Root Cause Analysis for Compressor Failure in Petrochemical Plant

Compressor Failures

• Equipment
  • Wear and Tear
  • Rotor damage
  • Bearing failure
  • Maintenance
  • Use of incorrect lubricants
  • Lack of preventive maintenance
  • Design Issues
  • Improper selection of components
  • Inadequate compressor design
• Process
  • Procedure
  • Improper startup/shutdown procedures
  • Lack of standardized operating procedures
  • Operating Conditions
  • Incorrect operating pressure
  • Overloading the compressor
• People
  • Human Error
  • Failure to follow maintenance protocols
  • Incorrect handling of the compressor
  • Training
  • Lack of awareness of emergency procedures
  • Insufficient operator training
• Materials
  • Contamination
  • Foreign particles in the lubrication system
  • Contaminated intake air
  • Quality of inputs
  • Use of incompatible materials
  • Substandard quality of lubricants
• Environment
  • Location
  • Proximity to corrosive chemicals
  • Poor ventilation in the compressor room
  • External Conditions
  • Humidity causing corrosion
  • High ambient temperature
• Management
  • Budget
  • Delayed investment in equipment upgrades
  • Insufficient budget for spare parts
  • Policies
  • Lack of clear responsibility for compressor operation
  • Inadequate maintenance schedules

Suggested Actions Checklist

This detailed checklist can guide the implementation of corrective, preventive, and investigative actions to address the potential causes of cracking furnace failure.

• External Factors
  • Equipment
    • Wear and Tear
      • Corrective Actions:
      • Replace worn-out components such as rotors and bearings.
      • Repair or refurbish damaged parts to restore functionality.
      • Preventive Actions:
      • Implement a scheduled maintenance program to monitor and address wear and tear.
      • Use high-quality, durable components to extend the lifespan of the compressor.
      • Investigative Actions:
      • Analyze wear patterns to identify root causes.
      • Review maintenance records and operating conditions for contributing factors.
    • Rotor Damage
      • Corrective Actions:
      • Replace or repair damaged rotors.
      • Inspect the compressor for additional damage caused by rotor failure.
      • Preventive Actions:
      • Monitor rotor conditions regularly and perform routine inspections.
      • Ensure proper installation and alignment of rotors to prevent damage.
      • Investigative Actions:
      • Examine the causes of rotor damage, such as excessive load or foreign particles.
      • Review design and operational procedures to identify any design flaws.
    • Bearing Failure
      • Corrective Actions:
      • Replace failed bearings and check for additional damage.
      • Address any issues causing bearing failure, such as misalignment or inadequate lubrication.
      • Preventive Actions:
      • Implement a regular bearing inspection and lubrication schedule.
      • Use high-quality bearings appropriate for the operating conditions.
      • Investigative Actions:
      • Analyze bearing failure modes to determine root causes.
      • Review maintenance logs to identify any missed maintenance tasks.
  • Maintenance
    • Use of Incorrect Lubricants
      • Corrective Actions:
      • Drain and replace incorrect lubricants with the proper type.
      • Clean the lubrication system to remove contaminants.
      • Preventive Actions:
      • Ensure proper lubricant selection and handling procedures are followed.
      • Educate staff on the importance of using correct lubricants.
      • Investigative Actions:
      • Review lubricant specifications and supplier information.
      • Analyze incidents where incorrect lubricants were used to determine how errors occurred.
    • Lack of Preventive Maintenance
      • Corrective Actions:
      • Implement overdue preventive maintenance tasks.
      • Review and address any issues identified during the maintenance.
      • Preventive Actions:
      • Establish and adhere to a comprehensive preventive maintenance schedule.
      • Train personnel on the importance and procedures for preventive maintenance.
      • Investigative Actions:
      • Review past maintenance records to identify gaps and missed tasks.
      • Analyze the impact of missed maintenance on compressor performance.
  • Design Issues
    • Improper Selection of Components
      • Corrective Actions:
      • Replace improperly selected components with those that meet design specifications.
      • Review and correct any system design issues affecting component compatibility.
      • Preventive Actions:
      • Ensure component selection is based on thorough design analysis and specifications.
      • Use reputable suppliers and verify component specifications before purchase.
      • Investigative Actions:
      • Analyze component failure data to identify design issues.
      • Review design and selection processes to prevent future occurrences.
    • Inadequate Compressor Design
      • Corrective Actions:
      • Modify or replace the compressor design to meet operational requirements.
      • Address any immediate issues caused by the design inadequacy.
      • Preventive Actions:
      • Conduct thorough design reviews and simulations before implementation.
      • Regularly evaluate compressor performance and design to ensure ongoing suitability.
      • Investigative Actions:
      • Analyze design failures to identify root causes.
      • Review design changes and updates for impact on performance.
• Process
  • Procedure
    • Improper Startup/Shutdown Procedures
      • Corrective Actions:
      • Review and correct startup and shutdown procedures as per manufacturer guidelines.
      • Train personnel on proper procedures and monitor compliance.
      • Preventive Actions:
      • Develop and enforce standardized startup and shutdown procedures.
      • Implement automated systems to ensure correct procedures are followed.
      • Investigative Actions:
      • Review incidents related to improper procedures to identify root causes.
      • Analyze procedure documentation for completeness and accuracy.
    • Lack of Standardized Operating Procedures
      • Corrective Actions:
      • Develop and implement standardized operating procedures (SOPs).
      • Train all relevant personnel on the new SOPs and monitor adherence.
      • Preventive Actions:
      • Regularly review and update SOPs to reflect best practices and changes in technology.
      • Conduct periodic audits to ensure SOP compliance.
      • Investigative Actions:
      • Analyze incidents or failures related to SOP deficiencies.
      • Review existing procedures and identify areas for improvement.
  • Operating Conditions
    • Incorrect Operating Pressure
      • Corrective Actions:
      • Adjust operating pressure to within the recommended range.
      • Inspect and repair any damage caused by incorrect pressure.
      • Preventive Actions:
      • Implement pressure monitoring systems and alarms to maintain correct levels.
      • Regularly calibrate pressure gauges and control systems.
      • Investigative Actions:
      • Review incidents of pressure deviations to identify causes.
      • Analyze control system performance to ensure pressure settings are accurate.
    • Overloading the Compressor
      • Corrective Actions:
      • Reduce operational loads to within the compressor's capacity.
      • Repair any damage caused by overloading.
      • Preventive Actions:
      • Implement load monitoring systems to prevent overloading.
      • Regularly review load conditions and adjust as needed to avoid excessive loads.
      • Investigative Actions:
      • Analyze load data and operating conditions leading to overloading.
      • Review system design and load management practices for improvements.
• People
  • Human Error
    • Failure to Follow Maintenance Protocols
      • Corrective Actions:
      • Review and address any missed maintenance tasks.
      • Retrain personnel on correct maintenance protocols.
      • Preventive Actions:
      • Implement checks and balances to ensure adherence to maintenance protocols.
      • Use automated systems to remind and verify maintenance tasks.
      • Investigative Actions:
      • Analyze incidents related to maintenance protocol failures.
      • Review training programs and adherence to procedures.
    • Incorrect Handling of the Compressor
      • Corrective Actions:
      • Address any damage caused by improper handling.
      • Implement corrective actions to prevent recurrence.
      • Preventive Actions:
      • Provide comprehensive training on proper handling procedures.
      • Implement clear guidelines and labeling for compressor handling.
      • Investigative Actions:
      • Review incidents of improper handling to determine root causes.
      • Evaluate training and handling procedures for improvements.
  • Training
    • Lack of Awareness of Emergency Procedures
      • Corrective Actions:
      • Conduct emergency response drills and provide training on procedures.
      • Review and update emergency response plans as needed.
      • Preventive Actions:
      • Implement regular emergency response training and drills.
      • Ensure that all personnel are familiar with emergency procedures.
      • Investigative Actions:
      • Analyze past emergencies to assess the effectiveness of response procedures.
      • Review training records and emergency response plans for completeness.
    • Insufficient Operator Training
      • Corrective Actions:
      • Provide additional training for operators on compressor operation and maintenance.
      • Assess and address any knowledge gaps.
      • Preventive Actions:
      • Develop and implement a comprehensive training program for all operators.
      • Include regular refresher courses and updates on new procedures or equipment.
      • Investigative Actions:
      • Review training records and performance evaluations to identify areas for improvement.
      • Analyze incidents related to operator errors to determine training needs.
• Material
  • Contamination
    • Foreign Particles in the Lubrication System
      • Corrective Actions:
      • Clean and replace contaminated lubrication system components.
      • Implement filtration systems to prevent future contamination.
      • Preventive Actions:
      • Regularly inspect and maintain the lubrication system to avoid contamination.
      • Use high-quality filters and ensure proper handling of lubricants.
      • Investigative Actions:
      • Analyze the source of contamination to prevent recurrence.
      • Review lubrication system maintenance practices and identify improvements.
    • Contaminated Intake Air
      • Corrective Actions:
      • Clean or replace air filters and inspect the intake system.
      • Address any issues causing contamination of intake air.
      • Preventive Actions:
      • Implement air filtration and monitoring systems to ensure clean intake air.
      • Regularly inspect and maintain air filters and intake systems.
      • Investigative Actions:
      • Review contamination incidents to identify sources and contributing factors.
      • Evaluate air filtration systems and maintenance practices.
  • Quality of Inputs
    • Use of Incompatible Materials
      • Corrective Actions:
      • Replace incompatible materials with those suitable for the compressor.
      • Inspect and address any damage caused by the use of incorrect materials.
      • Preventive Actions:
      • Ensure proper material selection and compatibility before use.
      • Implement quality control checks for all materials.
      • Investigative Actions:
      • Analyze incidents involving material incompatibility to determine root causes.
      • Review material selection processes and specifications.
    • Substandard Quality of Lubricants
      • Corrective Actions:
      • Replace substandard lubricants with high-quality alternatives.
      • Clean the lubrication system to remove residues of substandard lubricants.
      • Preventive Actions:
      • Implement a quality assurance program for lubricant selection and handling.
      • Regularly review and update lubricant specifications and suppliers.
      • Investigative Actions:
      • Analyze the impact of substandard lubricants on compressor performance.
      • Review lubricant quality control processes and supplier performance.
• Environment
  • Location
    • Proximity to Corrosive Chemicals
      • Corrective Actions:
      • Relocate the compressor or implement protective measures to minimize exposure.
      • Repair any damage caused by corrosive chemicals.
      • Preventive Actions:
      • Evaluate the location and implement barriers or protective coatings to reduce chemical exposure.
      • Regularly inspect for signs of corrosion and address issues promptly.
      • Investigative Actions:
      • Analyze the impact of chemical exposure on compressor performance.
      • Review facility layout and chemical handling procedures for improvements.
    • Poor Ventilation in the Compressor Room
      • Corrective Actions:
      • Improve ventilation by installing or repairing ventilation systems.
      • Address any issues caused by poor ventilation, such as overheating.
      • Preventive Actions:
      • Ensure adequate ventilation in all compressor rooms.
      • Regularly inspect and maintain ventilation systems.
      • Investigative Actions:
      • Review ventilation system performance and its impact on compressor operation.
      • Analyze incidents related to poor ventilation and identify corrective actions.
  • External Conditions
    • Humidity Causing Corrosion
      • Corrective Actions:
      • Address corrosion issues and implement measures to prevent further damage.
      • Improve environmental controls to reduce humidity levels.
      • Preventive Actions:
      • Use corrosion-resistant materials and coatings for compressor components.
      • Implement dehumidification systems or controls in areas prone to high humidity.
      • Investigative Actions:
      • Analyze the impact of humidity on compressor components.
      • Review environmental control measures and their effectiveness.
    • High Ambient Temperature
      • Corrective Actions:
      • Implement cooling measures to reduce ambient temperature in the compressor room.
      • Repair any heat-related damage to the compressor.
      • Preventive Actions:
      • Use cooling systems or air conditioning to maintain optimal temperature.
      • Regularly monitor and manage ambient temperature conditions.
      • Investigative Actions:
      • Analyze the impact of high temperatures on compressor performance.
      • Review temperature control systems and their effectiveness.
• Management
  • Budget
    • Delayed Investment in Equipment Upgrades
      • Corrective Actions:
      • Prioritize and implement necessary equipment upgrades as soon as possible.
      • Address any issues caused by outdated equipment.
      • Preventive Actions:
      • Develop and adhere to a capital investment plan for equipment upgrades.
      • Regularly review and update the budget to ensure timely investments.
      • Investigative Actions:
      • Review the impact of delayed upgrades on compressor performance and reliability.
      • Analyze budgeting and investment processes to identify improvements.
    • Insufficient Budget for Spare Parts
      • Corrective Actions:
      • Allocate additional funds to ensure adequate spare parts inventory.
      • Address any issues caused by the lack of available spare parts.
      • Preventive Actions:
      • Develop and maintain a spare parts inventory management plan.
      • Regularly review spare parts needs and budget accordingly.
      • Investigative Actions:
      • Analyze the impact of spare parts shortages on compressor performance.
      • Review inventory management practices and budget allocation.
  • Policies
    • Lack of Clear Responsibility for Compressor Operation
      • Corrective Actions:
      • Define and assign clear responsibilities for compressor operation and maintenance.
      • Communicate responsibilities to all relevant personnel.
      • Preventive Actions:
      • Implement a structured policy framework outlining roles and responsibilities.
      • Regularly review and update policies to ensure clarity and effectiveness.
      • Investigative Actions:
      • Review incidents related to unclear responsibilities to identify improvements.
      • Evaluate the effectiveness of current policies and communication strategies.
    • Inadequate Maintenance Schedules
      • Corrective Actions:
      • Develop and implement a comprehensive maintenance schedule.
      • Address any missed maintenance tasks and their impacts on compressor performance.
      • Preventive Actions:
      • Establish a regular and detailed maintenance schedule based on manufacturer recommendations.
      • Monitor adherence to the maintenance schedule and adjust as needed.
      • Investigative Actions:
      • Review past maintenance records to identify gaps and missed tasks.
      • Analyze the impact of inadequate maintenance schedules on compressor reliability.