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EXTRACTOR-3 SHAFT FAILURE FAILURE DATE : BREAKDOWN DURATION : PRODUCTION LOSS TIME :

Root Cause Analysis : As per Annexture - I (Fish bone Diagram) Analysis


Sr No Noise as per RCA(N) PROPOSED SOLUTIONS ACTION TO BE/TAKEN REMARKS

Fishbone Diagram Generator 3.0

Problem Statement

Enter the problem you are trying to analyze in the white box below much information on the "what", "when", and "how much" of the pr "finished" to continue.

Leakage of steam from flanges

Major Cause Catagories

Fill in general cause catagories below. For suggested causes, cl business type.You can add or change suggested causes if you ch "finished" to continue.

MANUFACTURING
1 2 3 Men Materials Methods 4 5 6

Specific Causes
#1 ----> ----> ----> ----> ----> #2 ----> ----> ----> ----> ----> #3 ----> ----> ----> ----> ---->
Men

Enter specific causes associated with respective major causes below. Be precise and include data w Click "finished" to continue. #4 ----> ----> ----> ----> ----> #5 ----> ----> ----> ----> ----> #6 ----> ----> ----> ----> ---->

Materials

Flange material not compatible Gasket material not compatible

Methods

Uneven tightening

blem Statement

g to analyze in the white box below. Include as ", "when", and "how much" of the problem. Click nished" to continue.

e of steam from flanges

r Cause Catagories

es below. For suggested causes, click on your change suggested causes if you choose. Click nished" to continue.

OTHERS
Machine Measurement Mother nature

Specific Causes
Machine

e major causes below. Be precise and include data whenever possible. lick "finished" to continue. Flange not parallel Seating face damage Line in tension Vibration in line

Measurement

Mother nature

FISHBONE DIAGRAM
Men Materials Flange material not compatible Gasket material not compatible Methods

Uneven tightening

Leakage of steam from flanges Flange not parallel

Seating face damage

Line in tension

Vibration in line

Machine

Measurement

Mother nature

10/8/2013

Why-Why Analysis-

Leakage of steam from flange Method : Uneven tightening

Why Uneven tightening Poor workmanship OPL on tightening method of flange

Machine: Seating face damage

Why Seating face damage Errosion by flow of steam

Gasket damage Not replaced in time ( Life expire) Prepare checklist for gasket damage Why Seating face material not compatiable with steam

Prepare MP sheet Machine: Both face of flange is not parallel Why Both face of flange is not parallel 1 Prepare MP sheet 2 Correction in line to make flange face parallel

akage of steam from flange

Answer Poor workmanship Lack of training

on tightening method of flange

amage

Answer Errosion by flow of steam 1 Gasket damage 2 Seating face material not compatiable with steam Not replace in time ( Life expire) No schedule to check

re checklist for gasket damage Answer Not taken care during design

Prepare MP sheet

ange is not parallel Answer Not taken care during design

1 Prepare MP sheet n in line to make flange face parallel

FISHBONE DIAGRAM
Men Material Method

Backlach out of limit

Breather not functioning Oil level not maintained Improper cooling ( Fan damage/ cover block) Running at high temperature Oil leakage from gear boxes Misalignment

Gasket quality

No sealing of flange

Wrong oil selection

Poor workability

Oil seal MOC

Vibration

Wear & tear of internal parts

Shaft damage

Machine

Measurement

Mother nature

10/8/2013

Why-Why Analysis-

Oil leakage from gear boxes Method : Wrong oil selection

Why Wrong oil selection High temperature at the surface of gear box a) process vapors in contact with gear box Sankalp: Modification in exhaust hood to prevent un-necessary of gear box High temperature at the surface of gear box Selection of suitable (high temperature)gear box oil

Why

Prepare checklist for gasket damage Why Prepare MP sheet Machine: Both face of flange is not parallel Why Both face of flange is not parallel 1 Prepare MP sheet 2 Correction in line to make flange face parallel

l leakage from gear boxes

Answer High temperature at the surface of gear box a) process vapors in contact with gear box Gap between vapor exhaust hood & reactor manhole

n exhaust hood to prevent un-necessary heating of gear box b) gear box heated through conduction of process condition

uitable (high temperature)gear box oil

Answer

re checklist for gasket damage Answer Prepare MP sheet

ange is not parallel Answer Not taken care during design

1 Prepare MP sheet n in line to make flange face parallel

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