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Trinath Sahoo
Root Cause Failure Analysis
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Страница 1
Table of Contents
List of Tables
List of Illustrations
Guide
Pages
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1 FAILURE: How to Understand It, Learn from It and Recover from It
Failure Type
Preventable Failures
Unavoidable Failures in Complex Systems
Intelligent Failures
Building a Learning Culture
Detecting Failure
Analyzing Failure
Share the Lessons
Benefits of Failure Analysis
Conclusion
2 What Is Root Cause Analysis
The Causes of TITANIC disaster
What Is Root Cause Analysis?
Different Levels of Causes
Physical Roots
Human Roots
Latent Roots
When RCA Is Justified Equipment Damage or Failure
Operating Performance
Product Quality
Capacity Restrictions
Economic Performance
Safety
Top Reasons Why We Need to Perform RCFA
Root Cause Analysis in a Larger Context
Conclusion
3 Root Cause Analysis Process
What is root cause analysis
Define the problem
Collection of data
Interviews
Analyze Sequence of Events
Design Review
Operating and Maintenance Manuals
Operating Procedures and Practices
Maintenance History
Operating Envelope
Maintenance Procedures and Practices
Misapplication
Management Systems
Identify Possible Causal Factors What Is a Causal Factor?
What Is a Root Cause?
What Is the Difference Between a Causal Factor and a Root Cause?
The Five Whys
When to Use 5 Why
How to Use the 5 Whys
Fishbone Diagram
Fishbone Diagram Structure
How to Create a Cause and Effect Diagram
Fault Tree Analysis
Drawing Fault Trees: Gates and Events
FTA Gate Notes
How to Undertake a Fault Tree Analysis?
Benefits of Fault Trees
Identify the Root Cause
Recommend and Implement Solution
Conclusion
4 Managing Human Error and Latent Error to Overcome Failure
Review of Some of the Accidents
Types of Human Failure: What Types of Errors Do Humans Make?
Active Failures
Latent Failures
What Factors Influence Human Reliability?
What Factors Influence Human Variability
The Prevention of Human Error
Ways to Reduce Human Error The Procedures
Audits
Increased Discipline
Increased Automation
Improved Training
Motivational Campaigns
Conclusion
5 Metallurgical Failure
Understanding the Basics
Elastic Limit
Elastic and Plastic Ranges
Yield Point
Ultimate Strength
Rapture Strength
Elastic Deformation
Plastic Deformation
Identification of Types of Failures
Brittle vs. Ductile Fracture characteristics
Ductile Fracture
Brittle Fracture
Example: Failure of a Pipe
Stages in Ductile Fracture
Brittle Fracture Characteristics
Origin of Fractures (Ductile and Brittle)
Fatigue Failures
Stress Concentration
Thermal Fatigue Failure
Stress Corrosion Cracking
How to Prevent SCC
Chloride SCC
Hydrogen Damage
Failure Due to Hydrogen Damage
Addressing Hydrogen Damage
Corrosion Damage
How to Control Corrosion
Wear and Erosion Damage
Failure Investigation
Stages of a Failure Analysis
Collection of Background Data and Samples
Visual Examination
Testing
Non‐Destructive Evaluation/Non‐Destructive Testing (NDE/NDT)
Mechanical Testing
Macroscopic Examination
Microscopic Examination
Metallographic Examination
Chemical Analysis
Simulations
Data Analysis, Conclusions and Report
Impact of working condition on metallurgical failure
Improper Design
Improper Selection of the Materials
UnFavorable Manufacturing Processing Conditions
Poor Assembling
Poor Service Conditions
Poor Maintenance Strategy
Conclusion
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