RCM Analysis CTN Steam

Function Function failure Failure mode/consequences

1) To supply 1A) To supply steam for 1A1 Isolation valve fails
steam at correct filler surge heated jacket at Unable to stop steam in an emergency.
pressure. 1.0 bar Action
Shire task to check operation
Monthly

1A2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1A3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1A4 Reducing valve DP type fails to maintain set steam

pressure.
Plant stopped
Action
Weekly steam leak check
Recommended spare for DP17 25mm.

1A5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1A6 Pressure relief valve fails. Set at 1.5 bar

Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1A7 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1A8 Control valve fails.

Incorrect steam flow.
Action

1
 Shire task to check operation of control valve.
6 monthly

1A9 Insulation insufficient.

Safety issue and cost saving
Action
Shire task to check for missing insulation.
Monthly

1B) To supply steam for 1B1 Isolation valve fails

process water at 4.0 bar Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1B2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1B3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1B4 Reducing valve DP type fails to maintain set steam

pressure.
Plant stopped
Action
Weekly steam leak check
Recommended spare for DP17 50mm.

1B5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1B6 Pressure relief valve fails. Set at 5.0 bar.

Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1B7 Isolation valve fails

Unable to stop steam in an emergency.

2
 Action
Shire task to check operation
Monthly

1B8 Control valve fails.

Incorrect steam flow.
Action
Shire task to check operation of control valve.
6 monthly

1B9 Insulation insufficient.

Safety issue and cost saving
Action
Shire task to check for missing insulation.
Monthly

1C) To supply steam for 1C1 Isolation valve fails

frozen vegetable 4.0 bar Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1C2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1C3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1C4 Reducing valve DP type fails to maintain set steam

pressure.
Plant stopped
Action
Weekly steam leak check
Recommended spare for DP17 40mm.

1C5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1C6 Pressure relief valve fails. Set at 5.0 bar

3
 Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1C7 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1C8 Control valve fails.

Incorrect steam flow.
Action
Shire task to check operation of control valve.
6 monthly

1C9 Insulation insufficient.

Safety issue and cost saving
Action
Shire task to check for missing insulation.
Monthly

1D) To supply steam for 1D1 Isolation valve fails

CIP system at 4.0 bar Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1D2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1D3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1D4 Reducing valve DP type fails to maintain set steam

pressure.
Plant stopped
Action
Weekly steam leak check
Recommended spare for DP143 80mm.

4
 1D5 Gauge fails
Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1D6 Pressure relief valve fails. Set at 5.5 bar.

Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1D7 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1D8 Control valve fails.

Incorrect steam flow.
Action
Shire task to check operation of control valve.
6 monthly

1D9 Insulation insufficient.

Safety issue and cost saving
Action
Shire task to check for missing insulation.
Monthly

1E) To supply steam for 1E1 Isolation valve fails

heating line 2 and pick Unable to stop steam in an emergency.
heater 2 at 4.0 bar to 5.5 Action
bar. Shire task to check operation
Monthly

1E2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1E3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

5
 1E4 Reducing valve EP5 type fails to maintain set steam
pressure.
Plant stopped
Action
Shire task to check operation
6 monthly

1E5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1E6 Pressure relief valve fails. Set at ????????

Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1E7 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1E8 Control valve fails.

Incorrect steam flow.
Action
Shire task to check operation of control valve.
6 monthly

1E9 Insulation insufficient.

Safety issue and cost saving
Action
Shire task to check for missing insulation.
Monthly

1F) To supply steam for 1F1 Isolation valve fails

ware house heating at 4.0 Unable to stop steam in an emergency.
bar Action
Shire task to check operation
Monthly

1F2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

6
 1F3 Gauge fails
Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1F4 Reducing valve DRV7 type fails to maintain set

steam pressure.
Plant stopped
Action
Weekly steam leak check
Recommended spare for DRV7 25mm.

1F5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1F6 Pressure relief valve fails. Set at 6.5 bar.

Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1F7 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1F8 Control valve fails.

Incorrect steam flow.
Action
Shire task to check operation of control valve.
6 monthly

1F9 Insulation insufficient.

Safety issue and cost saving
Action
Shire task to check for missing insulation.
Monthly

1G) To supply steam for 1G1 Isolation valve fails

Fuji at 4.0 bar Unable to stop steam in an emergency.
Action
Shire task to check operation

7
Monthly

1G2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1G3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1G4 Reducing valve Gestra PR5801 type fails to

maintain set steam pressure.
Plant stopped
Action
Weekly steam leak check
Recommended spare for PR5801 15mm.

1G5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1G6 Pressure relief valve fails.

Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1G7 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1G8 Control valve fails.

Incorrect steam flow.
Action
Shire task to check operation of control valve.
6 monthly

1G9 Insulation insufficient.

Safety issue and cost saving
Action

8
 Shire task to check for missing insulation.
Monthly

1H) To supply steam for 1H1 Isolation valve fails

heating line 1 and pick Unable to stop steam in an emergency.
heater 1 at 4.0 bar to 5.5 Action
bar. Shire task to check operation
Monthly

1H2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1H3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1H4 Reducing valve EP5 type fails to maintain set

steam pressure.
Plant stopped
Action
Shire task to check operation
6 monthly

1H5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1H6 Pressure relief valve fails. Set at 5.5 bar

Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1H7 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1H8 Control valve fails.

Incorrect steam flow.

9
 Action
Shire task to check operation of control valve.
6 monthly

1H9 Insulation insufficient.

Safety issue and cost saving
Action
Shire task to check for missing insulation.
Monthly

1I) To supply steam for 1I1 Isolation valve fails

filler bowl heated jacket at Unable to stop steam in an emergency.
1.0 bar. Action
Shire task to check operation
Monthly

1I2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1I3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1I4 Reducing valve DP type fails to maintain set steam

pressure.
Plant stopped
Action
Weekly steam leak check
Recommended spare for DP17 ½ inch

1I5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1I6 Pressure relief valve fails. Set at 2.5 bar

Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1I7 Isolation valve fails

10
 Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1I8 Control valve fails.

Incorrect steam flow.
Action
Shire task to check operation of control valve.
6 monthly

1I9 Insulation insufficient.

Safety issue and cost saving
Action
Shire task to check for missing insulation.
Monthly

1J) To supply steam for 1J1 Isolation valve fails

hot power wash system at Unable to stop steam in an emergency.
3 bar. Action
Shire task to check operation
Monthly

1J2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
Monthly

1J3 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

1J4 Reducing valve DP type fails to maintain set steam

pressure.
Plant stopped
Action
Weekly steam leak check
Recommended spare for DP17 50mm.

1J5 Gauge fails

Incorrect pressure reading
Action
Shire task to check gauge reading
Monthly

11
 1J6 Pressure relief valve fails. Set at 4.0 bar
Potential fatality.
Action
Shire task to check operation of safety valve.
6 monthly

1J7 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
Monthly

1J8 Control valve fails.

Incorrect steam flow.
Action
Shire task to check operation of control valve.
6 monthly

1J9 Insulation insufficient.

Safety issue and cost saving
Action
Flow meter? Shire task to check for missing insulation.
Monthly

2) Unable to 2A Trap set fails 2A1 Isolation valve fails

remove Unable to stop steam in an emergency.
condensate. Action
Shire task to check operation
3 Monthly

2A2 Strainer fails

Loss of steam flow or erosion
Action
Shire task to check condition of strainer
3 Monthly

2A3 Trap fails

Loss of production.
Action
Shire task to check trap is working correctly.
3 Monthly

2A4 Sight glass fails.

Condensate leak.
Action
Shire task to check condition of sight glass
3 monthly

12
 2A5 Non return valve fails
Steam line will fill with condensate on shutdown
Action
Shire task to check valve.
3 monthly

2A6 Isolation valve fails

Unable to stop steam in an emergency.
Action
Shire task to check operation
3 Monthly

2B Condensate not 2B1 Condensate return pump fails.

pumped to boiler house Plant stoppage.
Action
Shire task to swop pumps
3 monthly

2B2 Condensate tank level switch fails

Plant stoppage
Action
Run to failure

13