Failure Mode Effect Analysis (FMEA) on Heat Recovery Steam Generator (HRSG): Water Tube Boiler

This study is on Failure Mode Effect Analysis (FMEA) on Heat Recovery Steam Generators (HRSG) at UTP Gas District Cooling (GDC) plant. HRSG is a heat exchanger which converts water to steam at elevated temperature for power generation or process purposes. Operating at high temperature and pressure, the HRSG is subjected to several types of failures. The focus of this analysis are on sub equipment such as evaporator tubes, economizer tubes, boiler feed water (BFW) pump and steam drum. By using FMEA, failures associated with each sub system/component were identified and corresponding remedial methods to counteract the failures were recorded and tabulated in an FMEA table. The critical equipment of the HRSG was discovered through developing Risk Priority Number (RPN) and the critical equipment that was identified is evaporator tube. Proposed FMEA methodology can assist the maintenance engineers to analyze the HRSG’s failure and reliability.