Failure Mode and Effects Analysis of Hotwell System Motor Operated Butterfly Valve
Failure Mode and Effects Analysis of Hotwell System Motor Operated Butterfly Valve
41, 2017
Victor Ouma
Kenya Electricity Generating Company Ltd
Keywords
Motor operated Butterfly Valve, Failure Mode and Effects Analysis, Reliability Priority
Number, Maintenance, Geothermal Power Plant
ABSTRACT
Olkaria 280 MW Geothermal Power Plants (GPPs) have been experiencing breakdowns of the
Motor Operated Butterfly Valves (MOBFVs) over the years with negative impacts on safety,
reliability, power plant revenue and cost. The MOBFV function is to control and regulate
condensate flow from the condenser to the cooling tower. The failure of these valves have led to
turbine trip or delay turbine start up.
This paper applies the Failure Mode and Effects Analysis (FMEA) tool to evaluate the reliability
of the MOBFVs in Olkaria 280 MW GPPs in order to improve safety and reliability of the
hotwell pump system. FMEA is a method used to study the reliability characteristics of systems,
processes and components. Reliability assessment of the MOBFVs will plays a very important
role in the definition of a suitable maintenance strategy and hence improve the overall plant
availability. The strategy aims to reduce unplanned shutdowns, component repair times and
elimination of risk significant components. This evaluation identified the most risk significant
components in the MOBFVs as valve seat, disc pins, driven gear, seals and bearings. Upon
implementation of new maintenance procedures, there was significant decrease in reliability
priority number (RPN) value for individual components leading to a reduced risk of failure. In
addition, a financial evaluation estimated that the application of the revised maintenance
strategies reduced the financial cost and losses by 51.10%.
1. Introduction
A butterfly valve (BFV) is a flow control valve used for isolating and regulating flow of fluids.
The BFV operation time is short because the disc element is rotated a quarter turn (90°) to open
or close the passageway. BFVs are quite versatile and can be used for industrial applications
under varying conditions such as type of fluid, sizes, pressures and temperatures. (Patil &
Basavaraj, 2015). These valves are ideal because they are lower in cost, lighter in weight
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compared to other valve designs. They can also be used to perform throttling operation. Figure. 1
shows the operation of the motor operated butterfly valve;
Figure 1: The figure above illustrates the operation of a motor operated butterfly valve (TLV, 2017)
3. Problem Statement
This paper seeks to identify major causes of failure in 280MW GPPs MOBFVs, the effects of
such failure whenever they occur and calculate the risk significance of the failures by calculating
the reliability priority number (RPN). The RPN number gives the importance of the failure and
can easily identify which failure bears the highest risk to the operation of the plant. A review of
the design and maintenance strategies is done and maintenance tasks are selected that can
adequately mitigate the failure. Furthermore, a financial review is undertaken to estimate the
benefits of the prescribed changes.
5. Results
To increase understanding level and detailed component knowledge of the MOBFV system, the
system is broken down to individual components. The Olkaria 280 GPPs MOBFVs are
composed of three major components:
1. Butterfly valve
2. Actuator
3. Electric motor
4. Mechanical Gearbox
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Figure 3: The figure above is a motor operated actuator with hand wheel
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Gears Transfer torque Wear, Pitting Open/ closing fail Excessive compressive stresses,
from actuator shock loading, bad lubricant, too
much cycling
Shaft Seal Prevent water Tear, wear Leakage to into gearbox, Damaged seal, poor installation,
from accessing contamination of grease non fitting seals, over compression,
the gearbox leading to wear and twisting
corrosion
Driven Gear Rotates the valve Shear, Wear Open/ closing fail Grease contamination, corrosion
disc
Bearings Carry gear loads High vibration, Overload, overheating, Overloading, Improper,
and hold gear Seizure, wear, no rotation, hindered aged/insufficient lubricant, solid/
shaft in position pitting, fatigue, rotation liquid contaminants, improper
and reduce corrosion mounting, Shaft misalignment
rotational friction
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Figure 4 and 5 below show the RPN values of the risk significant components in the MOBFV
and their respective severity, occurrence and detection ratings respectively.
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Figure 5. Severity, Occurrence and Detection (SOD) scale of high risk components
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Figure 6: Maintenance task selection process (Ouma, Osama, Mpakani, Baik, & Gomma, 2015)
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Table XII: Estimated Reliability Priority Number after Review of Maintenance Strategy
Component Sub - RPN
component Severity Occurrence Detection RPN Group
Butterfly Hand wheel 8 4 2 64 D
Valve
Stem 8 5 4 160 C
Body 8 4 3 96 C
Seat 8 6 7 336 B
Disc 10 5 4 200 C
Bearing 8 4 6 192 C
Bolts 5 6 4 120 C
Coupling 8 5 5 200 C
Pins 8 5 7 280 B
Seal 5 4 5 100 C
Upon implementation of the new maintenance task a financial review was undertaken. The
analysis was performed in order to estimate the saving in revenue.
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7. Conclusion
This paper was able to identify the most risk significant sub-components on the MOBFVs. The
butterfly valve had the highest number of risk significant components while the actuator had the
least. In the BFV the seat, pins, stem and disc were found to have high RPN values, hence risky
components. In the actuator the actuator controls and electric connection were found to be risk
significant. While the gearbox, the driven gear and shaft seal were identified as risk significant
components. Furthermore, motor bearing, insulation and stator were found to be risk significant
in the motor. It was observed that there was no maintenance plan for the motor operated butterfly
valve prior to this study and the butterfly valves are more or less operated on a run to failure
basis. The application of the new maintenance strategies individual component RPN values
decreased significantly. This is an indication of improved reliability of the MOBFVs and
availability of the 280 MW GPPs. In addition, an estimated loss reduction of 51.10 % annually
was predicted.
Recommendations
References