System

Subsystem
Component
Design Lead
Core Team

Item / Function

Pump

Pump

Pump
 Pump

Pump

Pump seal

Pump seal

Pump bearing

Electric motor

Electric motor

Electric motor
Control valve (block)

Control valve (block)

Control valve (block)

Control valve (block)

Control valve (block)

Hydraulic actuator

Hydraulic actuator

Hydraulic actuator

Hydraulic actuator

Hydraulic actuator

Hydraulic actuator

Hydraulic actuator

Hydraulic actuator
Hydraulic actuator
Hydraulic actuator

Hydraulic actuator
Hydraulic actuator

Hydraulic actuator
Hydraulic actuator

Hydraulic actuator

Hydraulic actuator

Hydraulic actuator

Hydraulic hose

Hydraulic hose

Hydraulic hose

Hydraulic hose

Hydraulic hose

Hydraulic hose
Hydraulic hose

Hydraulic hose

Electrical system

Electrical system
Electrical system

Electrical system

Electrical system

Electrical system
WINDTURBINE

HYDRAULIC PITCH

ALL RELEVANT COMPONENTS

ANDRÉ AND FAWZY

ANDRÉ AND FAWZY

Potential Failure Mode(s)

Excessive pump noise

System excessively hot

Pump not delivering pressure

Pump not delivering pressure

Pump not delivering oil

Leakage at oil seal

Lack of volume

Bearing failure

Overloading motor

Motor noisy

Motor heated
 Fails to open, close and leaks

Variations in flow

Erratic pressure

Improper flow

Oil heats

Piston rod scored

Cylinder bore scored

Bent piston rod

Split weld on base and ports

Eye bearing broken

Rod worn on one side

Gland blown out

Leaking from around the gland od

Piston rod pitting
Barrel internally corroded

Regular seal leakage

 Regular seal leakage

Cylinder is getting hot

Rod kick up at end of stroke

Piston rod will not retract

Loss of power

Slip stick or juddering

Fitting blown off the hose

Hose is hard and brittle

Leakage between shell/hose fitting

Hose has burst

The hose leaks (via pinholes or weepage)

Hose inner tube is badly deteriorated

Numerous hose cover blisters

The hose bore appears restricted

Electrical short-circuit

Deadband
Deadband

Hysteresis

Stiction

Nonlinearity
 S
Potential Effect(s)
of Failure e
v

Loss of pump efficiency 3

Dangerous environment exposition for work labor inside nacelle 4

Reduced sealing of components 3

Undesired load generation 3

Reduced life cycle of components working in vibrational modes 3

Loss of pump efficiency 3

Reduced lifecycle of components 4

Dangerous environment for work labor due to heat radiation 5

Fast degradation of oil and grease (lubricants) 4

Activation of corrosion modes by temperature 3

Stoppage of the system 5

Reduced efficiency of the system 4

 Reduced efficiency of the system 4

System being damaged by wrong setup 4

Failure of the system 5

Reduced efficiency of the system 3

Wear acting on the components 3

Stress concentration 4

Vibrational loads 4
Reduced efficiency of the system 3
Wear and corrosion inside the system 4
Reduced efficiency of the system 3
Wear inside components 3
Vibrational loads 3

Mechanical damage in the components 4

Reduced efficiency of the system 3

Damage and reduced lifecycle of the component 4

Loads induced by vibration 3

Reduced efficiency in transmitting loads 3

Damage into the components 3
Failure of the system 4
 Oil in bad condition (particles and impurities) 3

Failure of the system 5

Compromise the behaivor of the pitch system 4

Compromise the behaivor of the pitch system 3

Overpressure of the system 4

Overheating of the system 3

Compromise the behaivor of the pitch system 3
3
Reduced efficiency in transmitting loads
4

Particles inside the hydraulic oil 4

Particles inside the hydraulic oil 4

Reduced efficiency 4

Mechanical failure of the actuator 5

Failure of the cylinder 5

Failure in the actuator 5

Reduced efficiency 4

Failure in the actuator 5

Leakage and maybe damage in the surroundings 3

Failure of the piston rod 5
Failure of the barrel 5

Reduced overall system efficiency 4

 Reduced overall system efficiency 4

Reduced overall system efficiency 4

Mechanical damage per stroke 4

Stoppage of the system 3

Reduced overall system efficiency 4

Wear acting on the components 4

Leakage and maybe damage in the surroundings 5

Lost control of the system 4

Lose system efficiency 3

Lost control over the pitch system 5

Lose system efficiency 3

Addition of particles inside the hydraulic oil 3

Reduced lifecycle of the component 3
Reduced efficiency 3

Overpressure of the system 4

Lost of the current path from the system and beyond 4

Inconsistency in the electrical system 3

Fisical damage due to the malfunction of the controlling 4

Reduced confiability with the values displayed by the sensor 3

Reduced confiability with the values displayed by the sensor 3

Oscilating measurements 3

Sticking system 4

Reduced actuator efficiency 3

Lost stability between valve control and oil flow 3

 K

Potential Cause(s)/ Mechanism(s) of Failure

Wrong direction of pump rotation

Low oil level
Wrong type of oil
Pump running too fast
Reservoir air vent plugged
Reservoir not vented
Air leak in suction line
Air leak in case drain line
Air leak around shaft packing
Air bubbles in intake line
Restricted flow through suction piping
Air bound pump
Slip line (case drain) does not terminate below oil level
Worn pressure ring
Restricted filter or strainer
Sticking vane
Coupling misalignment
Worn or broken parts
Pump operated at higher pressures than required
Pump discharging through relief valve
Pump not unloaded during idle periods of the windturbine operating cycle
Excessive pump slippage
Excessive friction
Restricted or undersize valves on hydraulic lines
Excessive system leakage through cylinders or valves
High ambient or radiant temperature
Pump drain line too close to pump suction line returning heated oil back into the pump
Insufficient cooling facilities
Reservoir too small
Low oil in reservoir
Pump not delivering oil
Pressure adjusting screw not set high enough
Pressure being relieved through relief valve
Oil bypassing to reservoir
Pressure ring sticking
Governor piston sticking
Defective pressure gauge
Gauge line is shut off
Vane or vanes stuck in rotor slots
Pump running too slowly
Adjusting screw for pressure adjustment too loose
Wrong direction of pump rotation
Oil level low in reservoir
Pump running too slowly
Air leak in suction line
Oil viscosity too heavy for proper priming
Maximum volume control turned in too far
Bleed-off in other portion of circuit
Suction line or suction filter plugged
Pump cover too loose
Broken pump shaft or rotor
Sheared key at rotor or coupling
Pump shaft turning too slowly
Pressure ring sticking
Abrasives on pump shaft
Packing damaged at installation
Scratched or damaged shaft seal
Coupling misalignment
Pressure in pump case
Oil too hot
Dirt or chips under vanes holding pressure ring on center
Governor piston stuck
Pressure ring sticking
Chips or other foreign matter in bearings
Coupling misalignment
Excessive or shock loads
Electric motor shaft end play or driving or hammering coupling on or off pump shaft
Overhung load
System excessively hot
Incorrect fluid
Motor not properly sized for pressure and volume requirements
Pump delivering full volume through relief valve
Excessive internal slippage in pump
Starting pump with full pressure and volume
Motor overload protection undersized
Low voltage
Motor wired for wrong voltage
Coupling misaligned
Motor or coupling worn or damaged
Fluid heated
Relief or unloading valve set too high
Excessive load
Worn or damaged motor
Corrosion
Dirt and debris trapped in valve seat
Line pressure too high
Mechanical damage
Valve spool binds in the body
Cylinder leaks
Oil viscosity is too high
Pressure drop is insufficient across a valve
Oil is dirty
Valve’s poppet or seat is worn
Oil is dirty
Valve was not adjusted properly
Valve-piston travel is restricted
Passages or orifice is restricted
Valve piston is cocked
Relief valves leak
Oil is too hot
Pump speed is improper
Hydraulic functions are holding in relief
Connections are incorrect
Contamination of the oil
Contamination of the gland bearing
Gland bearing failure
Contamination of the oil
Piston bearing failure
Operation problem
Possible overload
Outside impact
Under specification of piston rod
Shock loading
Poor original weld
Shock loading
Under specification of bearing
Overloading of cylinder
Lack of bearing support
Too much side load
Rod too small
Possible intensification of internal pressure
Threads worn
Deformation of cylinder tube
O-ring failure
Cracked gland
Corrosion
Water in the oil
Incorrect seals fitted
Seal grooves corroded or marked
Air trapped in the oil
Incorrect metalwork clearances
Contamination of the oil
Seals fitted incorrectly
Seal housing sizes incorrect
Internal leakage
Internal bearing wear
Incorrect alignment of piston to gland
Internal leakage
Port blockage
Internal leakage
Hydraulic pump failure
Valve settings incorrect
Lack of lubricant for the gland bearing & seals
Not inserted deeply enough
Damage in the shell fitting
Overpressure in the system
Heat exceeding the maximum recommended temperature
Aerated oils cause oxidation
Combination of oxygen and heat
Cavitation create the same effect
Ozone exposition
Crimped too much or too little in the assembly
Hose exceeded its service life
High number of pressure cycles
Continuous flexing of the hose
Inner tube damaged during fitting
Lack of lubrication in the assembly
Allowed moisture to enter around the fitting socket
Corroding the reinforcement wires
Fluid is incompatible with the inner tube material
Fluid is incompatible with the inner tube material
There was a vacuum failure
Hose been kinked
Flattened
Bent too sharply
Short-circuit in the wiring
Brushes
Slip rings
Tower wiring
Rectifier or controller
Alternator windings
Blown diode in the rectifier
Multiple grounding
Battery voltage falls
Discharge or failure
Higher possibility of rupturing pressure relief discs or vessels
More errors from load disturbances
Increased dead time
More oscillations in the control loop
Increased control variance
Process cycling around the setpoint
Slower controller responses
Increased control variance
Sticky valve internals
Media viscosity
Tight shutoff
Undersized actuators
Deadband
Hysteresis
Stiction
 Potential
Failure Mode and Effects Analysis
(Risk FMEA)
Key Date 12/8/2016

P D R
r
o Current Process Controls e P
t N
b
2 Test and inspect the system before startup 1 6
2 Visual inspection or level sensor 2 12
1 Verify the right lubrication oil with the manufacturer 3 9
2 Check the designed range matches with the operational 2 16
2 Sealing inspection 3 24
2 Verify the venting 3 24
3 Inspection for leakages 4 12
3 Inspection for leakages 4 36
3 Inspection for leakages 4 36
3 Visual inspection for holes and leakages 4 36
3 Visual inspection inside and damage/bending outside 3 27
3 Check oil level 3 27
2 Quality control of the wear due to inspection 3 18
3 Schedule maintenance for replacement 2 18
3 Inspection in sealing and operational conditions 3 27
3 Check inside conditions 2 18
2 Alignment inspection 4 24
3 Schedule maintenance over the parts 2 18
3 Check for obstructions or valve related failures 3 27
2 Evaluate the suitability of the relief valve 3 18
2 Inspection after the stoppage of the turbine 3 18
2 Monitoring the pump operation 4 24
3 Inspection in the oil searching for wear fragments 2 24
2 Check inside conditions 3 24
4 Check valves and cylinders 1 16
3 Monitoring ambient temperature 3 45
3 Change in the design or add heatexchanger to system 4 48
3 Instalation of enviroment controlers 4 48
2 Check compatibility of the reservoir volume 4 24
3 Inspection searching for the causes of low level 3 27
2 Inspection in the pump 1 10
3 Check the adjusting screw in the assembly 3 36
2 Inspection over the suitability of the relief valve 3 24
2 Check with the manufacturer before start-up 3 24
4 Monitoring the system due to leakages 3 48
3 Check oil conditions inside the system 3 36
3 Inspect and replace the component 2 24
3 Inspect and repair the system 3 36
2 Search for oil problem or mechanical 3 24
3 Inspect the system for the causes 2 24
3 Scheduled inspections in the adjusting screw 3 36
2 Better folow up procedures 2 8
3 Inspect the reservoir and the level gauge 3 12
3 Inspect the system for the causes 2 24
3 Check sealing and leakages in the system 3 36
3 Inspect the system for the causes or add a heater 3 36
2 Inspect the valves and their control setup 1 8
2 Inspect the system for the reason of this bleed-off 4 32
4 Check the oil conditions or mechanical obstructions 3 48
3 Maintenance to tight the cover 2 24
2 Inspect for the damage causes and replace component 1 10
3 Inspect the source and replace the component 1 9
3 Check the setup or system problems 2 18
3 Check oil or mechanical damages 3 27
4 Inspect for excessive wear inside the system 4 48
2 Update procedures to avoid this failure 4 32
2 Inspect the causes and replace the component 4 32
3 Search for the cause and maybe vibrational analysis 4 48
3 Check operational parameter and match with design 3 36
3 Inspect the causes 3 27
3 Check for sealing problems and mechanical wear 4 48
2 Inspect oil, sealing, filter and wear 3 18
3 Inspect oil, sealing, filter and wear 3 27
3 Check bearing sealing 4 36
3 Search for the cause and maybe vibrational analysis 4 36
4 Identify causes and mitigate 4 64
2 Identify causes and mitigate 4 32
4 Monitoring the system behaivour and identify causes 4 64
3 Inspect the causes 3 27
2 Replace the fluid and update procedures 4 24
2 Inspection over the design requirements 4 32
2 Inspection over the relief valve 2 8
2 Monitorng loads and bearing 3 24
3 Consistent manual of procedures 3 36
2 Inspection over the design requirements 4 32
3 Monitoring the setup of the system 3 36
2 Inspection after the assembly 4 32
3 Alignment inspection 3 27
2 Identify causes and replace component 4 24
3 Monitoring the fluid temperature 3 27
3 Calibrate to the right position 2 18
3 Identify causes and mitigate 4 36
2 Identify cause and replace component 4 32
3 Inspect the oil 3 27
3 Monitoring the amount of wear particles in the oil 3 27
2 Monitoring the system pressure 2 20
2 Scheduled maintenance to identify earlier the damage 3 30
3 Check for obstructions, damage or oil quality 3 36
3 Scheduled maintenance to identify earlier the damage 3 36
3 Inspect filter, sealing and the oil itself 3 36
2 Changing of the control logic 4 32
3 Inspect oil and filter 3 36
3 Scheduled maintenance to identify earlier the damage 3 27
3 Inspect oil and filter 3 27
2 Improve maitenance procedures 3 24
3 Check oil or mechanical damages 4 48
3 Check oil or mechanical damages 4 48
3 Verify the sealing and the filter 3 36
2 Check the sealing components 3 18
3 Inspection for leakages 3 27
2 Verify the settings of the pump speed 2 12
3 Check the instalation of the valves 3 27
1 Inspection over the assembly and connections 3 12
3 Verifying during the programmed inspections 3 36
3 Verifying during the programmed inspections 3 36
2 Monitoring the bearing 2 16
3 Verifying during the programmed inspections 3 36
2 Monitoring the bearing 2 16
3 Cover with scheduled maintenance 3 36
2 Monitoring the system behaivour and identify causes 3 24
2 Identify source and mitigate 2 20
1 Replace and inform the manufacturer 2 10
2 Monitoring the system behaivour and identify causes 3 30
2 Replace and inform the manufacturer 2 20
2 Monitoring the system behaivour and identify causes 3 30
1 Replace and inform the manufacturer 2 10
3 Monitoring the system 3 45
2 Disassembly and make a better support 4 32
2 Redesign of the assembly 4 32
1 Replace the component and inform the manufacturer 3 12
3 Monitoring the system 3 45
3 Replace and identify sources 2 30
3 Replace the component 3 45
3 Replace the component 2 18
3 Replace the component 2 18
3 Inspection over the surface of the components 3 45
3 Monitoring the sealing and filtering system 3 45
2 Inspection and replace 2 16
3 Replace the component and identify the source 2 24
3 Inspection over the filtering system 3 36
2 Verified during inspections 3 24
3 Inspection over the filter, wear and leakages 2 24
2 Disassembly and make a better fitting 4 32
1 Verified due to inspection 3 12
2 Monitoring the sealing 3 24
3 Monitoring the bearing 2 24
2 Inspect the assembly 3 24
3 Monitoring the sealing 3 27
2 Regular inspection over the internal conditions 4 24
3 Monitoring the sealing 3 36
2 Monitoring the pump behaivor 3 24
1 Resetting of the valves 4 16
3 Monitoring quality and level of the oil 3 36
2 Scheduled maintenance over the components 2 20
3 Visual inspection 3 45
3 Monitoring the pump operation and pressure sensor 3 45
3 Analysis to identify the sources of the problem 4 48
4 Inspection in the valves and sealing 3 48
4 Inspection over the sealing and temperature monitoring 3 48
3 Monitoring of the pump operation 4 48
3 Inspection over the possible sources from ozone formation 4 48
3 Inspection after every reassembly 3 27
3 Scheduled maintenance to replace the component 3 45
3 Monitoring the pressure of the system 4 60
3 Verify the dynamical behaivor of the hose after installation 2 30
3 Follow the adequate manual of procedures during fitting 4 36
2 Follow the adequate manual of procedures during assembly 4 24
4 Regular inspection of the sealing 3 36
3 Control of the enviroment to avoid corrosion 2 18
3 Check with the manufacturer before start-up 3 27
3 Check with the manufacturer before start-up 3 27
2 Monitoring system pressure and sealings 3 18
3 Visual inspection over the hope 2 24
3 Visual inspection over the hope 2 24
2 Visual inspection over the hope 1 8
2 Inspection over the generator 3 24
3 Inspection over the generator 3 36
3 Inspection over the generator 2 24
2 Inspection inside the tower 2 16
3 Inspection over the electrical chain 3 36
3 Inspection over the generator 2 24
3 Inspection over the electrical chain 3 36
1 Inspection over the electric circuit 4 16
3 Check by sensor the status of the battery 2 18
3 Scheduled maintenance over the components 2 18
2 Inspection over the system pressure with optimum sensor 4 32
3 Changing of the control logic 3 27
3 Inspection over the component sensor 4 36
3 Changing of the control logic 3 27
3 Changing of the control logic 3 27
2 Inspection over the component sensor 3 18
3 Changing of the control logic 3 27
3 Changing of the control logic 3 27
3 Inspection over the valves 3 36
3 Verification of the compatibility of the media 2 24
2 Check the sliding bar 3 24
3 Contact the manufacturer over the suitability 2 18
3 Inspection over the outputs 3 27
2 Check for deviations around one target value 2 12
3 Inspection in the sensor surroundings 4 36
 Recommended Responsibility & Target
Action(s) Completion Date

Check after each disassembly André; 06/12/2016

Verify the sensor calibration André; 06/12/2016
Better documentation for the oil replacement André; 06/12/2016
Elaborate a operational routine André; 25/01/2016
Improve the verification of the sealing André; 25/01/2016
Automatization of the venting status André; 25/01/2015
Increase the effort to reduce leakage André; 25/01/2015
Increase the effort to reduce leakage André; 25/01/2015
Increase the effort to reduce leakage André; 25/01/2015
Increase the effort to reduce leakage André; 25/01/2015
Monitoring by intake pressure behaivor André; 12/02/2016
Increase the maitenance over level sensor André; 12/02/2016
Improve the inspection André; 12/02/2016
Change the supplier of the rings André; 12/02/2016
Verify the oil operational conditions André; 12/02/2016
Contact the manufacturer André; 12/02/2016
Decrease the calibration time Fawzy; 15/03/2016
Increase the quality of the monitoring Fawzy; 15/03/2016
Improvement of the inspection Fawzy; 22/02/2015
Contact the manufacturer of the Hydraulic pitch Fawzy; 22/02/2015
Check to unload pump Fawzy; 22/02/2015
Reduce the time beetwen inspection Fawzy; 22/02/2015
Improve the oil inspection André; 02/03/2014
Service inside or manufacturer contact André; 02/03/2014
Improve inspection for leakage André; 02/03/2014
Build a control logic to better control this parameter André; 02/03/2014
Better selection of the system since the beginning André; 02/03/2014
Perceive this problems before start up André; 02/03/2014
Add this new better size in the maintenance part list Fawzy; 17/03/2015
Verify the sealing Fawzy; 17/03/2015
Verify for leakage, obstruction and damage André; 12/07/2015
Implement procedures to avoid this problem André; 12/07/2015
Check the connections and update procedures André; 12/07/2015
Find out the reason for the fail André; 12/07/2015
Scheduled maitenance for leakages André; 12/07/2015
Check filter, leakages and oil used André; 12/07/2015
Verify the causes and update procedures André; 12/07/2015
Check for the conditions of the failure André; 12/07/2015
Update procedures if the fail occurs often André; 12/07/2015
Check the control instrumentation André; 12/07/2015
Check procedures during the assembly Fawzy; 27/05/2015
Check the controlling setup Fawzy; 27/05/2015
Check the component and the controller Fawzy; 27/05/2015
Check obstructions, mechanical damage, controller Fawzy; 27/05/2015
Check for damage in the suction line Fawzy; 27/05/2015
Check contaminants inside the system Fawzy; 27/05/2015
Verify the sealing and filter mainly André; 13/06/2015
Inspect the circuit to find source of leakage André; 13/06/2015
Check filter and sealing also André; 13/06/2015
Check the assembly of the cover André; 13/06/2015
Failure analysis over the shaft André; 13/06/2015
Inspection at the causes that shear the key André; 13/06/2015
Inspection in the power system and pump Fawzy; 01/02/2014
Verify the causes and update procedures Fawzy; 01/02/2014
Check contact between moving components Fawzy; 05/07/2014
Check procedures during the assembly Fawzy; 05/07/2014
Check the causes to the failure Fawzy; 05/07/2014
Vibration analisys proposed Fawzy; 05/07/2014
Vibration analisys proposed Fawzy; 05/07/2014
Change the instrumentation that monitors temperature Fawzy; 05/07/2014
Check procedures during the assembly André; 22/05/2016
Update procedures if the fail occurs often André; 22/05/2016
Verify the causes and update procedures André; 22/05/2016
Require more tests from the manufacturer André; 22/05/2016
Alignment service André; 22/05/2016
Inspection in the loads acting on the shaft André; 22/05/2016
Inspection in the alignment of the component André; 22/05/2016
Check the conditions to overload Fawzy; 11/03/2015
Check the oil film Fawzy; 11/03/2015
Check with manufacturer Fawzy; 11/03/2015
Replace the component and contact the manufacturer Fawzy; 05/07/2015
Improve the procedures over the relief valve inspection Fawzy; 05/07/2015
Implement a better method to control the loads Fawzy; 05/07/2015
Better follow up for the maintenance staff Fawzy; 05/07/2015
Require more tests from the manufacturer Fawzy; 05/07/2015
Check for right voltage in the control system Fawzy; 05/07/2015
Replace the component and contact the manufacturer Fawzy; 05/07/2015
Update procedures if the fail occurs often André; 13/07/2015
Vibration analisys proposed André; 13/07/2015
Change the instrumentation that monitors temperature Fawzy; 15/09/2015
Hire a third party company to calibrate Fawzy; 15/09/2015
Search for back reactions in the pump system Fawzy; 15/09/2015
Check for vibration, contact and corrosion Fawzy; 15/09/2015
Change the oil and inspect sealings and filter André; 22/05/2016
Verify the possible cause inside the system André; 22/05/2016
Stop the system to avoid damage and verify André; 22/05/2016
Identify the source and replace the component André; 22/05/2016
Stop the system to avoid damage and verify Fawzy; 05/07/2016
Replacement of the cylinder and improve procedures Fawzy; 05/07/2016
Identify if the cause is chemical, by heating or another Fawzy; 05/07/2016
Identify if the cause is mechanical or by controlling Fawzy; 05/07/2016
Inspect sealing and filtering but also mechanical wear Fawzy; 05/07/2016
Replace the component and identify causes André; 02/04/2015
Replace the components and identify causes André; 02/04/2015
Improve adjust of the components Fawzy; 17/03/2014
Stop the system to avoid damage and verify Fawzy; 17/03/2014
Search for the causes and update procedures Fawzy; 17/03/2014
Inspect the causes and change the component Fawzy; 17/03/2014
Check relief valve and if necessary replace Fawzy; 17/03/2014
Verify the causes and update procedures Fawzy; 17/03/2014
Check if the reason is mechanical or instrumental André; 15/07/2015
Inspection for damages in the valves André; 15/07/2015
Check the connections and update procedures André; 15/07/2015
Change the oil Fawzy; 11/11/2016
Change the oil Fawzy; 11/11/2016
Change the oil or the filter Fawzy; 11/11/2016
Change the oil or the filter André; 25/02/2014
Search for misalignments or replace oil André; 25/02/2014
Search in the operation the cause for bent Fawzy; 01/05/2015
Search and try mitigate the source of overload Fawzy; 01/05/2015
Investigate the surroundings Fawzy; 01/05/2015
Inform the manufacturer and replace Fawzy; 01/05/2015
Identify the source of the shock André; 15/06/2016
Inform the manufacturer and replace André; 15/06/2016
Identify the source of the shock Fawzy; 21/06/2016
Inform bearing manufacturer and replace Fawzy; 21/06/2016
Identify the source of the overload Fawzy; 21/06/2016
Inform the manufacturer and make a better support André; 25/06/2016
Inform the manufacturer and change the component André; 25/06/2016
Inform the manufacturer André; 25/06/2016
Inspect the causes and change the component Fawzy; 01/07/2015
Replace the component and previne the failure again Fawzy; 01/07/2015
Search for the cause and mitigate Fawzy; 01/07/2015
Avoid the same failure and replace the component André; 25/07/2016
Avoid the same failure and replace the component André; 25/07/2016
Analisys of the enviroment, oil and replace component Fawzy; 01/08/2016
Correct the sealing and filtering system André; 25/08/2015
Change the seals and improve the procedures Fawzy; 27/08/2015
Search for the root cause and replace component Fawzy; 27/08/2015
Correct the sealing and filtering system Fawzy; 27/08/2015
Replace and inform the manufacturer Fawzy; 27/08/2015
Find the source of contamination and mitigate Fawzy; 27/08/2015
Improve the procedures to avoid the failure again Fawzy; 27/08/2015
Replace and inform the manufacturer Fawzy; 27/08/2015
Find the source of heating in the cylinder and solve André; 05/09/2014
Replace the bearing and identify the cause Fawzy; 02/10/2014
Correct the alignment if not possible replace Fawzy; 02/10/2014
Find the source of the leakage and solve or replace André; 05/10/2014
Find the source of the stuck and solve or replace André; 05/10/2014
Find the source of leakage and solve Fawzy; 03/11/2016
Find the failed part and repair the system Fawzy; 03/11/2016
Inform the manufacturer and replace Fawzy; 03/11/2016
Improve the procedures to avoid this error André; 05/11/2015
Elaborate a procedure to the propper fitting Fawzy; 03/04/2015
Protect the fittings or purchase better ones Fawzy; 03/04/2015
Define an acurate range for system pressure Fawzy; 03/04/2015
Thermal cam to find the hot spot André; 05/02/2014
Filtering system with gas removing André; 05/02/2014
System setup to avoid the misture André; 05/02/2014
Increase the pressure in the suction line André; 05/02/2014
Analisys of the actual hope state André; 05/02/2014
Elaborate a procedure to the propper fitting André; 13/06/2015
Replace the component or purchase more durable Fawzy; 23/05/2016
Intervention if the pressure keeps out of range Fawzy; 23/05/2016
Intervene in the cause of the movement Fawzy; 23/05/2016
Follow the procedures manual André; 07/07/2016
Follow the manual to lubrication at assembling André; 07/07/2016
Test the sealing after each disassembly André; 07/07/2016
Laboratory test with the hope and lubricant André; 07/07/2016
Replace the oil or the hope Fawzy; 13/09/2015
Replace the oil or the hope Fawzy; 23/01/2015
Elaborate procedures to avoid this failure André; 17/02/2015
Assembly of the component due to procedure André; 17/02/2015
Assembly of the component due to procedure André; 17/02/2015
Assembly of the component due to procedure André; 17/02/2015
Replacement in wirings André; 18/11/2014
Scheduled maitenance of the brushes André; 18/11/2014
Reduce the time interval in the maitenance André; 18/11/2014
Measure across the tower to find the idle current André; 18/11/2014
Regular inspections over the converter André; 18/11/2014
Change the procedure to inspect the alternator André; 18/11/2014
Request for a more reliable rectifier André; 18/11/2014
Identify the source of the current leakage André; 18/11/2014
Verify the reason for the discharge André; 18/11/2014
Test the components André; 18/11/2014
Include in the system maintenance this procedure André; 18/11/2016
Use new filters to try reduce the load effects André; 18/11/2016
Test the sensor after every disassemble André; 18/11/2016
Adequate the new system responses to the sensor André; 18/11/2016
Use new filters in the logic André; 18/11/2016
Change the component for a new one Fawzy; 13/02/2014
Adequate the new system responses to the sensor Fawzy; 13/02/2014
Use new filters in the logic Fawzy; 13/02/2014
Maitenance over the sticking valves André; 28/01/2014
Contact the manufacturer about the hydraulic oil André; 28/01/2014
Change the procedures to validate this component André; 28/01/2014
Change the related control component André; 28/01/2014
Test the sensor before instal Fawzy; 28/01/2015
Suitability of the sensor and the system Fawzy; 28/01/2015
Improvement of the inspection routine Fawzy; 28/01/2015
 FMEA Number
Prepared By
FMEA Date
Revision Date
Page

Action Results

Actions Taken

Action included in the scheduled maintenance

Sensor analysis included beyond visual inspection
Elaboration of a new document profile for the lubrication
Installation of a speed sensor
Acquisition of sealing inspection system
Acquisition of vent monitoring equipment
Improvement of the sealing and increase number of leakage inspection
Improvement of the sealing and increase number of leakage inspection
Improvement of the sealing and increase number of leakage inspection
Improvement of the sealing and increase number of leakage inspection
Reformulation of the inspection over the pump intake
Reduce time intervals over the level equipment
Change in the inspection procedures according to better standards references
New contract with a company that provides better rings for the application
Replacement of the old oil
Agreement to change the component
Change in the procedures to short calibration intervals
Hire a third company to do specialized monitoring of the wear component
Better condition monitoring during operation
Exchange of the component
Unload pump
Implementation of the new schedule
Using of a more sensible method to detect wear in the oil
Service inside to remove obstrusion
Change in the scheduled maitenance for leakage
Implemented the new control logic
Replacement of the component by the manufacturer
Changes in the system parameters solved the problem
Replacement of the component
Identified problem was level sensor malfunction
The shaft failed and the component was replaced
New procedure added into the manual
Relief valve failed and was replaced
Poor design of the pitch system, replace of the system
Pressure ring replaced and new supplier contracted
Improper oil replaced and problems with sealing
Pressure gauge replaced
Mechanical damage due to overload and component replaced
Problem with wear and emulsion in the oil, component and oil replaced
The speed sensor failed the pump was operating right
Error in the assembly, update procedures to prevent
Error in the system operation, improve procedures
Level gauge damaged and replaced
Obstruction inside the system, replace the component
Corrosion and damage in the suction line, replaced
Environmental problems due winter, use heatexchanger or improve environment
Valve adjusted and new procedures released for maintenance
Leakage due to pitting damage in the system
Sealing was damaged and replaced
Assembly was done wrong and new procedures implemented to avoid error
Failed due impurities inside the steel that iniciate the crack, replaced
Overpressure of the system and replace the component
Failed rollers in the bearing, replaced component
Wrong selection in pressure ring, replace and change type
Agressive oil to some polymeric materials inside the system, replace oil and components
Over tension during installing, update procedures and orient technicians
Wrong heat treatment in the shaft, manufacture fault and replace of the component
Vibration caused contact and misalignments and wear of component
Vibration caused fail in valve and overpressure
Update procedures, thermal sensor was not calibrated
Wrong procedures in the assembly, update of the manual
Problem with wear and emulsion in the oil, component and oil replaced
Wrong selection in pressure ring, replace and change type
Bearing under designed
Failure due to bad foundation in the equipament
Shaft transmiting unexpected loads in the design to the bearing
Alignment was good the overheat increased the size and had hits
Unexpected overload by strong gust and component replaced
Flow speed not enought to keep the oil film in the bearing, increase speed
Fluid was contaminated before use, keep with the same oil and replace the old
Component replaced by the manufacturer
Update in the manual of procedures for the relief valve
New method based on standards implemented in the pitch system
Implementation of the new follow up
Manufacturer replaced the component and implement more tests
Logic implemented in the control system
Component replaced by the manufacturer
Elaboration and implementation of new alingment procedures
Performing a third company vibration analisys
New instrumentation purchased and installed
Instrument metrological tests made and proper calibration
Failure analisys over the pump system and found the source of damage
Vibration caused contact and misalignments and wear of component
Replacement in the deteriored oil and maitenance over sealing and filter
Problem with the filter and missalignments inside the pump
Replacement of one clogged hose
Damage in one screw and replacement of the component
Replace of the valve due to damage
Identified the source and replaced the component
Replace the oil and fix the source of the problem
Replace of the component It was a mechanical damage
Replacement of one weared component
Replacement of the component due fatige over pressure cycles
Problem with wrong filter element, filter replaced and procedures updated
Valve adjusted and new procedures released for maintenance
Damage in the components and replacement
Spoiled oil inside the system replaced
No need to change the component the problem was in the control system
No need to replace the valve was cleaned and the oil changed
Heatexchanger was not working properly
Pitting was found inside the components of the pump, replaced
The valves were working the assembly was wrong, corrected
Connections wrong and leakages, procedures updated
Oil was replaced
The problem was in the filtter and was replaced
Problem was in contact inside components. The part was replaced
Filter replaced
Misalignments corrected
Unexpected overload and the component was replaced
The control of the nacelle movement was not properly adjusted
Poor design of the pitch system, replace of the system
Replaced the old system for a new one
Non identified the source and component replaced, probably human failure
Component replaced
One gust with abnormal rate and component replaced
Bearing replaced
Material acummulation inside the cylinder by failure of the filter
New support solved the problem
Manufacturer informed and it was a design problem
Problem during the assembly by the manufacturer
Component replaced and oil stuck in the system
Component replaced and failed by fatige
Cylinder failed by buckling and component replaced
Overpressure of the system and component replaced
Overpressure of the system and component replaced
Due wear the material lost his protection and started the pitting
System not well sealed and water entered and mix with oil
Seals replaced and new procedures released
Corrosion over tension and replace of the component
New sealing and filtering system
Error in the manufacturer production and replace
Filter failure and abnormal wear inside the components
Corrected the fitting and release of the new procedures
Incorrect seals replaced by the manufacturer
Excesive friction due to low lubrication of the piston rod
The roller was damaged due to abnormal alternating loads
Alignment corrected and component replaced
The piston got stucked with a mix of bad oil and a failed cylinder
Damage close the path to the piston move
Hole near the gland and component replaced
Bearing failed due to missalignment during instalation
Wrong valves for the application and manufacturer exchange
System lost much oil due leakage without be detected
Manual updated with the new procedures
New fittings purchased
New setup to work within the pressures
Hired a company to identify the thermal spots with termocam
Replaced the old system for a new one
The steps in the manual were changed
Changed the setup of the valve to work with more pressure
Replacement of the hope for one better to work with ozone
New procedure added into the manual
Purchased other kind of hose
Replace of the control valve of the system
Add some dampers to reduce the vibration of the assembly
Replace of the hope and update in the procedures manual
Update in the procedures manual
Change of the model of the seal due to a design error
Better solution to replace the hope for a better resistent one
The hope and fluid were incompatible and the hope was changed
The hope and fluid were incompatible and the hope was changed
Manual with new procedures released
Acquisition of a fixing system for the hope beyond the manual procedure
Acquisition of a fixing system for the hope beyond the manual procedure
Acquisition of a fixing system for the hope beyond the manual procedure
Purchase a new on and learn from errors about the failure
Replace the failed component
Contact the manufacturer about the premature fail of the component
Start the maitenance to replace the wiring leakage of power
Replacement of the failed component
Replacement of the failed component
Contact the manufacturer informing the problem
Replacement of the damaged isolation
Replace the battery and monitoring the system
Replacement of the wires with damaged cover
Update of the new maintenance schedule
Changing in the control setup
Modification of the folow up in the maintenance of the component
Change the system response in the maitenance
Replacement of the component due to inviability to change the filters
Replacement of the component made by the manufacturer
Change the system response in the maitenance
Replacement of the component due to inviability to change the filters
Replacement of the failed sealing
Replacement of the hydraulic oil
Modification of the folow up in the maintenance of the component
Purchase of the component with a new manufacturer due incompatibility
Tests are now done in the disassemble and inspections
Replacement of the sensor and decreased calibration intervals
Implementation of the new inspection routine and replacement of the sensor
 678546

ANDRÉ AND FAWZY

5/10/2015

12/8/2016

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New RPN
New Occ
New Sev

New Det

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