Root Cause Failure Analysis (RCFA)

Guaranty Partners Root Cause Failure Analysis course will equip the participants to:
• Learn fundamental concepts around failures of machines and equipment, both moving and static
• Understand relationship between failures of machines and equipment and the associated HSE incidents
• Comprehend failure mechanisms of various identified major machines and equipment
• Learn and use Root Cause Failure Analyses (RCA) to arrive at root and generic causes of failures of machines and equipment
• Check effectiveness of the implementation of CAP’s and PAP’s
• Understand and practice skills to draft and generate RCFA Report
• Comprehend the importance of RCFA Close-out
• Cascade lessons learnt from the failure Incident and the RCFA Report
• Address accurately the various Insurance, Legal and Statutory Implications
Cours Content:
Fundamental Concepts and Some Failure Analysis Tools
• Reliability Engineering and Predictive Maintenance
• Failure Mode Effects Analysis
• Fault-Tree Analysis
• Cause-and-Effect Analysis
• The Fishbone Graph
• Sequence-of-events diagram
• Bow-Tie method
• Introduction to Root Cause Failure Analysis
• Purpose of RCFA
• Effective use of RCFA
• Personnel Requirement
• Conditions for using the method
Root Cause Failure Analysis Methodology
• Reporting a Failure Incident or Problem
• Symptoms and Boundaries/Conditions
• Perceived Causes of Problem
• Event-Reporting Format
• Failure Incident Classification
• Typical Failure Incident-Reporting Form
• Equipment Damage or Failure
• Operating Performance
• Economic Performance
• Safety
• Regulatory Compliance
• Data Gathering: Interviews, Questions to Ask
• Collecting Physical Evidence
• Analyze Sequence of Events
• Design Review: Minimum Design Data
• Objectives of the Design Review
• Application/Maintenance Review: Installation, Operating Envelope, SOPs
• Maintenance History and the associated Procedures and Practices
• Observations & Measurements: Vibration Analysis, Process Parameters, Visual Inspection, Measurement Devices, Failed Machine Components, Wear Particles
• Other testing techniques: NDT (Non-Destructive Testing), metallography, fractography etc
Determining The Failure Root Cause(s)
• Misapplication
• Poor Design Practices
• Aging: Depreciation, Remainder Life, Replacement Planning not predictive.
• Procurement Practices: Inadequate Specifications, Substitutions, Low Bid versus Lifecycle Cost, Vendor Evaluations,
• Poor Operating, Inspection & Maintenance Practices and Procedures
• Poor Training
• Inadequate Supervision
• Ineffective Communication
• Faulty Human Engineering
• Work Environment: Physical and Phycological
• Management Systems
• Substandard Qualify Control
Evaluating Potential Corrective Actions
• Involvement of SMEs (Subject Matter Experts)
• HSE Risk Assessment Matrix.
• Regulatory Requirements
• Costs Involved: Process, Materials, Labour, Training, other considerations.
• Cost-Benefit Analysis
• Management Decision
Report and Recommendations
• Failure Incident Summary
• Initial Plant Condition
• Initiating Event
• Failure Incident Description
• Immediate Corrective Actions
• Causes and Long-Term Corrective Actions
• Internal and External Reports Filed
• Lessons Learned
• References And Attachments
• Failure Investigator or Investigating Team Description
• Review And Approval Team Description
• Distribution List
• Verification of Implementation of Corrective Action and Its Effectiveness
HSE-Related Issues
• Fatigue
• Physical Impairment
• Personal Problems
• Repetition/Boredom
• Machine-Human interface not friendly
• Operations Problems/Short-cuts/capacity stretching
• Economic Considerations to avoid HSE best practices
• Inspection and maintenance priorities side-lined
Regulatory and Internal Compliance Issues
• Spill Hazards: Recommended Spill Responses
• Worker Education and Communication
• Prevention
• Worker Responsibilities
• Legislation and Reporting Requirements including Pollution Control Board if failures entail it.
• Occupational Health & Safety Management | ISO 45001:2018
• Process Safety Management (PSM)
• Emergency Planning and Community Right-to-Know Act
• Resource Conservation and Recovery Act
• Hazardous Materials Transportation Act
Design Evaluation Aspects: Selected Machines & Equipment
• Pumps
• Compressors
• Turbines
• Fans, Blowers, and Fluidizers
• Driving Conveyors and Conveyer Belts
• Mixers And Agitators
• Dust Collectors
• Rollers
• Fasteners
• Ropes and cables
• Gearboxes/ Speed Reducers
• Steam Traps
• Electric Inverters
• Control Valves
• Seals And Packing
• Preventive Trouble Shooting for The Above Machines & Equipment to Avoid Failures
Live Failure Incidents, Case Studies and Exercises to do RCFA
• Failure Videos and discussions
• Tutor runs the above RCFA methodology with respect to one incident case study to refresh the attendees.
• Tutor presents a few other case studies and asks course participants to work them out with RCA and Investigation Reports
• Tutor observes progress and provides support

Methodology
The training methodology integrates lectures, interactive discussions, collaborative group exercises, and illustrative examples. Participants will acquire a blend of theoretical insights and hands-on practical experience, emphasizing the application of learned techniques. This approach ensures that attendees return to their professional environments equipped with both the competence and self-assurance to effectively implement the acquired skills in their responsibilities.

DATE:
1ST BATCH: 9th – 12th Jan, 2024
2ND BATCH: 4th – 7th June, 2024