Potential risks assessment of electronics unit of combined cycle power plant by Failure Mode and Effect Analysis (FMEA)

Failure Mode and Effects Analysis (FMEA) is a method to systematically identify the failures of systems, subsystems and their components in the different operational processes. The study aimed to identify the failures modes and assess their potential effects on other systems, subsystems and other system components in the electronic unit of combined cycle power plants by FMEA. Based on our design in the first step, a team of experts was formed to identify the potential failures as well as determining their Occurrences (O), severities (S), and capabilities of failure detection (Detectability) (D) leading to their interaction as Risk Priority Number (RPN) in electronics unit. Then, administrative or engineering control measures or Personal Protective Equipment (PPE) were proposed to diminish the high risk failures to lower ones. Obtained data were analyzed with Excel software based on related procedures and guidelines finally. Results showed numbers of potential risks identified in this unit were 37 cases of which 68% were unacceptable level and 32% of those were at acceptable levels. Among these risks, the highest risk of electrocution when replacing coal generators and electrocution caused accidentally energized wires went to an abandoned area of unit with RPN equals to 300. Considering electrocution to the high risk score units, Engineering and management control measures to reduce the risk of accidents caused by Electrocution should has been considered in order to achieve optimum results and reducing the risk to acceptable levels.