RCM II

INFORMATION
WORKSHEET

SYSTEM: BOILER

SYSTEM. NO.

Facilitator: Ed Fantinel

Date:

Sheet no. 1

SUB-SYSTEM:

SUB-SYSTEM. NO.

Auditor:

Date:

Page 1 of 2

FUNCTION
FUNCTIONAL FAILURE
1 To be capable of heating 1000gpm A Unable to heat water at all
of a glycol/water mixture to a
maximum temperature of 185 deg
F

FAILURE MODE
FAILURE EFFECT
1 Safety shut off valve fails in closed The safety shutoff valve fails to remain open thereby cutting off the flow of gas to the burner. This will cause a flame failure
position
which will be detected by the flame scanner and signal the boiler to shut down. A signal will be sent to the guard notifying of the
boiler failure. A gas contractor will have to contacted to replace the valve. Downtime will vary depending on how rapidly the
temperature drops in the plant and on the availability of a contractor. It will take 1 -2 hours for a contractor to arrive on site. It
will take 1 hour to change the valve.

2 First stage regulator fails in closed The main gas regulator fails in the closed position thereby cutting off the flow of gas to the burner. This will cause a flame
position
failure which will be detected by the flame scanner and signal the boiler to shut down. A signal will be sent to the guard
notifying of the boiler failure. A gas contractor will have to contacted to replace the valve. Downtime will vary depending on how
rapidly the temperature drops in the plant and on the availability of a contractor. It will take 1 -2 hours for a contractor to arrive
on site. It will take 1 hour to change the regulator.
3 Second stage regulator fails in
closed position

The main gas regulator fails in the closed position thereby cutting off the flow of gas to the burner. This will cause a flame
failure which will be detected by the flame scanner and signal the boiler to shut down. A signal will be sent to the guard
notifying of the boiler failure. An gas contractor will have to contacted to replace the valve. Downtime will vary depending on
how rapidly the temperature drops in the plant and on the availability of a contractor. It will take 1 -2 hours for a contractor to
arrive on site. It will take 1 hour to change the regulator.

4 Pilot solenoid valve fails to open

The pilot solenoid valve fails to open while attempting to light the burner thus not allowing any gas flow to the igniter. The pilot
solenoid valve only operates when lighting the boiler therefore an operator will be present and will notify the appropriate
personnel. The boiler is started when the plant is started to prevent fog from forming at the dryer in feed. If the boiler cannot run
the plant will not be able to startup. A gas contractor will have to be contacted to replace the valve. Downtime will be 2 to 3 hrs.

5 Pilot regulator fails in closed

position

The regulator fails in the closed position while attempting to light the burner thus not allowing any gas flow to the igniter. The
pilot regulator only operates when lighting the boiler therefore an operator will be present and will notify the appropriate
personnel. The boiler is started when the plant is started to prevent fog from forming at the dryer in feed. If the boiler cannot run
the plant will not be able to startup. A gas contractor will have to be contacted to replace the regulator. Downtime will be 2 to 3
hrs.

6 Combustion air fan motor bearing

fails over time

As the bearing begins to fail an audible noise should be noticeable. Heat will be generated by the failing bearing which will
eventually seize and cause the motor to overload. If there is sufficient play in the bearing before failure the impeller may impact
the housing and damage the impellar.The lack of air flow will be detected by the pressure switch and cause the boiler to shut
down. A signal will be sent to the guard notifying of the boiler failure. Downtime will vary depending on how rapidly the
temperature drops in the plant. Replacement of the motor will require 2 hrs if a spare is available on site. If no spare on site it
could take up to 24 hrs to replace the motor.

7 Control valve actuator fails with the The control valve actuator fails with valve in the closed position thereby cutting off the flow of gas to the burner. This will cause
valve in the closed position
a flame failure which will be detected by the flame scanner and signal the boiler to shut down. A signal will be sent to the guard
notifying of the boiler failure. Downtime will vary depending on how rapidly the temperature drops in the plant. Replacement of
the actuator will require 2 hrs.

2 To be capable of shutting down the A Not capable of shutting down the 1 Sensor fails to operate
boiler in the event of a low water
boiler during a low water condition
condition

When the water level drops the boiler tubes will not be surrounded by water. The temperature of the tubes will continue to rise.
When the temperature of the tubes exceeds 800 deg F the strength of the steel will drop rapidly. Since the boiler is in a remote
location there will be no indication of failure until the temperature drops in the plant. The needed repairs will range from
retubing to total destruction of the boiler. Repairs to the boiler will take 4 months. Downtime will be dependant on whether a
temporary boiler can be used to heat the plant.

3 To be capable of maintaining the

A Not capable of keeping the boiler 1 Pressure relief valve fails to open
pressure in boiler to less than 125
pressure less than 125 psi
psi

When the pressure in the boiler exceeds 125 psi the shell stresses in the boiler shell will exceed the design parameters which
will lead to distortion or cracking in the shell. A failure of the shell will result in the escape of up to 10,000 gallons of the glycol
water mixture. Since the boiler is in a remote location there will be no indication of failure until the temperature drops in the
plant. The boiler has no spill containment which will allow glycol to exist the plant through a rollup door. Depending on the
amount of damage repairs may take several days to a complete boiler replacement which could take 4 months. Downtime will
be dependant on whether a temporary boiler can be used to heat the plant.

4 To be capable of shutting down the A Not capable of shutting down

1 Sensor fails to operate
boiler if the temperature exceeds
boiler if temperature exceeds 240
240 deg F
deg F

The shell of the boiler is designed to operate at a maximum temperature and pressure .When these limits are exceeded
stresses in the boiler shell will exceed the design parameters which will lead to distortion or cracking in the shell. A failure of
the shell will result in the escape of up to 10,000 gallons of the glycol water mixture. Since the boiler is in a remote location
there will be no indication of failure until the temperature drops in the plant. The boiler has no spill containment which will allow
glycol to exist the plant through a rollup door. Depending on the amount of damage repairs may take several days to a
complete boiler replacement which could take 4 months. Downtime will be dependant on whether a temporary boiler can be
used to heat the plant.

5 To be capable of shutting down the A Not capable of shutting down

1 Pressure switch fails to operate
boiler if the gas pressure exceeds
boiler if gas pressure exceeds 35"
35 "wc
WC

The gas pressure will continue to climb which will force the control valve to operate in a nearly closed position. This will result in
erratic operation of the control resulting in an unstable flame causing a flame failure. This will result in a flame failure. A signal
will be sent to the guard notifying of the boiler failure. An gas contractor will have to contacted to replace the pressure switch.
Downtime will vary depending on how rapidly the temperature drops in the plant and on the availability of a contractor. It will
take 1 -2 hours for a contractor to arrive on site. It will take 1 hour to change the switch.

6 To be capable of shutting down the A Not capable of shutting down

boiler in the event of a flame failure
boiler in the event of a flame
failure

On a flame failure natural gas will continue to be discharged into the burner chamber and eventually out the stack. Since the
boiler is in a remote location there will be no indication of failure until the temperature drops in the plant. Downtime will vary
depending on how rapidly the temperature drops in the plant . Replacement of the sensor will take 1 hr.

1 Sensor fails to operate