure mode and effects analysis: an integrated approach for product design and process control. Int. J. Qual. Reliab. Manag. 13(5), 8–26 (1996)

    Article  Google Scholar 

  8. K. Lough, R. Stone, I. Tumer, The risk in early design method. J. Eng. Des. 20(2), 155–173 (2009)

    Article  Google Scholar 

  9. H.E. Lambert, Systems Safety Analysis and Fault Tree Analysis (Univ. of California, Livermore, 1973)

    Google Scholar 

  10. H. Wang, N. Zhu, X. Bai, Reliability model assessment of grid-connected solar photovoltaic system based on Monte-Carlo. Appl. Solar Energy 51(4), 262–266 (2015)

    Article  Google Scholar 

  11. B. Reinhart, K. Howell, K. Black, Unlocking the potential of combined cycle plants. Power Engineering (2018). https://www.power-eng.com/articles/print/volume-122/issue-4/features/unlocking-the-potential-of-combined-cycle-plants.html. Accessed 26.02.2019

  12. G. Campatelli, G. Arcidiacono, Reliability improvement of a diesel engine using the FMETA approach. Qual. Reliab. Eng. Int. (2004). https://doi.org/10.1002/qre.627

    Article  Google Scholar 

  13. R. Yan, S.J. Dunnett, L.M. Jackson, Reliability modelling of automated guided vehicles by the use of failure modes effects and criticality analysis, and fault tree analysis (2016)

  14. D. Panchal, D. Kumar, Risk analysis of compressor house unit in thermal power plant using integrated fuzzy FMEA and GRA approach. Int. J. Ind. Syst. Eng. 25(2), 228–250 (2017)

    Google Scholar 

  15. J. Magott, P. Skrobanek, Timing analysis of safety properties using fault trees with time dependencies and timed state-charts. Reliab. Eng. Syst. Saf. 97(1), 14–26 (2012)

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. British University in Dubai, Dubai, United Arab Emirates

    Kirk Shanks, Abdallah Hamad & Alaa Ameer

Authors
  1. Kirk Shanks
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Abdallah Hamad
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Alaa Ameer
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Kirk Shanks.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Shanks, K., Hamad, A. & Ameer, A. Failure Modes Effects and Criticality Analysis and Fault Tree Analysis Case Study of Waste Heat Recovery Plant in a Cement Factory, United Arab Emirates. J Fail. Anal. and Preven. 20, 40–50 (2020). https://doi.org/10.1007/s11668-020-00827-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11668-020-00827-8

Keywords

Search

Navigation