2013ARS in Red S1 Chivukula

2013 ARS, India: Pune
Red Room, Session 1

Begins at 9:10 AM, Wednesday, September 25th
AREVA Flexbio Boiler Grate DFMEA

Ramesh Chivukula AREVA Renewable Energies India Pvt. Ltd.
PRESENTATION SLIDES
The following presentation was delivered at the:
International Applied Reliability Symposium, India September 25 - 27, 2013: Pune, India
http://www.ARSymposium.org/india/2013/
The International Applied Reliability Symposium (ARS) is intended to be a forum for reliability and maintainability practitioners within industry and government to discuss their success stories and lessons learned regarding the application of reliability techniques to meet real world challenges. Each year, the ARS issues an open "Call for Presentations" at http://www.ARSymposium.org/india/presenters/index.htm and the presentations delivered at the Symposium are selected on the basis of the presentation proposals received. Although the ARS may edit the presentation materials as needed to make them ready to print, the content of the presentation is solely the responsibility of the author. Publication of these presentation materials in the ARS Proceedings does not imply that the information and methods described in the presentation have been verified or endorsed by the ARS and/or its organizers.
The publication of these materials in the ARS presentation format is Copyright 2013 by the ARS, All Rights Reserved.
ABOUT AREVA
AREVA is a French multinational company based in Paris that has a commercial presence all over the world. Ranked first in the Global Nuclear Power Industry, AREVA is a global leader in solutions for Power Generation With Less Carbon. AREVA Renewable Energies India (P) Ltd., is a subsidiary of AREVA Renouvelables SAS.
PRESENTER PROFILE
Mr. C Ramesh Head of Engineering B.E. (Hons) in Mechanical Engineering Total Experience 28 years Age 51 With AREVA since Nov 2007 Experience: Almost 3 decades of experience in design & engineering within the power plants industry. OEM engineering (Steam Turbines) with BHEL of more than a decade. Over 15 years of hands on engineering management - EPC Contracting Companies (Thermax in India, National Contracting Co, Saudi Arabia).
Ramesh Chivukula , AREVA Renewable Energies India Red Room Session 1 Slide Number: 3
Applied Reliability Symposium, India 2013
Ramesh Chivukula , AREVA Renewable Energies India
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Slide Number: 2
AREVA FLEXBIO
AREVA FlexBio refers fired Boiler designed steam at required flow temperature by biomass. to Biomass to produce / pressure / combusting
AREVAFlexBio Boiler
AREVA FLEXBIO FEATURES

AREVA FlexBio is a Three Pass Design Boiler. Radiant heat transfer surfaces in First and Second pass. Convective Super heaters in the third pass. Economiser down stream of Super heater (No boiler bank). Air preheater down stream of Economiser.
FlexBio is provided with a suitable combusting grate like Sloping Grate, Step Grate, Vibrating Grate and Travelling Grate depending upon fuel / fuel mix to be fired.
Major auxiliaries ID / FD / FGR / SA fans and Boiler Feed Pumps. Other auxiliaries - Deaerator, Dosing Systems, Soot Blowers and Blow Down tank.
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Slide Number: 4
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AREVA FLEXBIO FOR COMPLEX BIOMASS

CHEMICAL & PHYSICALPROPERTIES OF COMPLEX BIOMASS
AREVA FLEXBIO FOR COMPLEX BIOMASS

High Chlorine contents High moisture content Highly fibrous material High Alkali content Coarse particles High size dispersion
IMPACT ON BOILER
High Corrosion & Fouling Difficult to Feed Erosion
GRATE MANUFACTURING FACILITY IN CHENNAI
Examples of complex biomass:
SLOPING GRATE UNDER MECHANICAL TEST
WOOD BARK
EMPTY FRUIT BUNCH (EFB)
COCONUTS
RICE STRAW
ANIMAL LITTER
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Slide Number: 6
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Slide Number: 7
FMEA
What is FAILURE ANALYSIS (FMEA)? MODE EFFECT
WHY FMEA?
FMEA is a systematic method of identifying and preventing system, product and process problems before they occur...
Applied Reliability Symposium, India 2013 Applied Reliability Symposium, India 2013
FMEA is a procedure that examines each item in a system, considers how that item can fail and then determines how that failure will affect (or cascade through) the system.
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Slide Number: 8
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Slide Number: 9
TYPES OF FMEA
DESIGN FMEA
It focuses on potential failure modes of products caused by design deficiencies. This type of FMEA is used to analyze hardware, functions or a combination. Design FMEAs are normally done at three levels system, subsystem, and component. Provides logical, sequential steps for specifying product and process area of concern.
Provides format for communication across the disciplines. Cost-effective tool for maximizing and documenting the collective knowledge, experience, and insights of the engineering and manufacturing community. Contributes to improved designs for products and processes.
Higher Reliability. Better Quality. Increased Safety. Enhanced Customer Satisfaction.
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Slide Number: 10
DESIGN FMEA
Contributes to Cost Savings. Decreases development time and re-design costs. Decreases warranty costs. Decreases waste, non-value added operations. Cost benefits associated with FMEA are usually expected to come from the ability to identify failure modes earlier in the process, when they are less expensive to address.
DFMEA OUTCOMES
Actual / Potential Failure Modes. Customer and Legal Design Requirements. Duty Cycle Requirements. Product Functions & Specifications. Key Product Characteristics. Product Verification and Validation. Highlights of the Impact of the Failures. Methodology to Characterize the Product Safety. Potential Failure Modes from Things That Have Gone Wrong In the Past, Concerns of Designers, and Brainstorming. Possible Considerations on Partial Function, Intermittent Function, or Excess Function of the System. Potential Effects Are Consequences to the Design, the User, and the Environment.
Rule of Ten
If the issue costs $100 when it is discovered in the field, then It may cost $10 if discovered during the final test But it may cost $1 if discovered during an incoming inspection. Even better, it may cost $0.10 if discovered during the design or process engineering phase. The Design FMEA is used to analyze products before they are released to production.
Contributes to Continuous Improvement.

WHY FMEA FOR FLEXBIO?

FlexBio is a tailored design for Complex Biomass. Step / Sloping Grate is an evolved design. Examine the new system for possible failures. Ensure healthiness of product design. Ask ourselves how will the product fail? A systematic process for:
RESOURCES & THE TEAM FOR DFMEA

Commitment of Top Management. Knowledge of the individuals. People resources both internal & external to the business. Reliability Consultant - M/S ReliaSoft, ReliaSoft Is The Industry Leader in Software, Training and Consulting for Reliability Engineering and Related Fields. Boiler & Grate Experts From External Engineering Consultants.
Identifying and Evaluating Potential failure modes. Potential causes of the failure mode. Identify and quantify the impact of potential failures. Identify and prioritize actions to reduce or eliminate the potential failure. Implement action plan based on assigned responsibilities and completion dates. Document the associated activities.
Cross Functional Team from In-house Including:

Engineering Project Management Site Construction Manufacturing Quality Safety Tendering Business Development Inputs from Management
Red Room Session 1 Slide Number: 15
THE DFMEA SOFTWARE TOOL

M/S ReliaSofts Xfmea Software tool
It facilitates data management and reporting for all types of Failure Modes and Effects Analysis. The software provides predefined settings to fit the major industry standards (such as AIAG, SAE J1739 and MILSTD-1629A). It also provides extensive customization options to fit the FlexBio boiler particular analysis and reports.
THE DFMEA PROCESS

The DFMEA Process: 1. Ground Rules. 2. Determining the scope. 3. Gathering background reference materials. 4. Creating block diagrams. 5. Identifying item functions, failure modes and their effects. 6. Reviewing the design & the process. 7. Brainstorm potential failure modes. 8. Listing potential failure effects. 9. Determining the effect (both locally and globally) on the system. 10. Classifying the failure by its effects on the system operation. 11. Assigning Severity ratings, Occurrence ratings, Detection ratings & calculate RPN (Risk Priority Number). 12. Developing an action plan to address high RPNs. 13. Providing Design Controls & Recommended Actions with target dates.
AREVA FLEXBIO BOILER OUTLOOK

Integration of Step / Sloping Grate with Flex Bio Boiler for complex Biomass. Areas of importance received critical attention & were classified with suitable action plans. Identified potential areas were further provided with suitable action plans.
AREVA FLEXBIO DFMEA

Design FMEA conducted on the following:
Potential Failure Modes Identified Along With Probable Causes And Level Of Mitigation Already Built In. Identified Possible Recommended Actions.
Such as Design Audit / CFD (Computational Fluid Dynamics). Looking Into Alternate Designs Like Additional Cooling Fan, Water Cooling For Oil. Fabric Type Expansion Joint. Increase In Thickness Of Casing, Lining, Cooling Water Jacket At Entrance Of Screw Feeder Casing. More Stringent Quality Checks ; Etc.
FlexBio Grate Primary System
Critical O & M Issues Identified. Identified High Failure Rate Items And Recommended Spares For The Same. Identified High Risk Areas Of Design Which Would Need Extra Care During Detail Engineering.
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Slide Number: 18
TYPICAL SPREADSHEET ADOPTED FOR FLEXBIO DFMEA

Item / Failure Effect of Function Mode Failure 2.3 - Grate primary System 2.3.1 - Grate bar Impurities in fuel (Foreign 7 C particles 4 especially metallic) Fuel not to specification (especially higher 8 C 6 content of low melting ash component)
Red Room
FAILURE ASSESSMENT CRITERIA
Potential Potential
Potential Cause of Failure
Current Current Design Design Controls Controls (Preven (Detecti tion) on)
Classification SEVi
Recomm & Target ended Completion Actions Date
Responsibility
RPNi DETi
OCCi
21-05-2013
Field indicatio n, visual 3 inspecti on
Ensure the fuel Specifica tions are met during

operation
O&M
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Holding and transmit the fuel from one zone to other
Clinker formation Blockag in the bed e to free leading to movem degradatio ent of n in fuel performan ce
Higher plenum 3 pressure , visual
O&M/ Design
84 144
21-05-2013
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Slide Number: 21
FMEA FOLLOW-UP WORKSHOP-1

Broad revisit of all potential failure modes. Broad classification of all potential failure modes. Identification of high priority action items & launch of road map including responsibility matrix. Reformatting of the FMEA spreadsheet with drop-down menus, filters and including target completion dates with responsibilities.

Boiler Interface Erection items already covered in main study. Pressure parts supplier. Ash Extraction system proposed shall be further explored with the suppliers.
Design Audit. Review of DFMEA on 11.07.2013.
Planned involvement of Sub suppliers for the following Sub systems of Grate & Boiler: Fuel feeding system proposed shall be further explored with the suppliers. Grate primary system:
Manufacturing workshop already included in FMEA workshop. Hydraulic system. PLC (Programmable Logic Control) system.
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Slide Number: 23

Completed involvement of Sub suppliers for the following Sub systems of Boiler:
ACTION ITEMS BROAD CLASSIFICATION

Sub-System / RPNi 1. FUEL FEEDING SYSTEM 2. GRATE SYSTEM a) Hydraulic power pack b) Secondary System Actuating Mechanism c) Grate primary system 3. BOILER INTERFACE WITH GRATE 4. ASH EXTRACTION SYSTEM Total A 0 to 30 2 0 2 3 3 0 10 B 31 - 72 8 4 10 11 12 1 46 97 C 73 - 199 4 1 2 5 19 1 32 D 200 - 360 3 0 0 0 6 0 9
Fuel feeding system

Engineering specification towards varying screw pitch, angle at entrance.
Grate :
Grate bar Engineering Specification for 100 % PMI (Positive Material Identification) Inspection. Hydraulic system supplier Engineering Specification for redundancy and safety interlocks. PLC supplier Engineering Specification for redundancy. Refractory / Insulation Supplier Engineering Specification and vendor document review. Vendor selection / Quality audits.
Ash Extraction system:

o Supplier O&M Manual.
Design Audit: Order to be placed with Engineering Consultancy. Next review of DFMEA planned on 13.08.2013.
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Slide Number: 25
ACTION ITEMS BROAD CLASSIFICATION

1. FFS 2. GRATE 3. BOILER INTERFACE WITH GRATE 4. ASH EXTRACTION SYSTEM Total
ACTION POINTS
Total number of actionable points - 97 Total no. of action points previously closed 62 Total no. of action points that are closed after taking up with suppliers 15
5 0 0 5
6 0 1 16
3 3 14 7 97
1 0 0 0
15 3 15 28
FMs (failure modes) to be taken care of in Contract Specification FMs managed by offering recommended spares FMs to be reviewed during design audit FMs to be evaluated with suppliers FMs to be taken care of during Manufacturing / Fabrication FMs to be taken care of during Installation / Execution FMs to be taken care of during O&M Total
1 0 6
8 2 5
1 4 8
0 0 1
10 6 20
Total no. of action points that are open and to be addressed during design audit 20 Cold commissioning of the FlexBio grate To be initiated after arranging necessary quantity of fuel. Safety aspects / protective features of rotating / moving parts analyzed and report prepared. Visit of Engineering Director, ENMAS (Boiler Supplier) (Mr. Satyajit Chakraborty) on 12th July 2013. Good feedback received.
Witness Grate mechanical operation.
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Slide Number: 26
ACTION POINTS
Updated Status of action on Managements recommendation on FMEA report :
FMEA finding to be shared with Brazil Team for their inputs. Quickly put in place an action plan for all recommendations of the FMEA study. FMEA is an ongoing process and hence the action plan is to be dynamic in nature and frequent reviews to take place up to the running of first pilot.
CONCLUSION
Brazil team response awaited. Done; Follow up workshop held on 11.06.2013 & 11.07.2013. Supplier FMEA completed. Design audit order to be placed with Engineering Consultant.
FMEA is an ongoing process; this is just a start for an ongoing process.
Can cold commissioning on the model grate be conducted? Consider OPEX vs. CAPEX carefully while implementing recommended actions. Road map for new steps until commissioning of the Pilot plant. All actions on FMEA are independent of booking Orange Power order.
Fuel to be arranged at Workshop. To be considered after Design Audit.
As outlined during follow-up email 11.06.2013. Understood by the team.
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Slide Number: 28
Evaluate whether further deeper FMEA study needs to be done or not.
Ongoing exercise.
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Questions
Thank you for your attention. Do you have any questions?
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Slide Number: 30

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2013 ARS, India: Pune

Red Room, Session 1

AREVA Flexbio Boiler Grate DFMEA

Applied Reliability Symposium, India 2013

Ramesh Chivukula , AREVA Renewable Energies India

Applied Reliability Symposium, India 2013

AREVA FLEXBIO FEATURES

Applied Reliability Symposium, India 2013

Ramesh Chivukula , AREVA Renewable Energies India

Ramesh Chivukula , AREVA Renewable Energies India

AREVA FLEXBIO FOR COMPLEX BIOMASS

AREVA FLEXBIO FOR COMPLEX BIOMASS

High Corrosion & Fouling Difficult to Feed Erosion

GRATE MANUFACTURING FACILITY IN CHENNAI

Examples of complex biomass:

Applied Reliability Symposium, India 2013

SLOPING GRATE UNDER MECHANICAL TEST

EMPTY FRUIT BUNCH (EFB)

Ramesh Chivukula , AREVA Renewable Energies India

Ramesh Chivukula , AREVA Renewable Energies India

Ramesh Chivukula , AREVA Renewable Energies India

Ramesh Chivukula , AREVA Renewable Energies India

Applied Reliability Symposium, India 2013

Applied Reliability Symposium, India 2013

Ramesh Chivukula , AREVA Renewable Energies India

Contributes to Continuous Improvement.

WHY FMEA FOR FLEXBIO?

RESOURCES & THE TEAM FOR DFMEA

Cross Functional Team from In-house Including:

Ramesh Chivukula , AREVA Renewable Energies India

THE DFMEA SOFTWARE TOOL

THE DFMEA PROCESS

Applied Reliability Symposium, India 2013

Applied Reliability Symposium, India 2013

AREVA FLEXBIO BOILER OUTLOOK

AREVA FLEXBIO DFMEA

FlexBio Grate Primary System

Ramesh Chivukula , AREVA Renewable Energies India

TYPICAL SPREADSHEET ADOPTED FOR FLEXBIO DFMEA

FAILURE ASSESSMENT CRITERIA

Potential Cause of Failure

Recomm & Target ended Completion Actions Date

Applied Reliability Symposium, India 2013

Field indicatio n, visual 3 inspecti on

Ensure the fuel Specifica tions are met during

Ramesh Chivukula , AREVA Renewable Energies India

Applied Reliability Symposium, India 2013

Holding and transmit the fuel from one zone to other

Higher plenum 3 pressure , visual

Ramesh Chivukula , AREVA Renewable Energies India

FMEA FOLLOW-UP WORKSHOP-1

FMEA FOLLOW-UP WORKSHOP-1

Ramesh Chivukula , AREVA Renewable Energies India

FMEA FOLLOW-UP WORKSHOP-2

ACTION ITEMS BROAD CLASSIFICATION

Fuel feeding system

Applied Reliability Symposium, India 2013

Ash Extraction system:

Applied Reliability Symposium, India 2013

Ramesh Chivukula , AREVA Renewable Energies India

ACTION ITEMS BROAD CLASSIFICATION

Applied Reliability Symposium, India 2013

Applied Reliability Symposium, India 2013

Witness Grate mechanical operation.