ABS 215-2015 GUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION.pdf

1、 GUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION MAY 2015 Guide to Color Coding Used in Online Version of the Guidance Notes The following summarizes the colors corresponding to Rule Changes, Corrigenda items and editorial changes in the Guidance Notes files which are a

2、vailable for download. Rule Changes: Corrigenda: CORRIGENDA/EDITORIALS 1 July 2015 Editorials: Editorial Changes Guidance Notes on Failure Mode and Effects Analysis (FMEA) for Classification GUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION MAY 2015 (Updated July 2015 see

3、 next page) American Bureau of Shipping Incorporated by Act of Legislature of the State of New York 1862 Copyright 2015 American Bureau of Shipping ABS Plaza 16855 Northchase Drive Houston, TX 77060 USA Updates July 2015 consolidation includes: May 2015 version plus Corrigenda/Editorials Foreword Fo

4、reword ABS requires clients to develop and submit FMEAs as part of Classification requirements for select systems. For instance, FMEAs are required for achieving many of the special or optional Classification notations such as CDS, ACC, ACCU, R1, RQ, DPS-2, DPS-3, ISQM. This document provides guidan

5、ce and insight into the development process for FMEAs to comply with ABS Classification rule requirements. The utilization of this guidance will provide tangible benefits as the marine and offshore industry is able to realize the positive results of FMEAs that are developed correctly and managed app

6、ropriately throughout the lifecycle of a system. Some of these benefits include FMEAs that meet the intended objectives and are a support to the classification process Consistency in scope, depth and quality among comparable FMEAs Expedited FMEA review process Reduced failures, downtimes and inciden

7、ts These Guidance Notes become effective on the first day of the month of publication. Users are advised to check periodically on the ABS website www.eagle.org to verify that this version of these Guidance Notes is the most current. We welcome your feedback. Comments or suggestions can be sent elect

8、ronically by email to rsdeagle.org. ABSGUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION .2015 iii Table of Contents GUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION CONTENTS SECTION 1 Introduction 1 1 Background . 1 2 Purpose of FMEAs 1 3 FME

9、A Overview 1 3.1 FMEA Process in a Nutshell 2 TABLE 1 Index of System-Specific Guidance for ABS FMEA Requirements 3 FIGURE 1 Process Flow for Classification Required FMEAs 4 SECTION 2 Before the FMEA. 5 1 Preparing for the FMEA 5 1.1 FMEA Standards . 5 1.2 Design Philosophy and FMEAs . 6 2 FMEA Scop

10、e and Ground Rules 7 2.1 Equipment Scope and Physical Boundaries 7 2.2 Operational Boundaries (Global and Local) . 9 2.3 Failure Criteria and Types of Failure 9 2.4 Depth of Analysis . 9 2.5 Criticality Ranking (FMECA) 10 2.6 FMEA Naming Convention within this Document 11 2.7 US Coast Guard Suppleme

11、ntal Requirements for Qualitative Failure Analyses (QFA) . 11 3 FMEA Team 12 3.1 Stakeholders Workshop Setting 12 3.2 Third-Party FMEA Practitioner(s) . 12 3.3 ABS Participation in the FMEA Workshop . 13 3.4 Team Preparation 13 4 Ideal Timing to Conduct FMEAs . 13 TABLE 1 Typical Corrective Actions

12、to Control Failure Scenarios . 6 TABLE 2 Examples of System/Subsystems Physical Boundaries (for a DP System) 8 FIGURE 1 Typical Risk Matrix for FMECA . 11 iv ABSGUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION .2015 SECTION 3 Developing the FMEA 15 1 Developing the FMEA

13、 15 2 Data Management 15 2.1 Data Collection to Support the Analysis 15 2.2 Other Risk Analysis as Input to the FMEA . 15 2.3 Data Analysis 15 3 FMEA Study 17 3.1 Define the Analysis 18 3.2 Develop the Analysis Approach . 18 3.3 Identify Failure Modes . 20 3.4 Analyze Effects 24 3.5 Identify Failur

14、e Detection Methods 25 3.6 Identify Existing Risk Control Methods 25 3.7 Criticality Ranking (for FMECA) . 25 3.8 Identify Corrective Actions . 26 TABLE 1 Risk Analyses that could Provide Input Information to an FMEA 16 TABLE 2 Sample FMEA/FMECA Worksheet . 20 TABLE 3 Sample Failure Modes of Mechani

15、cal and Electrical Components 21 FIGURE 1 FMEA Study Flowchart . 17 FIGURE 2 Reliability Block Diagram (or Dependency Diagrams) 18 FIGURE 3 Example of External/Operational Forces That May Impact FMEA Study 19 SECTION 4 FMEA Report and Classification Review of FMEA 27 1 FMEA Report 27 1.1 Report Stru

16、cture 27 1.2 FMEA Internal Review Process . 29 2 Classification Review of the FMEA . 29 2.1 Pitfalls and Common Problems in Classification Submitted FMEA 29 2.2 FMEA and Supporting Documentation Submittal 30 TABLE 1 Sample FMEA Report Structure . 28 FIGURE 1 Sample Cause and Effect Matrix 31 SECTION

17、 5 FMEA Verification Program . 32 1 Purpose . 32 1.1 Scope of FMEA Verification Program 32 1.2 Verification Program Test Sheets 33 1.3 Performing FMEA Verification Program 34 1.4 Results and Recommendations . 34 1.5 FMEA Verification Program Report . 35 1.6 United States Coast Guard Design Verificat

18、ion Test Procedure . 36 ABSGUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION .2015 v TABLE 1 Sample FMEA Verification Program Report Structure (for a DP FMEA) 35 FIGURE 1 FMEA Trial Test Sheet Example . 34 SECTION 6 FMEA Lifecycle Management 37 1 Best Practices for FMEA a

19、s a Living Document . 37 1.1 Best Practices for FMEA as an Operations Resource Document 37 1.2 Best Practices for FMEA Lifecycle Management . 38 1.3 Changes to the Classed System and FMEA Revisions and Submittals 38 1.4 FMEA and Management of Change 38 TABLE 1 Suggested Entries in Management of Chan

20、ge Form for FMEAs 39 FIGURE 1 FMEA Lifecycle Management . 39 SECTION 7 System-Specific FMEA Requirements 40 1 Guidance for System-Specific FMEA Requirements 40 1.1 Automation (General Control, Safety-Related Functions of Computer-Based Systems, Wireless Data Communication, Integrated Automation Syst

21、ems) 44 1.2 Electronically Controlled Diesel Engines . 50 1.3 Remote Control Propulsion Automatic Centralized Control (ACC), Automatic Centralized Control Unmanned (ACCU), Automatic Bridge Centralized Control Unmanned (ABCU) . 54 1.4 Gas Turbine . 58 1.5 Redundant Propulsion and Steering 62 1.6 Sing

22、le Pod Propulsion . 66 1.7 Dynamic Positioning Systems (DPS) . 69 1.8 Software Control System . 78 1.9 Jacking Systems 86 1.10 Subsea Heavy Lifting . 90 1.11 Drilling Systems/Subsystems/Individual Equipment 93 1.12 Integrated Drilling Plant . 100 1.13 Dual Fuel Diesel Engines (DFDE) . 108 1.14 Gas-F

23、ueled Engines 113 1.15 Motion Compensation and Rope Tensioning Systems for Cranes . 119 TABLE 1 Index of FMEA Requirements in ABS Rules and Guides . 41 TABLE 2 Structure of the Guidance for Each FMEA Requirement 42 TABLE 3 Sample DP FMEA Worksheet Template. 77 vi ABSGUIDANCE NOTES ON FAILURE MODE AN

24、D EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION .2015 APPENDIX 1 Definitions, Acronyms and Abbreviations . 122 1 Definitions . 122 2 Acronyms and Abbreviations 125 APPENDIX 2 Sample FMEA/FMECA Worksheets 126 1 Sample FMEA/FMECA Worksheets . 126 1.1 FMECA Worksheet Example (for ISQM and for CDS) 126 TAB

25、LE 1 Example of BOP Control Functional Items . 127 TABLE 2 FMECA Worksheet Example (Select Sections of a FMECA for BOP Control System) . 128 ABSGUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION .2015 vii This Page Intentionally Left Blank Section 1: Introduction SECTION 1

26、 Introduction 1 Background In the marine and offshore industry, design and equipment configurations vary from one system to the next, and systems are in many cases increasingly complex. There are gaps in codes and standards which may lag technological innovations and there are issues related to inte

27、rfaces between systems. Risk analyses such as Failure Modes and Effects Analysis (FMEAs) provide a formalized approach to identify hazardous situations, address the gaps and interconnection variances, and improve safety, environmental performance and operational downtime. ABS requires clients to dev

28、elop and submit FMEAs as part of Classification requirements for certain systems and to obtain certain special notations. This document provides guidance and insight into the development process for FMEAs to comply with ABS Classification Rule requirements for various special notations. The utilizat

29、ion of this guidance will provide tangible benefits as the marine and offshore industry is able to realize the positive results of FMEAs that are developed correctly and managed appropriately throughout the lifecycle of a system. Some of these benefits include: FMEAs that meet the intended objective

30、s and are a support to the classification process Consistency in scope, depth and quality among comparable FMEAs Expedite the FMEA review process Reduce failures, downtimes, and incidents 2 Purpose of FMEAs Whenever a system failure could result in undesirable consequences such as loss of propulsion

31、 loss of propulsion control, etc., best practices advise carrying out a risk analysis, such as an FMEA, as an integral part of the design and operational development process. This analysis can be a powerful aid in identifying possible failures which could potentially leave a vessel, an offshore ins

32、tallation or its crew in peril. The ultimate goal of an FMEA from the point of view of Classification is to use it as supporting documentation to demonstrate compliance with the ABS design philosophy and related Classification notation requirements and design intent for the particular system. There

33、are instances where the goal of the vessel or asset owner is to have a comprehensive and systematic risk-based approach to the design. When such approach is taken, design choices are prioritized based on the assessment of risks, thus the much broader FMEA goal is to identify and reduce a wider range

34、 of risks that could arise from failures. The ISQM (Integrated Software Quality Management) for software development is an example of such risk-based design framework. 3 FMEA Overview An FMEA is a design and engineering tool which analyzes potential failure modes within a system to determine the imp

35、act of those failures. It was first developed by the US Department of Defense for use in systems design. The FMEA technique has since been adopted by commercial industries in an attempt to minimize failures and reduce safety, and environmental and economic impacts that could result from these failur

36、es. ABSGUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FOR CLASSIFICATION .2015 1 Section 1 Introduction FMEAs have more recently become a preferred risk analysis tool in the marine industry. It is required for certain systems by the International Maritime Organization, by Classification

37、Societies, select regulatory bodies, and industry groups to improve the safety of a design or operation, to increase its reliability and to minimize undesired events. As a risk management practice, FMEAs are also an integral part of the design process of many proactive companies. 3.1 FMEA Process in

38、 a Nutshell The FMEA is generated through a tabletop analytical process intended to identify system design and configuration weaknesses in all expected operational modes of the particular system. Once it has been determined that an FMEA will be performed and the scope of the study is agreed upon, an

39、 appropriate FMEA team of subject matter experts is assembled to carry out the analysis. A team is recommended for FMEAs, in particular for larger systems requiring different specialties. In some instances, a study carried out by an FMEA practitioner knowledgeable in the system(s) being analyzed and

40、 the development of FMEAs is an adequate alternative. System boundaries are defined, and agreed upon, to clearly delineate what parts of the subject will be analyzed. The team will include or interface with the owners/stakeholders to exchange data, including collection of system schematics, operatio

41、nal procedures and manuals and system configurations. The team brainstorms on the potential failure modes, their effects, detection methods and corrective actions. Recommendations are provided for corrective action throughout the development process and these recommendations may be ranked according

42、to the severity of the potential effect. This information is identified and recorded, usually in a tabulated format, and a preliminary report is issued to the owner/stakeholders and team for review and verification of accuracy. An option is to recommend practical tests and trials to conclusively ver

43、ify the analysis. For certain special notations and for certain organizations such as regulatory bodies, a further FMEA validation and trial program must be developed and executed on the vessel in order to validate that the system responds to failures and failures are detected and alarmed as describ

44、ed within the FMEA. Once the comments from the team, owner and stakeholders on the preliminary document review have been received by the practitioner or FMEA team leader, the document will be updated and should be ready to be submitted to ABS for review. The entity that has the contract with ABS (e.

45、g., shipyard, vessel owner) will have the ultimate responsibility for making sure the FMEA reports are submitted to Classification. The general elements of the FMEA process are discussed in detail in Sections 1-6 and illustrated in Section 1, Figure 1. Section 7 provides the specific guidance for se

46、lect ABS Classification FMEA requirements, as listed in Section 1, Table 1 below. Faced with a particular FMEA requirement, the user may choose to go directly to the respective requirement in Section 7 for guidance and clarification. 2 ABSGUIDANCE NOTES ON FAILURE MODE AND EFFECTS ANALYSIS (FMEA) FO

47、R CLASSIFICATION .2015 Section 1 Introduction TABLE 1 Index of System-Specific Guidance for ABS FMEA Requirements ABS Rule or Guide and Specific System Steel Vessel Rules (SVR) Offshore Support Vessels (OSV) Under 90 meters (1) Mobile Offshore Drilling Units (MODU) Mobile Offshore Units (MOU) Offsho

48、re Facilities High Speed Craft (HSC) High Speed Naval Craft (HSNC) Gas Fueled Ships (GF) Propulsion Systems for LNG Carriers Lifting Appliances 7/1.1 Automation General Automation, Computer-Based Systems, Wireless Data Communications for Vessel Services Integrated Controls 7/1.2 Electronically-contr

49、olled Diesel Engine 7/1.3 Remote Control Propulsion Automated Centralized Control (ACC) Automated Centralized Control Unmanned (ACCU) Automated Bridge Centralized Control Unmanned (ABCU) 7/1.4 Gas Turbine Safety Systems 7/1.5 Redundant Propulsion and Steering 7/1.6 Single Pod Propulsion Dynamic Positioning Systems (DP) 7/1.7 Dynamic Positioning (DP) Systems Integrated Software Quality Management (ISQM) 7/1.8 Software Mobile Offshore Drilling Units (MODU) 7/1.9 Jacking and associated Systems Offshore Support Vessels 7/1.10 Subsea Heavy Lifting C