FMEA
System
Design
Process
Page 1 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
005
Over temp
9
1
3
Vessel Failure
Veg Oil Spill onto floor
Visual Inspection
9
1
3
Loose Fitting
Veg Oil Spill onto floor
Visual Inspection
9
1
3
Vessel Failure
Veg Oil Spill onto floor
Visual Inspection
9
1
3
Loose Fitting
Veg Oil Spill onto floor
Visual Inspection
9
1
3
Vessel Failure
Veg Oil Spill onto floor
Visual Inspection
9
1
3
None
10
1
10
Veg Oil Too Cold
None
5
1
10
50
9 4 27
Hot Water Temp Control Failure Veg Oil Too Hot, up to limit of hot water (assumed to be controlled with high limit.)
Leakage
Jacket Failure
Shutoff Valve at Main Vegetable Oil Collection Tank
Leakage
Valve Failure / Stem Failure
Water in Oil Water on floor Veg Oil Spill onto floor
Visual Inspection Visual Inspection Visual Inspection
3 4 9
1 1 1
3 1 3
Veg Oil Spill onto basin / sump
DET
HV
Water Jacket for Vegetable Oil Collection Tank
Leakage
Visual Inspection
DETECTION METHOD
RPN
005
Vegetable Oil Collection Tank
Leakage
Veg Oil Spill onto floor
POTENTIAL EFFECTS
OCC
HEX
005
Vegetable Oil Settling Tank #2
Loose Fitting
POTENTIAL CAUSES
SEV
TNK
002
POTENTIAL FAILURE MODE Leakage
DET
TNK
FUNCTION Vegetable Oil Settling Tank #1
Consider basin / sump below oil storage tank. 27 Consider basin / sump below oil storage tank. 27 Consider basin / sump below oil storage tank. 27 Consider basin / sump below oil storage tank. 27 Consider basin / sump below oil storage tank. 27 Consider basin / sump below oil storage tank. 100 1. Consider temperature gauge at inlet when installing hot water system. 2. Consider including an aquastat or other electronic temperature control on hot water loop so visual becomes backup.
4
1
1
4
4
1
1
4
4
1
1
4
4
1
1
4
4
1
1
4
4
1
1
4
9
1
1
9
1. Consider temperature gauge at inlet when installing hot water system. 2. Consider including an aquastat or other electronic temperature control on hot water loop so visual becomes backup.
5
1
1
5
3 4 4
1 1 1
3 1 1
9 4 4
RPN
001
OCC
#
TNK
SEV
TYPE
Consider basin / sump below oil storage tank. 12 Consider basin / sump below oil storage tank. 36 Review pump design, seals? 135 1. Review motor drive controls and also pump dead-head pressure rise. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
HV
010
Shutoff Valve - Veg Oil to BD Reaction Tank
Leakage
Valve Failure / Stem Failure
Visual Inspection
4
1
3
PMP
100
Process Pump - Fill, Mix, Empty - All Fluids
Leakage Over pressure
Seal Failure Spill onto basin / sump Blockage, valves not open down Pump runs at max pressure, or upstream zero flow
Visual Inspection Visual inspection (PI-120), audible change in pump operation.
4 9
3 5
3 3
TNK
100
Biodiesel Reaction Tank
Leakage
Loose Fitting
Veg Oil Spill onto basin / sump
Visual Inspection
4
1
3
12
Reaction Mix Spill onto basin / sump
Visual Inspection
10
1
3
30
BD Spill onto basin / sump
Visual Inspection
4
1
3
Veg Oil Spill onto basin / sump
Visual Inspection
4
1
Reaction Mix Spill onto basin / sump
Visual Inspection
10
1
BD Spill onto basin / sump
Visual Inspection
4
Visual inspection of temperature gauge on vessel (TI-100).
9
Vessel Failure
Over temp
Printed: 5/14/2008
Hot Water Temp Control Failure Contents too hot, up to limit of hot water (assumed to be controlled with high limit.)
RECOMMENDED ACTION(S)
27
4
1
1
4
4 7
1 5
1 1
4 35
Consider level sensor in sump to detect severe leakage. 1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
9
1
1
9
12
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
3
12
1
1
4
30
Consider level sensor in sump to detect severe leakage. 1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
3
9
1
1
9
1
3
12
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
3
3
81
1. Consider temperature gauge at inlet when installing hot water system. 2. Consider including an aquastat or other electronic temperature control on hot water loop so visual becomes backup.
9
3
1
27
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
FMEA
System
Design
Process
Page 2 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
SEV
OCC
DET
RPN
POTENTIAL CAUSES
DET
Water Jacket for BD Reaction Tank
POTENTIAL FAILURE MODE
RPN
100
FUNCTION
OCC
HEX
#
SEV
TYPE
9
1
3
27
Consider pressure relief valve on BD reaction tank. Set point TBD.
9
1
3
27
Visual Inspection
4
3
3
36
Consider level sensor in sump to detect severe leakage.
4
3
1
12
Reaction Mix Spill onto basin / sump
Visual Inspection
10
3
3
90
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
9
3
1
27
BD Spill onto basin / sump
Visual Inspection
4
3
3
36
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
3
1
12
POTENTIAL EFFECTS
Over pressure
Blockage downstream (closed valve, etc.)
Over fill
Providing too much fluid to tank, Veg Oil Spill onto basin / sump or filling at too great a speed.
DETECTION METHOD
Mechanical failure of attached Visual inspection of pressure parts or vessel, overflow of gauge on vessel (PI-100), contents in unintended locations. audible spilling.
RECOMMENDED ACTION(S)
Over temp
Hot Water Temp Control Failure Reaction mix too hot
Visual inspection of temperature gauge on vessel (TI-100).
9
3
3
81
1. Consider temperature gauge at inlet when installing hot water system. 2. Consider including an aquastat or other electronic temperature control on hot water loop so visual becomes backup.
9
1
1
9
Under temp
Hot Water Temp Control Failure Reaction mix too cold, slow reaction
Visual inspection of temperature gauge on vessel (TI-100).
2
3
3
18
1. Consider temperature gauge at inlet when installing hot water system. 2. Consider including an aquastat or other electronic temperature control on hot water loop so visual becomes backup.
2
1
1
2
Leakage
Jacket Failure
LI
100
Level Indicator / Sight Tube for BD Reaction Tank
Unreadable
Fowling
Water in reaction Visual Inspection Water on floor Visual Inspection Unknown level or settling status Visual Inspection
2 3 5
1 1 5
4 3 1
8 9 25
Confirm cleaning plan.
2 3 5
1 1 1
4 3 1
8 9 5
TNK
200
Oxide Mixing Tank
Leakage Over fill
3 3
27 63
Consider overflow pipe
9 5
1 3
3 3
27 45
Level Indicator / Sight Tube for Oxide Mixing Tank
Unreadable
Visual Inspection Visual Inspection, sight tube (LI200) Visual Inspection
1 3
200
Spill onto basin / sump Spill out vent line, or to other vessels Unknown level or settling status
9 7
LI
Cracks, loose fittings Too much fluid pumped to vessel Fowling
5
5
1
25
5
5
1
25
Settling Tank
Leakage Leakage Over fill
Cracks, loose fittings Jacket Failure Too much fluid pumped to vessel
Spill onto basin / sump BD on floor Spill out vent line, or to other vessels
Visual Inspection Visual Inspection Visual Inspection, sight tube (LI300)
9 3 7
1 1 1
3 3 3
27 9 21
9 3 5
1 1 1
3 3 3
27 9 15
Level Indicator / Sight Tube for Settling Tank
Unreadable
Fowling
Unknown level or settling status Visual Inspection
5
5
1
25
5
5
1
25
Cracks, loose fittings Fowling
Spill onto basin / sump Unknown process flow or mixing status. Spill onto basin / sump Unknown pressure condition in BD tank. Vapor leakage overboard
Visual Inspection Visual Inspection
4 5
1 5
3 1
12 25
4 5
1 5
3 1
12 25
Visual Inspection Visual Inspection, possible backup in PI-120. None
9 9
1 1
3 5
27 45
9 9
1 1
3 5
27 45
TNK
LI
300
300
MI
100
Mix Indicator - Pump Outlet to Oxide and BD Tanks
Leakage Unreadable
PI
100
Pressure Indicator / Gauge - BD Reactor Tank
Leakage Bad / no reading
Cracks, loose fittings Gauge failure
Leakage
Cracks, loose fittings
PI
120
Pressure Indicator / Gauge - Pump Outlet
Bad / no reading
Gauge failure
Leakage
Cracks, loose fittings
Bad / no reading
Gauge failure
Leakage
Cracks, loose fittings
Bad / no reading
Gauge failure
TI
TI
Printed: 5/14/2008
120
100
Temperature Indicator / Gauge - Pump Outlet
Temperature Indicator / Gauge - BD Reactor Tank Bottom
9
1
10
90
No indication of pump operation Visual Inspection other than noise. Leakage of any fluid onto basin / Visual Inspection sump
10
1
3
30
9
1
3
27
None No indication of pump outlet temperature, or inaccurate indication. Leakage of pumped contents to Visual Inspection basin / sump
5
1
3
15
9
1
3
27
10
1
3
30
No indication of reaction mixture Could use TI-120 as substitute temperature, or inaccurate indication.
Consider overflow pipe. TNK300 is larger than TNK100, unlikely event
Consider combustibility sensor above process
9
1
1
9
10
1
3
30
Consider level sensor with alarm to alert operator that something has reached the sump.
9
1
1
9
TI120 is not a process critical instrument. It serves as a backup for TI100. Consider level sensor with alarm to alert operator that something has reached the sump.
9
1
1
9
9
1
1
9
Consider including an aquastat or other electronic temperature control on hot water loop so visual becomes backup.
9
1
1
9
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
FMEA
System
Design
Process
Page 3 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
DET
RPN
SEV
OCC
DET
RPN
FUNCTION
OCC
#
SEV
TYPE
Leakage
Cracks, loose fittings
Leakage of BD tank contents to Visual Inspection basin / sump
9
1
3
27
Consider level sensor with alarm to alert operator that something has reached the sump.
9
1
1
9
10
1
10
100 Consider including an aquastat or other electronic temperature control on hot water loop so visual becomes backup. 30 Consider combustibility sensor above process 90 Consider level sensor with alarm to alert operator that something has reached the sump.
9
1
1
9
9
1
1
9
9
3
1
27
1. Review secondary containment (trough in floor) 2. Consider high level sensor in basin with audible alarm. Need to review alcohol recovery process in detail. What is intended operation, what are intended controls. Consider combustibility sensor above process Consider combustibility sensor above process Confirm pressure relief at TNK100. Appropriate settings and line sizing?
9
3
1
27
2
3
10
60
9
1
1
9
9
1
1
9
2
5
3
30
7
5
1
35
POTENTIAL FAILURE MODE
POTENTIAL CAUSES
POTENTIAL EFFECTS
DETECTION METHOD
RECOMMENDED ACTION(S)
TI
500
Temperature Indicator / Gauge - Condenser Inlet
Bad / no reading
Gauge failure
No indication of condenser inlet None temperature, or innacurate indication.
Leakage
Cracks, loose fittings
10
1
3
001
Process Sump / Basin - Integrated with Base
Overflow
Too much fluid
Leakage of alcohol vapor or liquid Spill onto floor
Visual inspection
SMP
Visual Inspection
10
3
3
Blockage of areas, material displacement
Spill onto floor
Visual Inspection
10
3
3
90
Over temp
Water Temp Control Failure
Incomplete alcohol recovery
None
2
3
10
60
Leakage
Loose Fitting
Leakage of alcohol vapor or Visual Inspection 10 liquid Leakage of alcohol vapor or Visual Inspection 10 liquid Visual inspection, lack of 6 Will not permit condensate alcohol to leave HEX-500 and accumulation of alcohol, no rise drop back into TNK-200. in LI-200. Possible rise in pressure in TNK100, with subsequent pressure relief. Will prevent intended operation Visual inspection of sight tube on 7 and use of TNK-100 (vacuum fill other tanks (LI-100 / LI-300) to will be prohibited). Potential note unintended change in routing of any process fluid to levels. Inability to draw a vacuum TNK-200 when not intended. on other vessels. Possible routing of alcohol vapors to other vessels. Leakage of alcohol onto basin / Visual inspection. 10 sump.
1
5
50
1
5
50
5
3
90
5
3
105 Consider combustibility sensor above process.
1
3
30
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
9
1
1
9
Consider combustibility sensor above process.
9
1
1
9
HEX
500
Alcohol Condenser
Vessel Failure HV
500
Isolation Valve - Alcohol Condenser
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure
Seat seal failure
HV
HV
610
620
Vent Valve - Biodiesel Reaction Tank
Vent Valve - Oxide MixTank
Closed when should be Open
1
5
50
5
5
225 Consider pressure relief valve on BD reaction tank. Set point TBD.
7
5
5
175
5
5
7
5
3
105
No effect Vapor leakage overboard
None None
1 10
5 1
10 10
1 9
5 1
10 1
50 9
None
175 Consider pump suction pressure gauge (vac / pos) for better detection. 50 100 Consider combustibility sensor above process 100 Consider combustibility sensor above process 175 1. Consider pressure relief valve on Oxide mix tank. Set point TBD. 2. Consider pressure gauge on tank for detection. 175 Consider pump suction pressure gauge (vac / pos) for better detection. 50 100 Consider combustibility sensor above process 100 Consider combustibility sensor above process
9
1
1
9
5
5
1
25
7
5
3
105
1 9
5 1
10 1
50 9
9
1
1
9
Open when should be Closed Leakage
Operator error Stem seal failure Seat seal failure
Vapor leakage through valve
10
1
10
Closed when should be Open
Operator error
Lack of venting for oxide mix Visual inspection (PI-120). tank, pressure increase during fill
7
5
5
Lack of replacement air when emptying tank.
Low outlet flow, pump work increase.
7
5
5
Operator error Stem seal failure
No effect Vapor leakage overboard
None None
1 10
5 1
10 10
Seat seal failure
Vapor leakage through valve
None
10
1
10
Open when should be Closed Leakage
Printed: 5/14/2008
Operator error
Routing of any process fluid to Visual inspection of sight tube on 10 the oxide mix tank when not oxide mix tank (LI-200). intended. Possible routing of alcohol vapors to other portions of the system. Lack of venting for reaction Visual inspection, pressure 9 vessel, pressure increase during gauge on reaction tank (PI-100) fill. or pressure gauge at pump outlet (PI-120) Lack of replacement air when Low outlet flow, pump work 7 emptying tank. increase.
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
FMEA
System
Design
Process
Page 4 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
380
Isolation Valve - Outlet of Settling Tank to Pump
290
Outlet Valve - Oxide Mixing Tank
5
175 1. Consider pressure relief valve on Settling tank. Set point TBD. 2. Consider pressure gauge on tank for detection.
5
5
1
25
Lack of replacement air when emptying tank.
Low outlet flow, pump work increase.
7
5
5
7
5
3
105
No effect Vapor leakage overboard, possibly some residual alcohol vapor. Vapor leakage through valve
None None
1 10
5 1
10 10
175 Consider pump suction pressure gauge (vac / pos) for better detection. 50 100 Consider combustibility sensor over process.
1 9
5 1
10 1
50 9
None
10
1
10
Low outlet flow, pump work increase.
8
5
3
Operator error
Will not draw tank down, pump over work, suction pressure on pump inlet (PMP-100).
Open when should be Closed
Operator error
Mix of air (empty tank) or final Visual inspection by sight tubes product (BD/glycerin) with other and mixing indicator (MI-100) parts of process when not intended.
7
5
3
Leakage
Stem seal failure
Leakage of final product (BD or glycerin) onto basin / sump. Mix of air (empty tank) or final product (BD/glycerin) with other parts of process when not intended. Will not draw tank down, pump over work, suction pressure on pump inlet (PMP-100).
Visual inspection
7
1
3
Visual inspection by sight tubes and mixing indicator (MI-100)
7
1
3
Low outlet flow, pump work increase.
8
5
RECOMMENDED ACTION(S)
100 Consider combustibility sensor over process. 120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
9
1
1
9
7
5
3
105
105 Operator checklist and operation sheets need to be developed and followed. Consider LOTO prior to operating pump (PMP100). 21 Consider level sensor in sump to detect severe leakage. 21
7
5
3
105
7
1
1
7
7
1
3
21
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
105 Operator checklist and operation sheets need to be developed and followed. Consider LOTO prior to operating pump (PMP100). 21 Consider level sensor in sump to detect severe leakage. 21
7
5
3
105
7
1
1
7
7
1
3
21
7
5
3
105
7
5
3
105
9
1
1
9
7
1
3
21
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Mix of air (empty tank) or final Visual inspection by sight tubes product (BD/glycerin) with other and mixing indicator (MI-100) parts of process when not intended.
7
5
3
Leakage
Stem seal failure
Leakage of final product (BD or glycerin) onto basin / sump. Mix of air (empty tank) or final product (BD/glycerin) with other parts of process when not intended. Will not draw tank down, pump over work, suction pressure on pump inlet (PMP-100).
Visual inspection
7
1
3
Visual inspection by sight tubes and mixing indicator (MI-100)
7
1
3
Low outlet flow, pump work increase.
8
5
3
Mix of air (empty tank) or oxide mix with other parts of process when not intended. Leakage of oxide mix or alcohol onto basin / sump. Mix of air (empty tank) or oxide mix with other parts of process when not intended.
Visual inspection by sight tubes and mixing indicator (MI-100)
7
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider pressure relief valve at pump outlet with vent line referenced to secure containment. 105
Visual inspection.
10
1
3
30
Visual inspection by sight tubes and mixing indicator (MI-100)
7
1
3
21
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure Seat seal failure
Printed: 5/14/2008
5
DETECTION METHOD
Closed when should be Open
Seat seal failure
HV
7
POTENTIAL EFFECTS
Operator error Stem seal failure
Seat seal failure
HV
DET
Outlet Valve - Settling Tank
RPN
390
Lack of venting for settling tank, Visual inspection (PI-120). pressure increase during fill.
Open when should be Closed Leakage
Seat seal failure HV
OCC
POTENTIAL CAUSES Operator error
SEV
POTENTIAL FAILURE MODE Closed when should be Open
DET
FUNCTION Vent Valve - Settling Tank
RPN
630
OCC
#
HV
SEV
TYPE
Consider combustibility sensor above process.
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
FMEA
System
Design
Process
Page 5 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
DET
SEV
OCC
DET
RPN
FUNCTION Skim Valve - Oxide Mixing Tank
Closed when should be Open
Operator error
Will not draw tank down, pump over work, suction pressure on pump inlet (PMP-100).
Low outlet flow, pump work increase.
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
Open when should be Closed
Operator error
Visual inspection by sight tubes and mixing indicator (MI-100)
7
5
3
105
7
5
3
105
Leakage
Stem seal failure
Mix of air (empty tank) or oxide mix with other parts of process when not intended. Leakage of oxide mix or alcohol onto basin / sump. Mix of air (empty tank) or oxide mix with other parts of process when not intended. Will not draw tank down, pump over work, suction pressure on pump inlet (PMP-100).
Visual inspection.
10
1
3
30
9
1
1
9
Visual inspection by sight tubes and mixing indicator (MI-100)
7
1
3
21
7
1
3
21
Low outlet flow, pump work increase.
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
7
5
3
105
7
5
3
105
Consider level sensor in sump to detect severe leakage. 1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
9
1
1
9
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
9
36
POTENTIAL FAILURE MODE
POTENTIAL CAUSES
Seat seal failure
HV
190
Outlet Valve - BD Reaction Tank
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure
Seat seal failure
HV
400
Vacuum Reference Valve - Top of BD Reaction Tank
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure Seat seal failure
HV
800
Inlet Valve - Alcohol to Oxide Tank
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Printed: 5/14/2008
Stem seal failure
POTENTIAL EFFECTS
DETECTION METHOD
Mix of air (empty tank) or reactor Visual inspection by sight tubes mix with other parts of process and mixing indicator (MI-100) when not intended. Veg Oil Spill onto basin / sump Visual inspection
RPN
295
OCC
#
HV
SEV
TYPE
RECOMMENDED ACTION(S)
Consider combustibility sensor above process.
4
1
3
12
Reaction Mix Spill onto basin / sump
Visual inspection
10
1
3
30
BD Spill onto basin / sump
Visual inspection
4
1
3
12
Mix of air (empty tank) or reactor Visual inspection by sight tubes mix with other parts of process and mixing indicator (MI-100) when not intended. Inability to draw vacuum on Noted lack of fill, lack of vacuum vessels for vacuum fill process on specific vessel.
7
1
3
21
7
1
3
21
2
5
3
30
2
5
3
30
Possible leakage of vented vapors from BD tank or others. Possible vacuum on any vessel when unintended (would require double failure including vacuum pump on) Poor vacuum draw performance on system Possible leakage of vented vapors from BD tank or others. Possible vacuum on any vessel when unintended (would require double failure including vacuum pump on) Will not permit filling of oxide tank with alcohol and catalyst, potential spill onto sump / basin
Vacuum on TNK-100 when not intended.
2
5
3
30
2
5
3
30
Vacuum measurement on TNK100 Vacuum on TNK-100 when not intended.
2
2
3
12
2
2
3
12
2
5
3
30
2
5
3
30
Visual inspection
10
5
3
150 1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
9
5
1
45
250 Consider combustibility sensor above process. 150 Consider level sensor in sump to detect severe leakage.
Venting of vapor to area other Visual inspection than intended vent termination. Overflow of contents onto basin / Visual inspection sump. Venting of vapor to area other Visual inspection than intended vent termination. Overflow of contents onto basin / Visual inspection sump.
10
5
5
10
5
3
10
1
5
50
10
1
3
30
Consider combustibility sensor above process. Consider level sensor in sump to detect severe leakage.
9
5
1
45
9
5
1
45
9
1
1
9
9
1
1
9
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
FMEA
System
Design
Process
Page 6 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
900
System Drain Valve
950
Outlet Valve - Take Off for BD
Printed: 5/14/2008
975
Outlet Valve - Take Off for Glycerin
50
9
1
1
9
3
30
Consider combustibility sensor above process. Consider level sensor in sump to detect severe leakage.
10
1
9
1
1
9
RECOMMENDED ACTION(S)
Will not permit filling of settling tank / transfer of product. Pump blockage, increased pump work (PMP-100) and system pressure.
Visual inspection of sight tube on settling tank (LI-300). Pump work increase, audible change. Possible pump dead-end.
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
Open when should be Closed
Operator error
Routing of other fluids to settling Visual inspection of sight tube on tank when not intended. settling tank (LI-300).
7
5
3
105
7
5
3
105
Leakage
Stem seal failure
Leakage of final product (BD or Visual inspection glycerin) onto basin / sump. Routing of other fluids to settling Visual inspection of sight tube on tank when not intended. settling tank (LI-300).
7
1
3
21
7
1
1
7
7
1
5
35
7
1
5
35
Consider level sensor in sump to detect severe leakage.
Closed when should be Open
Operator error
Will not permit drainage of system, possible future blockages or spills.
Visual inspection of outflow, lack of flow. Audible change in pump if run during drain cycle.
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
Open when should be Closed
Operator error
Visual inspection, audible spilling.
10
5
3
150 Consider level sensor in sump to detect severe leakage.
9
5
1
45
Leakage
Stem seal failure
Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump. Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump. Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump. Will not permit take-off of final products. Pump blockage, increased pump work (PMP100) and system pressure.
Visual inspection, audible spilling.
10
1
3
30
Consider level sensor in sump to detect severe leakage.
9
1
1
9
Visual inspection, audible spilling.
10
1
3
30
Consider level sensor in sump to detect severe leakage.
9
1
1
9
Visual inspection of outflow, lack of flow. Audible change in pump.
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump. Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump. Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump. Will not permit take-off of final products. Pump blockage, increased pump work (PMP100) and system pressure.
Visual inspection, audible spilling.
10
5
3
150 Consider level sensor in sump to detect severe leakage.
9
5
1
45
Visual inspection, audible spilling.
10
1
3
30
Consider level sensor in sump to detect severe leakage.
9
1
1
9
Visual inspection, audible spilling.
10
1
3
30
Consider level sensor in sump to detect severe leakage.
9
1
1
9
Visual inspection of outflow, lack of flow. Audible change in pump.
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump.
Visual inspection, audible spilling.
10
5
3
150 Consider level sensor in sump to detect severe leakage.
9
5
1
45
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure
Seat seal failure
HV
5
Operator error
Seat seal failure
HV
1
Closed when should be Open
Seat seal failure
HV
DET
Inlet Valve - Settling Tank
RPN
300
10
DETECTION METHOD
OCC
HV
Venting of vapor to area other Visual inspection than intended vent termination. Overflow of contents onto basin / Visual inspection sump.
POTENTIAL EFFECTS
SEV
POTENTIAL CAUSES Seat seal failure
DET
POTENTIAL FAILURE MODE
RPN
FUNCTION
OCC
#
SEV
TYPE
Closed when should be Open
Operator error
Open when should be Closed
Operator error
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
FMEA
System
Design
Process
Page 7 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
Inlet Valve - Oxide Mixing Tank
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure
Seat seal failure
HV
HV
100
105
Fill Valve - BD Reaction Tank
Mix Inlet Valve - BD Reaction Tank
Visual inspection, audible spilling.
10
1
3
30
Consider level sensor in sump to detect severe leakage.
9
1
1
9
Visual inspection, audible spilling.
10
1
3
30
Consider level sensor in sump to detect severe leakage.
9
1
1
9
Visual inspection, pressure increase on pressure gauge (PI120) lack of intended flow. Audible change in pump operation.
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
Routing of any process fluid to Visual inspection of sight tube on 7 oxide mix tank (LI-200). the oxide mix tank when not intended. Possible routing of alcohol vapors to other portions of the system. Leakage of oxide mix or alcohol Visual inspection. 10 onto basin / sump.
5
3
105 Consider combustibility sensor above process.
7
5
1
35
1
3
30
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
9
1
1
9
Routing of any process fluid to Visual inspection of sight tube on 10 the oxide mix tank when not oxide mix tank (LI-200). intended. Possible routing of alcohol vapors to other portions of the system. 7 Will prevent filling of BD reaction Visual inspection of process tank. Pump work increase (PMP- sight tube (MI-100), audible 100), system pressure rise. change in pump operation.
1
5
50
Consider combustibility sensor above process.
9
1
1
9
5
3
105 Consider pressure relief at pump 7 outlet with vent line referenced to containment.
5
3
105
7
5
5
175
7
5
5
175
Consider level sensor in sump to detect severe leakage. 1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
9
1
1
9
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
POTENTIAL EFFECTS Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump. Routing of any process fluid overboard or to take-off termination. Likely spill onto basin / sump. Will not permit pump-driven mixing and circulation of alcohol oxide mix. Increased pump work (PMP-100) and system pressure.
DETECTION METHOD
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Routing of any process fluid to Visual inspection of BD tank the BD tank when not intended. sight tube (LI-100).
Leakage
Stem seal failure
Veg Oil Spill onto basin / sump
Visual inspection
4
1
3
12
Reaction Mix Spill onto basin / sump
Visual inspection
10
1
3
30
BD Spill onto basin / sump
Visual inspection
4
1
3
12
RECOMMENDED ACTION(S)
Seat seal failure
Routing of any process fluid to Visual inspection of BD tank the BD tank when not intended. sight tube (LI-100).
7
1
5
35
7
1
5
35
Closed when should be Open
Operator error
8
5
3
120 Consider pressure relief at pump 7 outlet with vent line referenced to containment.
5
3
105
Open when should be Closed
Operator error
Will prevent mixing and recirc of Visual inspection of process BD reaction tank contents. sight tube (MI-100), audible Pump work increase (PMP-100), change in pump operation. system pressure rise. Routing of any process fluid to Visual inspection of BD tank the BD tank when not intended. sight tube (LI-100).
7
5
3
105
7
5
3
105
Leakage
Stem seal failure
Consider level sensor in sump to detect severe leakage. 1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
9
1
1
9
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
7
1
5
35
Seat seal failure
Printed: 5/14/2008
DET
200
RPN
HV
OCC
Seat seal failure
SEV
POTENTIAL CAUSES Stem seal failure
DET
POTENTIAL FAILURE MODE Leakage
RPN
FUNCTION
OCC
#
SEV
TYPE
Veg Oil Spill onto basin / sump
Visual inspection
4
1
3
12
Reaction Mix Spill onto basin / sump
Visual inspection
10
1
3
30
BD Spill onto basin / sump
Visual inspection
4
1
3
12
7
1
5
35
Routing of any process fluid to Visual inspection of BD tank the BD tank when not intended. sight tube (LI-100).
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
FMEA
System
Design
Process
Page 8 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
DET
SEV
OCC
DET
RPN
FUNCTION Main Mix Line Valve - Pump Pressure Side
Closed when should be Open
Operator error
Will prevent flow of process fluids from pump (PMP-100)
Visual inspection at process sigh tube (MI-100), audible change in pump operation.
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
Open when should be Closed
Operator error
Routing of any process fluid to either BD tank or Oxide mixing tank when not intended.
7
5
5
175
7
5
5
175
Leakage
Stem seal failure
Veg Oil Spill onto basin / sump
Visual inspection at process sigh tube (MI-100), BD tank sight tube (LI-100) or oxide mix tank sight tube (LI-200) Visual inspection
4
1
3
12
1
1
4
Visual inspection
10
1
3
30
Consider level sensor in sump to detect severe leakage. 1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
Reaction Mix Spill onto basin / sump
9
1
1
9
BD Spill onto basin / sump
Visual inspection
4
1
3
12
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
7
1
5
35
7
1
5
35
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
3
5
1
15
3
5
1
15
Consider level sensor in sump to detect severe leakage. 1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
3
12
9
1
1
9
POTENTIAL FAILURE MODE
POTENTIAL CAUSES
Seat seal failure
HV
HV
Printed: 5/14/2008
150
160
Isolation Valve - Pump Inlet
Isolation Valve - BD Reaction Tank Bottom
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure
POTENTIAL EFFECTS
DETECTION METHOD
Routing of any process fluid to either BD tank or Oxide mixing tank when not intended.
Visual inspection at process sigh tube (MI-100), BD tank sight tube (LI-100) or oxide mix tank sight tube (LI-200) No flow, pump work increase, Visual inspection, pressure pump outlet pressure increase increase on pressure gauge (PIand suction pressure decrease. 120) lack of intended flow. Audible change in pump operation.
Leakage of system contents during maintence operation. Likely spill on containment basin into sump. Veg Oil Spill onto basin / sump
Visual inspection, leakage at point of intended line break (rapid detection).
RPN
120
OCC
#
HV
SEV
TYPE
RECOMMENDED ACTION(S)
Visual inspection
4
1
3
12
Reaction Mix Spill onto basin / sump
Visual inspection
10
1
3
30
BD Spill onto basin / sump
Visual inspection
4
1
3
12
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
1
4
3
Consider having a plug / cap available for these fittings. Or do not work on system unless it is completely drained. Install a dedicated drain for this purpose?
3
1
1
3
Seat seal failure
Slow leakage of system contents Visual inspection, leakage at during maintence operation. point of intended line break Likely spill on containment basin (rapid detection). into sump.
3
1
1
Closed when should be Open
Operator error
Will not draw tank down, pump over work, suction pressure on pump inlet (PMP-100).
8
5
3
120 1. Review motor drive controls and also pump dead-head pressure ride. 2. Consider recirc loop for pump. 3. Consider pressure relief valve at pump outlet with vent line referenced to secure containment.
7
5
3
105
Open when should be Closed
Operator error
7
5
5
175
7
5
5
175
Leakage
Stem seal failure
Mix of air (empty tank) or reactor Visual inspection by sight tubes mix with other parts of process and mixing indicator (MI-100) when not intended. Veg Oil Spill onto basin / sump Visual inspection
4
1
3
12
4
1
1
4
Low outlet flow, pump work increase.
Consider level sensor in sump to detect severe leakage.
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
FMEA
System
Design
Process
Page 9 of 9
Document name
Date
Issue
FMEA - State Line Farm Biodiesel System
1/2/2008
Final - Pre First Batch
Issued by
Approved by
Document status
Revision 1 RPN 200 RPN 100 -199 RPN 1-99
Level Indicator Valve - BD Reaction Tank Bottom
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure Seat seal failure
HV
175
Level Indicator Valve - BD Reaction Tank Top
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure Seat seal failure
HV
270
Level Indicator Valve - Oxide Mix Tank Bottom
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure Seat seal failure
HV
370
Level Indicator Valve - Settling Tank Bottom
Closed when should be Open
Operator error
Open when should be Closed
Operator error
Leakage
Stem seal failure Seat seal failure
DET
170
RPN
HV
OCC
Seat seal failure
SEV
POTENTIAL CAUSES
DET
POTENTIAL FAILURE MODE
RPN
FUNCTION
OCC
#
SEV
TYPE
Reaction Mix Spill onto basin / sump
Visual inspection
10
1
3
30
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
9
1
1
9
BD Spill onto basin / sump
Visual inspection
4
1
3
12
1. Consider level sensor in sump to detect severe leakage. 2. Consider combustibility senso above process.
4
1
3
12
7
1
5
35
7
1
5
35
POTENTIAL EFFECTS
DETECTION METHOD
Mix of air (empty tank) or reactor Visual inspection by sight tubes mix with other parts of process and mixing indicator (MI-100) when not intended. Unknown or inaccurate level or Visual Inspection settling status Leakage of oxide mix or alcohol Visual inspection, smell, audible onto basin / sump during spilling. maintenance operation (rapid detection). Spill of alcohol or oxide mix onto Visual Inspection basin / sump Leakage of oxide mix or alcohol Visual inspection, smell. onto basin / sump during maintenance operation (rapid detection). Unknown or inaccurate level or Visual Inspection settling status Leakage of oxide mix or alcohol Visual inspection, smell, audible spilling. onto basin / sump during maintenance operation (rapid detection). Spill of alcohol or oxide mix onto Visual Inspection basin / sump Leakage of oxide mix or alcohol Visual inspection, smell. onto basin / sump during maintenance operation (rapid detection). Unknown or inaccurate level or Visual Inspection settling status Leakage of oxide mix or alcohol Visual inspection, smell, audible spilling. onto basin / sump during maintenance operation (rapid detection). Spill of alcohol or oxide mix onto Visual Inspection basin / sump Leakage of oxide mix or alcohol Visual inspection, smell. onto basin / sump during maintenance operation (rapid detection). Unknown or inaccurate level or Visual Inspection settling status Leakage of settling tank contents Visual inspection, audible to basin / sump during spilling. maintenance procedure (rapid detection). Leakage of settling tank contents Visual inspection to basin / sump. Leakage of settling tank contents Visual inspection, audible to basin / sump during spilling. maintenance procedure (rapid detection).
6
5
3
90
6
5
3
90
10
5
1
50
Consider using on-body combustibility sensors (Crickets) during maintenance operations.
9
5
1
45
10
1
3
30
9
1
1
9
10
1
1
10
Consider level sensor in sump to detect severe leakage. Consider using on-body combustibility sensors (Crickets) during maintenance operations.
9
1
1
9
6
5
3
90
6
5
3
90
10
5
1
50
Consider using on-body combustibility sensors (Crickets) during maintenance operations.
9
5
1
45
10
1
3
30
1
1
9
1
1
10
Consider level sensor in sump to detect severe leakage. Consider using on-body combustibility sensors (Crickets) during maintenance operations.
9
10
9
1
1
9
6
5
3
90
6
5
3
90
10
5
1
50
Consider using on-body combustibility sensors (Crickets) during maintenance operations.
9
5
1
45
10
1
3
30
1
1
9
1
1
10
Consider level sensor in sump to detect severe leakage. Consider using on-body combustibility sensors (Crickets) during maintenance operations.
9
10
9
1
1
9
6
5
3
90
6
5
3
90
3
5
1
15
Consider level sensor in sump to detect severe leakage.
3
5
1
15
4
1
3
12
1
1
4
1
1
3
Consider level sensor in sump to detect severe leakage. Consider level sensor in sump to detect severe leakage.
4
3
3
1
1
3
MAX 250 AVG 60.2 MIN 3
Printed: 5/14/2008
RECOMMENDED ACTION(S)
MAX 175 AVG 35.5 MIN 2
C:\Documents and Settings\Chris\My Documents\Callahan Engineering Files\Jobs\2007\VSJF - State Line Farm\Engineering Scope\FMEA\FMEA - State Line Farm Biodiesel Process - Rev 1.xls
