Process FMEA Template
DESIGNDESIGN FMEA(Potential Failure Modes and Effects
Analysis)RPN Colours2500-249320350250-499400500500-749600Item
Name:FMEA Team:Prepared by: Jordan haas1000750-1000900LH2/CH2
Process Safety: Delivery to DispenserFMEA Date
(Orig):(Rev.):ComponentProductFunctionPotential Failure
ModePotential Failure EffectsSEVPotential CausesOCCCurrent Process
ControlsDETRPNActions RecommendedResp.& Target DateActions
TakenSEVOCCDETRPNWhat is the process step?In what ways can the
Component, Subsystem or System potentially fail and cause a safety
risk?What is the impact on Safety?How Severe is effect to
Safety?List every conceivable failure and/or failure mechanism for
each failure modeHow frequent is cause likely to Occur?What are the
Existing Controls, Procedures or Specifacations that prevent either
the cause or the failure modeHow probable is Detection of
cause?Risk Priority # to rank order concernsWhat are the actions
for reducing the Occurrence of the cause, or improving Detection?
Should have actions on high RPN's or EASY FIXESWho's Responsible
for the recommended action? What date?What were the actions
implemented? Include completion month/year. (Then recalculate
resulting RPN.)LH2 Storage (Dewar)Contain LH2
@~30psiLeakage/RuptureSpill to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Spill to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Spill to Storage Area and Pooling of LH29Stress
Cycling/Fatigue3Specification: Supplier4120Mechanical damage
(collision)2Design: BarrierProcedure: Restricted
Access6120Mechanical damage (impact)610600Restricted vehicle
access, ensure structure can withstand impact.Mechanical damage
(attack)510500Mechanical damage (structural)610600Seismic
Evaluation and certification.Operator Error4Procedure: Operator
Training4160Isolate LH2 from EnvironmentAllow Excess Heat
ConductionExcess Vapour Pressure6Vacuum Jacket Failure3Control:
Vent to StackSpecification: Supplier4726Mechanical damage
(impact)6Procedure/Design: Restricted AccessProcedure: Operator
Training6216Vent Excessive Vapour PressurePRD FailsExcess Pressure
Buildup7H2 Embrittlement4Specification: SupplierDesign: Rupture
Disk - Vent to Stack3847Corrosion3Specification:
Supplier4847Mechanical damage (impact)6Procedure/Design: Restricted
AccessProcedure: Operator Training62527Debris710490Vent Line
BlockageExcess Pressure Buildup7H2 Embrittlement4Specification:
SupplierDesign: Rupture Disk - Vent to
Stack3847Corrosion3Specification: Supplier4847Debris710490Provide
Vapour Pressure Signal to ControllerNo signalSystem
Fault3Electrical Damage (shock)6Control: Shutdown71263Out of
Range5Specification: Supplier4603Power Failure4101203Calibration
Error7Procedure: Supplier Calibration5105Signal Bias HighElectrical
Damage (shock)6100Calibration Error7Procedure: Supplier
Calibration50Signal Bias LowExcess Vapour Pressure6Electrical
Damage (shock)6Design: Rupture Disk - Vent to
Stack103606Calibration Error7Procedure: Supplier
Calibration5210Cryo PumpBoost LH2 PressureLow PressureSystem
Fault3Mechanical Wear2Control: Shutdown7423H2
Embrittlement4Specification: Supplier4483Corrosion3Specification:
Supplier4363Control Malfunction410120High PressureExcess Liquid
Pressure7Incorrect Design Specifications2Control: Vent to
Stack2287Control Malfunction410280Provide Flow Control (On/Off,
Variable)Insufficient FlowSystem Fault3Mechanical Wear2Control:
Shutdown7423H2 Embrittlement4Specification:
Supplier4483Corrosion3Specification: Supplier4363Control
Malfunction4101203Incorrect Design Specifications21060High FlowLow
Process Gas Temp1Control Malfunction4Control: System
warning0Contain LH2 @10000psi?Leakage/RuptureSpill to Storage Area
and Dissipation of H28H2 Embrittlement4Specification:
Supplier4160Spill to Storage Area and Combustion of
Vapour10Corrosion3Specification: Supplier4120Spill to Storage Area
and Pooling of LH29Stress Cycling/Fatigue3Specification:
Supplier4120Mechanical damage (impact)6Procedure/Design: Restricted
AccessProcedure: Operator Training6360Incorrect Design
Specifications210200Control Malfunction410400Thermally Isolate LH2
from EnvironmentAllow Excess Heat ConductionExcess Vapour
Pressure6Vacuum Jacket Failure3Control: Vent to Stack2366Mechanical
Damage6Procedure: Restricted AccessProcedure: Operator
Training10360Pressure RegulatorReduce LH2 Pressure from 10000psi to
7200psiPressure Too HighExcess Liquid Pressure7Mechanical
Damage6Control: Vent to Stack2847Debris6Control: Vent to
Stack284Pressure Too LowSystem Fault3Debris6Control:
Shutdown71263Mechanical Wear8Control: Shutdown71683Control:
Shutdown70Thermally Isolate LH2 from EnvironmentAllow Excess Heat
ConductionExcess Vapour Pressure6Incorrect Design
Specifications2Control: Vent to Stack224Provide LH2 Flow PathFlow
BlockedExcess Liquid Pressure7Debris6Control: Vent to
Stack2847Mechanical Damage610420Insufficient Flow
CapabilityDecreased Pressure3Incorrect Design
Specifications6Control: Shutdown71263Debris610180Contain LH2
@10000psiLeakage/RuptureSpill to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Spill to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Spill to Storage Area and Pooling of LH29Stress
Cycling/Fatigue3Specification: Supplier4120Mechanical damage
(impact)6Procedure/Design: Restricted AccessProcedure: Operator
Training6360Mechanical damage (collision)210200Mechanical Damage
(attack)510500Incorrect Design Specifications210200VapourizorFlow
Path: LH2-CH2Flow BlockedExcess Liquid Pressure7Debris7Control:
Vent to Stack298Excess Vapour Pressure6Corrosion3Control: Vent to
StackSpecification: Supplier4726Mechanical Damage610360Excessive
Pressure DropInsufficient Process Pressure3Debris7Control:
Shutdown71473Corrosion3Specification: Supplier4363Mechanical
Damage6101803Incorrect Design Specifications21060Contain LH2
@72000psi?Leakage/RuptureSpill to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Spill to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Spill to Storage Area and Pooling of LH29Stress
Cycling/Fatigue3Specification: Supplier4120Mechanical damage
(impact)6Procedure/Design: Restricted AccessProcedure: Operator
Training6360Mechanical damage (collision)210200Mechanical Damage
(attack)510500Incorrect Design Specifications210200Heat Exchange;
LH2 to -30C with Air @Varying Ambient TemperatureLow PressureSystem
fault3Ambient temperature too low10Control:
Shutdown72103Freezing/ice reducing heat conduction10Control:
Shutdown7210High PressureExcess Vapour Pressure6Ambient temperature
too high10Control: Vent to Stack2120Output Stream Too ColdSystem
Fault1Incorrect Design Specifications2Control: Warning241Ambient
Temperature too Low1010100Output Stream Too HotExcess Vapour
Pressure6Ambient Temperature too Hot10Control: Vent to
Stack21206Incorrect Design Specifications210120Contain CH2
@7200psiLeakage/RuptureRelease to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Release to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Stress Cycling/Fatigue3Specification:
Supplier4120Mechanical damage (impact)6Procedure/Design: Restricted
AccessProcedure: Operator Training6360Mechanical damage
(collision)210200Mechanical Damage (attack)510500Incorrect Design
Specifications210200Regenerator Thermal StorageModerate CH2
Temperature VariationsTemperature Too HighExcess Vapour
Pressure6Incorrect Design Specifications2Control: Vent to
Stack2246Corrosion3Specification: Supplier4726Mechanical
Damage6103606Debris710420Temperature Too LowSystem Fault1Incorrect
Design Specifications210201Corrosion3Specification:
Supplier4121Mechanical Damage610601Debris71070Contain CH2
@7200psiLeakage/RuptureRelease to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Release to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Stress Cycling/Fatigue3Specification:
Supplier4120Mechanical damage (impact)6Procedure/Design: Restricted
AccessProcedure: Operator Training6360Mechanical damage
(collision)210200Mechanical Damage (attack)510500Incorrect Design
Specifications210200Low Pressure Drop Flow PathExcessive Pressure
DropSystem fault3Debris7Control:
Shutdown71473Corrosion3Specification: Supplier4363Mechanical
Damage6101803Incorrect Design Specifications21060Flow BlockedExcess
Vapour Pressure6Debris7Control: Vent to
Stack2846Corrosion3Specification: Supplier4726Mechanical
Damage610360Buffer StorageContain CH2 @-25C,
7200psiLeakage/RuptureRelease to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Release to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Stress Cycling/Fatigue310300Mechanical damage
(impact)6Procedure/Design: Restricted AccessProcedure: Operator
Training6360Mechanical damage (collision)210200Mechanical Damage
(attack)510500Incorrect Design Specifications210200Flow Path: CH2
to DispensorFlow BlockedExcess Vapour Pressure6Debris7Control: Vent
to Stack2846Corrosion3Specification: Supplier4726Mechanical
Damage610360Excessive Pressure DropLow Process
Pressure3Debris7Control: Shutdown71473Corrosion3Specification:
Supplier4363Mechanical Damage6101803Incorrect Design
Specifications21060DispensorContain CH2
@6000psiLeakage/RuptureRelease into Occupied Area and Dissipation
of H29H2 Embrittlement4Specification: Supplier4160Release into
Occupied Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Stress Cycling/Fatigue3Specification:
Supplier4120Mechanical damage (impact)60Mechanical damage
(collision)210200Mechanical Damage (attack)510500Operator
Error4Procedure: Operator Training4160Incorrect Design
Specifications210200Control Malfunction410400Flow Path: Vehicle CH2
Supply @6000psiFlow BlockedExcess Vapour Pressure6Debris7Control:
Vent to Stack2846Corrosion3Specification: Supplier4726Mechanical
Damage610360Excessive Pressure DropLow Fueling
Pressure1Debris7Control: System Fault - abort
fueling01Corrosion3Specification: Supplier4121Mechanical
Damage610601Incorrect Design Specifications21020Provide CH2
@6000psi @xxpsiLow PressureLow Fueling Pressure1Incorrect Design
Specifications2Control: Abort Fueling241Control
Malfunction4Control: Abort Fueling28High PressureExcess Pressure
Buildup7Incorrect Design Specifications2Control: Vent to
Stack7987Control Malfunction4Control: Vent to Stack71967Fueling
Rate Too High6Control: Vent to Stack72947Inlet Gas Too
Warm5Control: Vent to Stack7245Monitor Fueling Status &
Communicate with ControllerNo SignalSystem fault3Electrical Damage
(shock)6Control: Shutdown71263Out of Range5101503Power
Failure4101203Calibration Error7Procedure: Supplier
Calibration5105Temp Bias LowExcess Tank Pressure: Potential
Rupture10Electrical Damage (shock)6Control:
Shutdown742010Calibration Error7Procedure: Supplier
Calibration5350Temp Bias HighDecreased tank Pressure: Incomplete
Fueling1Electrical Damage (shock)6Control: Shutdown7421Calibration
Error7Procedure: Supplier Calibration535Pressure Bias LowExcess
Tank Pressure: Potential Rupture10Electrical Damage
(shock)6Control: Shutdown742010Calibration Error7Procedure:
Supplier Calibration5350Pressure Bais HighDecreased tank Pressure:
Incomplete Fueling1Electrical Damage (shock)6Control:
Shutdown7421Calibration Error7Procedure: Supplier
Calibration535Provide User Emergency ShutdownNo Shutdown
InitiatedPotential Gas Leakage10Electrical Damage (shock)6Control:
Shutdown742010Power Failure410400LH2 ValveContain LH2
@10000psi?Leakage/RuptureSpill to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Spill to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Spill to Storage Area and Pooling of LH29Stress
Cycling/Fatigue3Specification: Supplier4120Mechanical damage
(impact)6Design: Restricted Access6360Incorrect Design
Specifications210200System Flow pathFlow BlockedExcess Liquid
Pressure7Debris7Control: Vent to Stack2987Corrosion3Specification:
Supplier484Excess Pressure Buildup7Mechanical Damage6Design:
Rupture Disk - Vent to Stack10420Excessive Pressure DropLow System
Pressure3Debris7Control: Shutdown71473Corrosion3Specification:
Supplier4363Mechanical Damage6101803Incorrect Design
Specifications21060Thermaly Isolate LH2 from EnvironmentAllow
Excess Heat ConductionExcess Vapour Pressure6Incorrect Design
Specifications2Control: Vent to Stack2246Mechanical
Damage610360Isolate Flowpath (Open/Close)Fails OpenCannot Isolate
System Components:5H2 Embrittlement4Specification:
Supplier4805Corrosion3Specification: Supplier4605Mechanical damage
(impact)6Design: Restricted Access61805Control
Malfunction410200Fails ClosedExcess Liquid Pressure7H2
Embrittlement4Control: Vent to StackSpecification:
Supplier4112Excess Pressure Buildup7Corrosion3Specification:
SupplierDesign: Rupture Disk - Vent to Stack3637Mechanical damage
(impact)6Design: Restricted Access62527Control Malfunction410280CH2
ValveContain CH2 @7200psiLeakage/RuptureRelease to Storage Area and
Dissipation of H28H2 Embrittlement4Specification:
Supplier4160Release to Storage Area and Combustion of
Vapour10Corrosion3Specification: Supplier4120Release into Occupied
Area and Dissipation of H29Stress Cycling/Fatigue3Specification:
Supplier4120Release into Occupied Area and Combustion of
Vapour10Mechanical damage (impact)6Design: Restricted
Access6360Incorrect Design Specifications210200System Flow pathFlow
BlockedExcess Liquid Pressure7Debris7Control: Vent to
Stack298Excess Pressure Buildup7Corrosion3Specification:
SupplierDesign: Rupture Disk - Vent to Stack3637Mechanical
Damage610420Excessive Pressure DropLow System
Pressure3Debris7Control: Shutdown71473Corrosion3Specification:
Supplier4363Mechanical Damage6101803Incorrect Design
Specifications21060Isolate Flowpath (Open/Close)Fails OpenCannot
Isolate System Components:5H2 Embrittlement4Specification:
Supplier4805Corrosion3Specification: Supplier4605Mechanical damage
(impact)6Design: Restricted Access61805Control
Malfunction410200Fails ClosedExcess Liquid Pressure7H2
Embrittlement4Control: Vent to StackSpecification:
Supplier41127Corrosion3Specification: Supplier4847Mechanical damage
(impact)6Design: Restricted Access62527Control
Malfunction410280Excess Pressure Buildup7Corrosion3Specification:
SupplierDesign: Rupture Disk - Vent to Stack3637Mechanical damage
(impact)6Design: Restricted Access62527Control
Malfunction410280Thermaly Isolate LH2 from EnvironmentAllow Excess
Heat ConductionExcess Vapour Pressure6Incorrect Design
Specifications2Control: Vent to Stack2246Mechanical damage
(impact)Design: Restricted Access60Check ValveProvide Single
Direction Flow PathFlow BlockedExcess Liquid
Pressure7Debris7Control: Vent to Stack298Excess Pressure
Buildup7Corrosion3Specification: SupplierDesign: Rupture Disk -
Vent to Stack3637Mechanical Damage610420Excessive Pressure DropLow
System Pressure3Debris7Control:
Shutdown71473Corrosion3Specification: Supplier4363Mechanical
Damage6101803Incorrect Design Specifications21060Fails to
CheckBackflow of Process Gases: Potential Rupture?10H2
Embrittlement4Specification: Supplier416010Corrosion3Specification:
Supplier412010Mechanical damage (impact)6Design: Restricted
Access636010Incorrect Design Specifications210200Contain CH2
@7200psiLeakage/RuptureRelease to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Release to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Release into Occupied Area and Dissipation of H29Stress
Cycling/Fatigue3Specification: Supplier4120Release into Occupied
Area and Combustion of Vapour10Mechanical damage (impact)6Design:
Restricted Access6360Incorrect Design Specifications2100Thermaly
Isolate LH2 from EnvironmentAllow Excess Heat ConductionExcess
Vapour Pressure6Incorrect Design Specifications2Control: Vent to
Stack2246Mechanical damage (impact)Design: Restricted
Access60Vacuum Jacket Lines (LH2)Thermally Isolate LH2 from
EnvironmentAllow Excess Heat ConductionExcess Vapour
Pressure6Vacuum Jacket Failure3Control: Vent to Stack2366Incorrect
Design Specifications2101206Mechanical damage
(impact)Procedure/Design: Restricted AccessProcedure: Operator
Training60Contain LH2 @1000psiLeakage/RuptureSpill to Storage Area
and Dissipation of H28H2 Embrittlement4Specification:
Supplier4160Spill to Storage Area and Combustion of
Vapour10Corrosion3Specification: Supplier4120Spill to Storage Area
and Pooling of LH29Stress Cycling/Fatigue3Specification:
Supplier4120Mechanical damage (impact)6Procedure/Design: Restricted
AccessProcedure: Operator Training6360Operator Error4Procedure:
Operator Training4160Incorrect Design Specifications210200Provide
Flow Path A-BFlow BlockedExcess Liquid Pressure7Debris7Control:
Vent to Stack298Excess Pressure Buildup7Corrosion3Specification:
SupplierDesign: Rupture Disk - Vent to Stack3637Mechanical
Damage610420Excessive Pressure DropLow System
Pressure3Debris7Control: Shutdown71473Corrosion3Specification:
Supplier4363Mechanical Damage6101803Incorrect Design
Specifications21060Pressure Sensor (LH2)Contain LH2 Under
PressureLeakage/RuptureSpill to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Spill to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Spill to Storage Area and Pooling of LH29Stress
Cycling/Fatigue3Specification: Supplier4120Mechanical damage
(impact)6Design: Restricted Access6360Incorrect Design
Specifications210200Output Pressure SignalHigh Pressure
BiasCalibration Error7Procedure: Supplier Calibration50Electrical
Damage (shock)6100Low Pressure BiasExcess Liquid
Pressure7Calibration Error7Procedure: Supplier CalibrationDesign:
Rupture Disk - Vent to Stack52457Electrical Damage
(shock)6Procedure: Supplier CalibrationDesign: Rupture Disk - Vent
to Stack10420No SignalSystem fault3Electrical Damage
(shock)6Control: Shutdown71263Out of Range5Control:
Shutdown71053Power Failure4Control: Shutdown7843Calibration
Error7Procedure: Supplier Calibration5105Pressure Sensor
(CH2)Contain CH2 Under PressureLeakage/RuptureRelease to Storage
Area and Dissipation of H28H2 Embrittlement4Specification:
Supplier4160Release to Storage Area and Combustion of
Vapour10Corrosion3Specification: Supplier4120Release into Occupied
Area and Dissipation of H29Stress Cycling/Fatigue3Specification:
Supplier4120Release into Occupied Area and Combustion of
Vapour10Mechanical damage (impact)6Design: Restricted
Access6360Incorrect Design Specifications210200Output Pressure
SignalHigh Pressure Bias1Calibration Error7Procedure: Supplier
Calibration5351Electrical Damage (shock)61060Low Pressure
BiasExcess Vapour Pressure7Calibration Error7Procedure: Supplier
CalibrationDesign: Rupture Disk - Vent to Stack52457Electrical
Damage (shock)6Control: Shutdown7294No SignalSystem
fault3Electrical Damage (shock)6Control: Shutdown71263Out of
Range5Control: Shutdown71053Power Failure4Control:
Shutdown7843Calibration Error7Procedure: Supplier
Calibration5105Flow Meter (LH2)Contain LH2 Under
PressureLeakage/RuptureSpill to Storage Area and Dissipation of
H28H2 Embrittlement4Specification: Supplier4160Spill to Storage
Area and Combustion of Vapour10Corrosion3Specification:
Supplier4120Spill to Storage Area and Pooling of LH29Stress
Cycling/Fatigue3Specification: Supplier4120Mechanical damage
(impact)6Design: Restricted Access6360Incorrect Design
Specifications210200Output FLow SignalHigh Flow BiasDecreased
Process Flow3Calibration Error7System Fault: ShutdownProcedure:
Supplier Calibration71473Electrical Damage (shock)67126Low Flow
BiasExcess System Pressure Flow6Electrical Damage (shock)6Design:
Rupture Disk - Vent to Stack103606Calibration Error7Procedure:
Supplier Calibration5210No SignalSystem fault3Electrical Damage
(shock)6Control: Shutdown71263Out of Range5Control:
Shutdown71053Power Failure4Control: Shutdown7843Calibration
Error7Procedure: Supplier Calibration5105Flow Path: Low
RestrictionFlow BlockedExcess Liquid Pressure7Debris7Control: Vent
to Stack298Excess Pressure Buildup7Corrosion3Specification:
SupplierDesign: Rupture Disk - Vent to Stack3637Mechanical
Damage6Control: Shutdown7294Excessive Pressure DropLow System
Pressure3Debris7Control: Shutdown71473Corrosion3Specification:
Supplier4363Mechanical Damage6Control: Shutdown71263Incorrect
Design Specifications2Control: Shutdown742Flow Meter (CH2)Contain
CH2 Under PressureLeakage/RuptureRelease to Storage Area and
Dissipation of H28H2 Embrittlement4Specification:
Supplier4160Release to Storage Area and Combustion of
Vapour10Corrosion3Specification: Supplier4120Stress
Cycling/Fatigue3Specification: Supplier4120Mechanical damage
(impact)6Design: Restricted Access6360Incorrect Design
Specifications210200Output FLow SignalHigh Flow BiasDecreased
Process Flow3Electrical Damage (shock)6System Fault:
Shutdown0Excess System Pressure Flow6Calibration Error7Procedure:
Supplier CalibrationDesign: Rupture Disk - Vent to Stack5210Low
Flow BiasExcess Liquid Pressure7Electrical Damage (shock)6Control:
Vent to Stack2847Calibration Error7Procedure: Supplier
Calibration5245No SignalSystem fault3Electrical Damage
(shock)6Control: Shutdown71263Out of Range5Control:
Shutdown71053Power Failure4Control: Shutdown7843Calibration
Error7Procedure: Supplier Calibration5105Flow Path: Low
RestrictionFlow BlockedExcess Liquid Pressure7Debris7Control: Vent
to Stack298Excess Pressure Buildup7Corrosion3Specification:
SupplierDesign: Rupture Disk - Vent to Stack3637Mechanical
Damage6Control: Vent to Stack10420Excessive Pressure DropLow System
Pressure3Debris7Control: Shutdown71473Corrosion3Specification:
Supplier4363Mechanical Damage6Control: Shutdown101803Incorrect
Design Specifications2Control: Shutdown1060Fittings (High
Pressure)Contain LH2 under PressureLeakage/RuptureRelease to
Storage Area and Dissipation of H28H2 Embrittlement4Specification:
Supplier4160Release to Storage Area and Combustion of
Vapour10Corrosion3Specification: Supplier4120Release into Occupied
Area and Dissipation of H29Stress Cycling/Fatigue3Specification:
Supplier4120Release into Occupied Area and Combustion of
Vapour10Mechanical damage (impact)6Design: Restricted
Access6360Incorrect Design Specifications210200Flow Path: Low
RestrictionFlow BlockedExcess Liquid Pressure7Debris7Control: Vent
to Stack298Excess Pressure Buildup7Corrosion3Specification:
SupplierDesign: Rupture Disk - Vent to Stack3637Mechanical
damage6Control: Vent to Stack3126Excessive Pressure DropLow System
Pressure3Debris7Control: Shutdown71473Corrosion3Specification:
Supplier4363Mechanical damage6Control: Shutdown101803Incorrect
Design Specifications2Control: Shutdown1060Fittings
(Cryogenic)Contain LH2 under PressureLeakage/RuptureSpill to
Storage Area and Dissipation of H29H2 Embrittlement4Specification:
Supplier4160Spill to Storage Area and Combustion of
Vapour10Corrosion3Specification: Supplier4120Spill to Storage Area
and Pooling of LH29Stress Cycling/Fatigue3Specification:
Supplier4120Mechanical damage (impact)6Design: Restricted
Access6360Incorrect Design Specifications210200Flow Path: Low
RestrictionFlow BlockedExcess Liquid Pressure7Debris7Control: Vent
to Stack3147Excess Pressure Buildup7Corrosion3Specification:
SupplierDesign: Rupture Disk - Vent to Stack3637Mechanical
damage6Control: Vent to Stack3126Excessive Pressure DropLow System
Pressure3Debris7Control: Shutdown71473Corrosion3Specification:
SupplierControl: Shutdown4363Mechanical damage6Control:
Shutdown71263Incorrect Design Specifications2Control:
Shutdown742Vent StackProvide Safe Vent Stream for Process
GasCombustion of GasCombustion Within Vent Stack8Ignition
Source2101608Control Malfunction410320BlockageRupture Of Process
Lines/Components10Corrosion3Specification: Supplier412010Mechanical
damage (impact)6Design: Restricted Access636010Mechanical damage
(attack)51050010Mechanical damage (structural)610600Structural
Modifications and assesmentRestrictedInsufficient
Venting9Debris4103609Corrosion3Specification:
Supplier41089Mechanical damage (impact)6Design: Restricted
Access63249Mechanical damage (attack)5104509Mechanical damage
(structural)610540Structural Modifications and assesment
&LPrinted:&D&CProcess FMEA Template&RPage &P
of &N
PROCESSItem Name:FMEA Team:Prepared by:FMEA Date
(Orig):(Rev.):Process Step or Variable or Key InputPotential
Failure ModePotential Failure EffectsSEVPotential CausesOCCCurrent
Process ControlsDETRPNActions RecommendedResp.& Target
DateActions TakenSEVOCCDETRPNWhat is the process step?In what ways
can the Process Step, Variable, or Key Input go wrong? (chance of
not meeting requirements)What is the impact on the Key Output
Variables (customer requirements) or internal requirements?How
Severe is effect to the customer?What causes the Key Input to go
wrong? (How could the failure mode occur?)How frequent is cause
likely to Occur?What are the existing controls that either prevent
the failure mode from occurring or detect it should it occur?How
probable is Detection of cause?Risk Priority # to rank order
concernsWhat are the actions for reducing the Occurrence of the
cause, or improving Detection? Should have actions on high RPN's or
Severity of 9 or 10.Who's Responsible for the recommended action?
What date?What were the actions implemented? Include completion
month/year. (Then recalculate resulting RPN.)0
&C&P of&NFMEA(Potential Failure Modes and Effects
Analysis)
RATING FACTORSRATINGDEGREE OF SEVERITYDEGREE OF
SEVERITYPROBABILITY OF OCCURRENCEABILITY TO DETECTFREQUENCY( 1 in
)CpkDetectionCertainty1Safety or environmental impact is
insignificant; customer will not notice any adverse effectsCustomer
will not notice the adverse effect or it is insignificantLikelihood
of occurrence is remote1,000,000> 1.67Sure that the potential
failure will be found or prevented before producing a safety
risk100%2Safety or environmental impact is slight; customer will
probably experience slight annoyanceCustomer will probably
experience slight annoyanceLow failure rate with supporting
documentation20,0001.33Almost certain that the potential failure
will be found or prevented before producing a safety risk99%3Safety
and/or environmental impact will be affected due to the slight
degradation of performance of components; customer will experience
annoyanceCustomer will experience annoyance due to the slight
degradation of performanceLow failure rate without supporting
documentation5,000approx. 1.0Low likelihood that the potential
failure will be prevented before producing a safety risk954Safety
and/or environmental impact affected due to continually poor system
performance; customer dissatisfiedCustomer dissatisfaction due to
reduced performanceOccasional failures2,000< 1.0Controls may
detect or prevent the potential failure from occuring during
operation905Considerable safety and/or environmental Impact due to
failure of components; customer is made uncomfortableCustomer is
made uncomfortable or their productivity is reduced by the
continued degradation of the effectRelatively moderate failure rate
with supporting documentation500Moderate likelihood that the
potential failure will occur before producing a safety
risk856Considerable safety and/or environmental Impact due to
continued degredation of components; warranty repair, down time or
significant manufacturing or assembly complaintWarranty repair,
down time or significant manufacturing or assembly
complaintModerate failure rate without supporting
documentation100Controls are unlikely to detect or prevent the
potential failure during operation807High safety risk and/or severe
environmental Impact without violating existing codes/standards;
High degree of customer dissatisfaction; productivity impacted by
high scrap or rework levels.High degree of customer dissatisfaction
due to component failure without complete loss of function.
Productivity impacted by high scrap or rework levels.Relatively
high failure rate with supporting documentation50Poor likelihood
that the potential failure will be detected or prevented before
producing a safety risk708High safety risk and/or severe
environmental Impact violating existing codes/standards; very high
degree of customer dissatisfactionVery high degree of
dissatisfaction due to the loss of function without a negative
impact on safety or governmental regulationsHigh failure rate
without supporting documentation20Very poor likelihood that the
potential failure will be detected or prevented before producing a
safety risk609Severe Safety impact with warning before failure or
violation of safety codes/regulations; customer endangeredCustomer
endangered due to the adverse effect on safe system performance
with warning before failure or violation of governmental
regulationsFailure is almost certain based on specifications or
significant DV testing10Current controls probably will not even
detect the potential failure5010Severe Safety impact without
warning before failure or violation of safety codes/regulations;
customer endangeredCustomer endangered due to the adverse effect on
safe system performance without warning before failure or violation
of governmental regulationsAssured of failure based on
specifications or significant DV testing2Absolute certainty that
the current controls will not detect the potential failure<
50
&APage &P
