Page 12 - Root Cause Failure Analysis

INTRODUCTION

Reliability engineering and predictive maintenance have two major objectives: pre-
venting catastrophic failures of critical plant production systems and avoiding devia-
tions from acceptable performance levels that result in personal injury, environmental
impact, capacity loss, or poor product quality. Unfortunately, these events will occur
no matter how effective the reliability program. Therefore, a viable program also must
include a process for fully understanding and correcting the root causes that lead to
events having an impact on plant performance.
This book provides a logical approach to problem resolution. The method can be used
to accurately define deviations from acceptable performance levels, isolate the root
causes of equipment failures, and develop cost-effective corrective actions that pre-
vent recurrence. This three-part set is a practical, step-by-step guide for evaluating
most recurring and serious incidents that may occur in a chemical plant.

Part One, Introduction to Root Cause Failure Analysis, presents analysis techniques
used to investigate and resolve reliability-related problems. It provides the basic
methodology for conducting a root cause failure analysis (RCFA). The procedures
defined in this section should be followed for all investigations.

Part Two provides specific design, installation, and operating parameters for particu-
lar types of plant equipment. This information is mandatory for all equipment-related
problems, and it is extremely useful for other events as well. Since many of the
chronic problems that occur in process plants are directly or indirectly influenced by
the operating dynamics of machinery and systems, this part provides invaluable
guidelines for each type of analysis.

Part Three is a troubleshooting guide for most of the machine types found in a chemi-
cal plant. This part includes quick-reference tables that define the common failure or

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