Failure Mode and Effect Analysis (FMEA) of a Taurus 60 Gas Turbine Power Plant System (GTPPS), in Mowe, Nigeria

Abstract

Failure Mode and Effect Analysis (FMEA) is an approach used for maintenance system reliability analysis. FMEA is applied to the Taurus 60 Gas Turbine Power Plant System (GTPPS). The unexpected failures with the associated maintenance costs are major problems in most power plants. In this study, critical components of the Taurus 60 gas turbine power plant were identified. Twenty-five sub-assemblies were identified and the probable failure modes of the main sub-assemblies. Failure analysis and the Risk Priority Numbers (RPN) of the critical sub-assemblies were determined using failure modes and effect analysis method. Failure analysis and the Risk Priority Numbers (RPN) of the critical sub-assemblies were determined using failure modes and effect analysis method. Based on criticality analysis, six (6) critical sub-assemblies were identified. These are fuel gas supply, air filter package, air trap package, gearbox, compressor rotor assembly and fuel injector with criticality numbers 12.5, 20.83, 20.83, 20.83, 16.67 and 20.83 respectively. The failure analysis for these critical sub-assemblies specified the failure modes, failure effects, maintenance tasks, frequency of inspection and strategies. The ranges of the Risk Priority Number (RPN) for the components of fuel gas supply, air filter package, air trap package, gearbox, compressor rotor assembly and fuel injector were 54-126, 60-90, 75-90, 72-84, 36-112 and 90-120 respectively. The critical sub-assemblies should be given close attention in terms of monitoring, routine checks which can be monitored using prepared checklists. The semi- critical and non- critical assemblies should not be neglected either.