The following report was created for educational purpose only and based on the engineering drawing only.
No real sight inspection was performed :)
FAILURE MODE
AND EFFECTS ANALYSIS
PREPARED BY
Young Kim
Javier Molina
E419 Spring 2013
Professor Joseph Berk
REVISION PAGE:
REVISION DATE DESCRIPTION
N/C 05-13-2013 Initial Release
1.0 SCOPE:
The following report is a Failure Modes and Effects Analysis detailing mathematical models and predicted possible failure modes and its effects of the Hydraulic Thermal Relief Valve, part number 2623-13, designed by PneuDraulics, Inc. With precisely predicted failure rates for each part in assembly, meantime between failures of the whole system is calculated to be 563799 hours with total failure rate of 1.774 per every million hours.
The following report is a Failure Modes and Effects Analysis detailing mathematical models and predicted possible failure modes and its effects of the Hydraulic Thermal Relief Valve, part number 2623-13, designed by PneuDraulics, Inc. With precisely predicted failure rates for each part in assembly, meantime between failures of the whole system is calculated to be 563799 hours with total failure rate of 1.774 per every million hours.
2.0 REFERENCE DOCUMENTS:
A. MIL-HDBK-217F
B. RIAC AUTOMATED DATABOOK(NPRD-2011)
C. LECTURE SLIDES
D. NPRD-95
A. MIL-HDBK-217F
B. RIAC AUTOMATED DATABOOK(NPRD-2011)
C. LECTURE SLIDES
D. NPRD-95
3.0 REFERENCE SOFTWARE:
For the prediction of the failure rates, MTBF Calculator software
developed by ALD is used
4.0 ITEM OVERVIEW:
The Hydraulic Thermal Relief Valve is designed to release the pressure if the systems pressure gets too extreme. This is done by poppet assembly, containing ball attached at the end and spring guide, which provides the spring to be compressed in designed way, pushing down spring due to over pressure to make opening space between the ball attached on poppet assembly and the seat.
The Hydraulic Thermal Relief Valve is designed to release the pressure if the systems pressure gets too extreme. This is done by poppet assembly, containing ball attached at the end and spring guide, which provides the spring to be compressed in designed way, pushing down spring due to over pressure to make opening space between the ball attached on poppet assembly and the seat.
5.0 ASSUMPTIONS:
a. Custom made mechanical parts were modeled after NPRD-95
b. The part is operating under high pressurized environment
c. Calculated Time (Hours) = 3 hours
d. Operating Temperature = -65°F to +165°F
a. Custom made mechanical parts were modeled after NPRD-95
b. The part is operating under high pressurized environment
c. Calculated Time (Hours) = 3 hours
d. Operating Temperature = -65°F to +165°F
6.0 FAILURE MODES AND EFFECTS ANALYSIS:
The FMEA has been developed to be used for the following purposes:
a. To identify all failure modes and ensure that corrective action has been taken
b. To identify effects of failure modes on the system under different level of assembly
c. Tool as a ranking technique to be used to concentrating on more severe possible failure modes
The FMEA has been developed to be used for the following purposes:
a. To identify all failure modes and ensure that corrective action has been taken
b. To identify effects of failure modes on the system under different level of assembly
c. Tool as a ranking technique to be used to concentrating on more severe possible failure modes
7.0 FMEA PROCEDURE
The Failure Modes and Effects Analysis is presented in tabular form in EXCEL. The worksheet has various columns detailing several of different facts related to FMEA. A description of each column is as follows:
Indentured Drawing Number – This FMEA column identifies the component’s drawing number according to its engineering drawing. For Hydraulic Thermal Relief system, drawing 2623-13 is used for this information.
Part Name - This FMEA column identifies component’s nomenclatures based on drawing 2623-13
Part Number - This FMEA column identifies component’s part or identification number based on drawing 2623-13.
Quantity - This FMEA column identifies quantity of each part needed for single assembly. The information is based on the drawing 2623-13.
Failure Mode - This FMEA column identifies all of the possible failure modes that a single component can have under its assumed operating condition.
Failure mode Rate(%) - This FMEA column identifies weighted percentage of each failure mode under one single component. For example, for the part shim, there are two possible failure modes identified. It can fracture but remain in intact or it fractures and releases. The failure mode rate for those two failure modes are 30% and 70%.
Failure Mode Cause - This FMEA column identifies the possible causes of each failure modes stated for each part.
Failure Rate(per million hours) - This FMEA column identifies the failure rate, per million hours. This information is predicted using NPRD-95 for custom made mechanical parts and NPRD-2011 for other mechanical parts.
Failure Rate Source - This FMEA column identifies sources used to predict the failure rate. Two sources used in this typical report are NPRD-95 and NPRD-2011
Component Level - This FMEA column identifies possible problem each failure mode may cause in component level of assembly.
Next Assembly Level - This FMEA column identifies possible problem each failure mode may cause in a next assembly level.
Visible Or Hidden - This FMEA column identifies if the failure modes are visible or not by inspection.
Criticality - This FMEA column identifies its severity and it is divided into 4 sub criteria.
I. Catastrophic - May cause death or weapon system loss.
The Failure Modes and Effects Analysis is presented in tabular form in EXCEL. The worksheet has various columns detailing several of different facts related to FMEA. A description of each column is as follows:
Indentured Drawing Number – This FMEA column identifies the component’s drawing number according to its engineering drawing. For Hydraulic Thermal Relief system, drawing 2623-13 is used for this information.
Part Name - This FMEA column identifies component’s nomenclatures based on drawing 2623-13
Part Number - This FMEA column identifies component’s part or identification number based on drawing 2623-13.
Quantity - This FMEA column identifies quantity of each part needed for single assembly. The information is based on the drawing 2623-13.
Failure Mode - This FMEA column identifies all of the possible failure modes that a single component can have under its assumed operating condition.
Failure mode Rate(%) - This FMEA column identifies weighted percentage of each failure mode under one single component. For example, for the part shim, there are two possible failure modes identified. It can fracture but remain in intact or it fractures and releases. The failure mode rate for those two failure modes are 30% and 70%.
Failure Mode Cause - This FMEA column identifies the possible causes of each failure modes stated for each part.
Failure Rate(per million hours) - This FMEA column identifies the failure rate, per million hours. This information is predicted using NPRD-95 for custom made mechanical parts and NPRD-2011 for other mechanical parts.
Failure Rate Source - This FMEA column identifies sources used to predict the failure rate. Two sources used in this typical report are NPRD-95 and NPRD-2011
Component Level - This FMEA column identifies possible problem each failure mode may cause in component level of assembly.
Next Assembly Level - This FMEA column identifies possible problem each failure mode may cause in a next assembly level.
Visible Or Hidden - This FMEA column identifies if the failure modes are visible or not by inspection.
Criticality - This FMEA column identifies its severity and it is divided into 4 sub criteria.
I. Catastrophic - May cause death or weapon system loss.
II. Critical – May cause severe injury or damage and may result in
mission loss.
III.
Marginal – May cause minor injury or damage and may result in delay in
mission degradation
IV. Minor – It is not serious enough to cause the damage or injury to the part or system.
IV. Minor – It is not serious enough to cause the damage or injury to the part or system.
Means of Detection - This FMEA
column identifies how failure can be detected if it occurs.
Compensating Provisions - This FMEA column identifies what features prevent or mitigate failure occurrence.
Compensating Provisions - This FMEA column identifies what features prevent or mitigate failure occurrence.
8.0 Failure Rates and MTBF:
- Total Failure Rates for the system came out to be 1.773683*10^-6 hours.
- The MTBF for this particular system under the assumptions made is calculated by taking inverse if total failure rates and comes out to be 563799 hours.
- Total Failure Rates for the system came out to be 1.773683*10^-6 hours.
- The MTBF for this particular system under the assumptions made is calculated by taking inverse if total failure rates and comes out to be 563799 hours.
9.0 FMEA Table and Engineering Drawing:
The following embed FMEA Table in EXCEL and
Engineering Drawing is provided below as an embedded files as reference to this
report.FMEA Engineering Drawing
(original report have these two files embedded inside of report, :( too bad this won't let me do it)
Acutual FMEA in tabular form is here (for some reason, lines are not showing :( srry!)
| PART IDENTIFICATION | FAILURE DATA | FAILRUE EFFECTS | COMMENTS | |||||||||||
| Indentured Drawing Number | Part Name | Part Number | Quantity | Failure Mode | Failure mode Rate(%) | Failure Mode Cause | Failure Rate Million per hour | Failure Rate Source | Component Level | Next Assembly Level | Visible Or Hidden | Criticality | Means of Detection | Compensating Provisions |
| 1 | VALVE,HYDRAULIC THERMAL RELIEF | 2623-13 | 1 | See below | 1.773683 | See below | ||||||||
| 1.1 | HOUSING | 16726 | 1 | 0.4 | NPRD-95 | |||||||||
| Minor internal leakage | 23.00% | Wear, installation damage, contaminant presence | 0.092 | Minor leakage to interior | None, other than requirement to repair at next maintenance opportunity | HIDDEN | IV | OPERATIONAL | Use correct surface finishes,and materials for specification enviroments | |||||
| Major internal leakage | 2.00% | Wear, installation damage, contaminant presence | 0.008 | Major leakage to interior | loose of valve function | VISIBLE | II | VISUAL | Use correct surface finishes,and materials for specification enviroments | |||||
| Minor external leakage | 29.00% | Wear, installation damage, contaminant presence | 0.116 | Minor leakage to exterior | None, other than requirement to repair at next maintenance opportunity | HIDDEN | IV | OPERATIONAL | Use correct surface finishes,and materials for specification enviroments | |||||
| Major external leakage | 3.00% | Wear, installation damage, contaminant presence | 0.012 | Major leakage to exterior | Loose of Hydraulic fluid | VISIBLE | I | VISUAL | Use correct surface finishes,and materials for specification enviroments | |||||
| fractures | 16.00% | Excess shock or other load | 0.064 | Housing Fractured | Loose of Hydraulic fluid | VISIBLE | II | VISUAL | Use correct surface finishes,and materials for specification enviroments | |||||
| Deformed | 16.00% | Excess shock or other load | 0.064 | Hoousing deformed | None, other than requirement to repair at next maintenance opportunity | VISIBLE | II | VISUAL | Use correct surface finishes,and materials for specification enviroments | |||||
| Striped threads | 11.00% | installation damage,Assembly damage | 0.044 | damaged threads | Difficult assembly | VISIBLE | II | VISUAL | Use correct surface finishes,and materials for specification enviroments | |||||
| 1.2 | INLET NUT | 16727 | 1 | 0.005523 | NPRD-2011 | |||||||||
| fracture and release | 40.00% | Excess shock or other load | 0.0022092 | loose of valve function | Loose of Hydraulic fluid | VISIBLE | I | VISUAL | Use of inlet nut designed for specification environments | |||||
| Fracture and no release | 5.00% | Excess shock or other load | 0.00027615 | Inlet nut fractured | None, other than requirement to repair at next maintenance opportunity | VISIBLE | IV | VISUAL | Use of inlet nut designed for specification environments | |||||
| Strip | 10.00% | Poor assembly technique | 0.0005523 | Damaged threads | Difficult assembly | VISIBLE | III | VISUAL | Use of inlet nut designed for specification environments | |||||
| Jam | 15.00% | installation damage,Assembly damage,corrosion | 0.00082845 | Jammed inlet nut | damage threads of Housing, equirement to repair at next maintenance opportunity | HIDDEN | II | OPERATIONAL | Use of inlet nut designed for specification environments | |||||
| Loosens | 30.00% | Improper installation, vibration | 0.0016569 | Inlet nut loose | Loose of hydraulic fluid | HIDDEN | I | OPERATIONAL | Use of inlet nut designed for specification environments | |||||
| 1.3 | SEAT | 16728 | 1 | 0.18682 | NPRD-95 | |||||||||
| Fracture | 15.00% | Excess shock or other load | 0.028023 | Fractured seat | Loose of pressure and hydraulic fluid | VISIBLE | II | VISUAL | Use of appropriate design for specification environments | |||||
| bent | 15.00% | Excess shock or other load | 0.028023 | Bented seat | None, other than requirement to repair at next maintenance opportunity | VISIBLE | II | VISUAL | Use of appropriate design for specification environments | |||||
| Deform | 15.00% | Excess shock or other load | 0.028023 | deformed seat | Loose of pressure and hydraulic fluid | VISIBLE | II | VISUAL | Use of correct seals, surface finishes, and materials | |||||
| Leakeage | 55.00% | Wear, installation damage, contaminant presence | 0.102751 | Minor or major leakage to interior | loose of pressure ,possible spring corrosion,loose of valve function | VISIBLE | I | VISUAL | Use of correct seals, surface finishes, and materials | |||||
| 1.4 | POPPET ASSY | 16729 | 1 | See below | 0.46 | |||||||||
| 1.4.1 | SPRING GUIDE | 16730 | 1 | 0.16 | NPRD-95 | |||||||||
| Major internal leakage | 1.50% | Wear, installation damage, contaminant presence | 0.0024 | Major leakage to interior | None, other than requirement to repair at next maintenance opportunity | VISIBLE | II | VISUAL | Use of correct seals, surface finishes, and materials | |||||
| Minor internal leakage | 23.50% | 0.0376 | Minor leakage to interior | loose of pressure ,possible spring damage ,loose of valve function | HIDDEN | III | OPERATIONAL | Use of correct seals, surface finishes, and materials | ||||||
| fracture and jam | 60.00% | Excess shock or other load | 0.096 | Spring guide jammed | loose of pressure ,possible spring damage,loose of valve function | VISIBLE | I | VISUAL | Use of correct seals, surface finishes, and materials | |||||
| fracture and no jam | 10.00% | Excess shock or other load | 0.016 | Spring guide Fractured | loose of valve function | VISIBLE | II | VISUAL | Use of correct seals, surface finishes, and materials | |||||
| Wears such that exces clearance | 5.00% | Vibration, excessive Frecuency | 0.008 | Excess wear and clearance; loose spring guide | Loose of valve function | VISIBLE | IV | VISUAL | Use of correct seals, surface finishes, and materials | |||||
| 1.4.2 | BALL | MS19060-1004 | 1 | 0.3 | NPRD-95 | |||||||||
| Fracture and release | 10.00% | Excess shock or other load | 0.03 | Fractured Ball and loose of valve function | loose of pressure ,possible spring damage,loose of valve function | VISIBLE | III | VISUAL | Use of appropriate material for design loads and specification environments | |||||
| Fracture and no release | 53.00% | Excess shock or other load | 0.159 | Fractured Ball | loose of pressure and loose of valve function | VISIBLE | I | VISUAL | Use of appropriate material for design loads and specification environments | |||||
| internal leakage | 20.00% | Wear, installation damage, contaminant presence | 0.06 | minor leakege to interior | loose of pressure and loose of valve function | HIDDEN | II | OPERATIONAL | Use of appropriate material for design loads and specification environments | |||||
| jam | 17.00% | 0.051 | jammed ball | loose of pressure | VISIBLE | II | VISUAL | Use of appropriate material for design loads and specification environments | ||||||
| 1.5 | SHIM | 16731 | 1 | 0.001 | NPRD-95 | |||||||||
| Fracture but remains intact | 30.00% | Excess shock or other load | 0.0003 | Fractured shim | no flow of hydraulic fluid ,high pressure on the system | VISIBLE | II | VISUAL | Use of Shim designed for specification environments | |||||
| Fractures and release | 70.00% | Excess shock or other load | 0.0007 | Fractured shim and loose of valve function | None effect | VISIBLE | I | VISUAL | Use of Shim designed for specification environments | |||||
| 1.6 | NAMEPLATE | 16732-13 | 1 | 0.034 | NPRD-95 | |||||||||
| Fracture | 50.00% | Excess shock or other load | 0.017 | Fractured Nameplate | No effect | VISIBLE | I | VISUAL | Use of appropriate design for loads and specification environments | |||||
| Falls off | 50.00% | Vibration, excess shock or other load | 0.017 | missing nameplate | No identification | VISIBLE | I | OPERATIONAL | Use of appropriate design for loads and specification environments | |||||
| 1.7 | ORIFICE | 60296-200 | 1 | 0.2872 | NPRD-95 | |||||||||
| closes | 85.00% | corrosion,contaminant presence | 0.24412 | blocked orifice and loose of valve function | blocked flow and loose of valve function | HIDDEN | I | OPERATIONAL | Use of appropriate design for specification environments | |||||
| corrode | 15.00% | contaminant presence,corrosive enviroment | 0.04308 | corroded orofice | possible blocked orifice | VISIBLE | IV | VISUAL | Use of appropriate design for specification environments | |||||
| 1.8 | G T RING | 7007MR952T | 1 | 0.10414 | NPRD-2011 | |||||||||
| Minor external leakage | 75.00% | Wear, installation damage, contaminant presence | 0.078105 | Minor leakage to exterior | None, other than requirement to repair at next maintenance opportunity | HIDDEN | III | VISUAL | Use of appropriate seal for design loads and specification environments | |||||
| Major external leakage | 25.00% | Wear, installation damage, contaminant presence | 0.026035 | Major leakage to exterior | loose of valve function and loose of hydraulic fluid | VISIBLE | I | VISUAL | Use of appropriate seal for design loads and specification environments | |||||
| 1.9 | SPRING | C0180-032-0620S | 1 | 0.012 | ||||||||||
| springs does not compress | 38.00% | Misalignment ,corrosive enviroment,fatigue | 0.00456 | NPRD-95 | Damaged spring | loose of valve function | VISIBLE | I | OPERTIONAL | Use of appropriate spring for loads and specification environments | ||||
| fracture | 24.00% | Misalignment ,corrosive enviroment,high frecuency | 0.00288 | Fractured spring | loose of valve function | VISIBLE | II | VISUAL | Use of appropriate spring for loads and specification environments | |||||
| Yielding | 19.00% | Wear,corrosive enviroment,high frecuency | 0.00228 | Damaged spring | loose of valve function | HIDDEN | IV | OPERATIONAL | Use of appropriate spring for loads and specification environments | |||||
| compress at lower pressure | 11.00% | Relaxation,creep | 0.00132 | Damaged spring | loose of valve function | HIDDEN | III | OPERATIONAL | Use of appropriate spring for loads and specification environments | |||||
| Fatigue | 7.00% | Wear,corrosive enviroment,high frecuency | 0.00084 | Damaged spring | loose of valve function | VISIBLE | III | VISUAL | Use of appropriate spring for loads and specification environments | |||||
| Corrosion | 1.00% | corrrosive enviroment | 0.00012 | Damaged spring | loose of valve function | VISIBLE | IV | VISUAL | Use of appropriate spring for loads and specification environments | |||||
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