Guidance Notes on Failure Mode and Effects Analysis (FMEA ...

1 Guidance Notes OnFailure Mode and Effects Analysis (FMEA) forClassificationMay 2015 Guidance Notes ONFAILURE MODE AND Effects Analysis (FMEA) FORCLASSIFICATIONMAY 2015 American Bureau of ShippingIncorporated by Act of Legislature ofthe State of New York 1862 2015 American Bureau of Shipping. All rights Plaza1701 City Plaza DriveSpring, TX 77389 USAF orewordABS requires clients to develop and submit FMEAs as part of Classification requirements for selectsystems. For instance, FMEAs are required for achieving many of the special or optional Classificationnotations such as CDS, ACC, ACCU, R1, RQ, DPS-2, DPS-3, ISQM. This document providesguidance and insight into the development process for FMEAs to comply with ABS Classification rulerequirements.

2 The utilization of this Guidance will provide tangible benefits as the marine and offshoreindustry is able to realize the positive results of FMEAs that are developed correctly and managedappropriately 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 incidentsThese Guidance Notes become effective on the first day of the month of are advised to check periodically on the ABS website to verify that this version ofthese Guidance Notes is the most welcome your feedback.

3 Comments or suggestions can be sent electronically by email of UseThe information presented herein is intended solely to assist the reader in the methodologies and/ortechniques discussed. These Guidance Notes do not and cannot replace the Analysis and/or advice of aqualified professional. It is the responsibility of the reader to perform their own assessment and obtainprofessional advice. Information contained herein is considered to be pertinent at the time of publication,but may be invalidated as a result of subsequent legislations, regulations, standards, methods, and/or moreupdated information and the reader assumes full responsibility for compliance. This publication may not becopied or redistributed in part or in whole without prior written consent from Guidance Notes ON Failure MODE AND Effects Analysis (FMEA) FOR CLASSIFICATION of Process in a 1 Index of System-Specific Guidance for ABS 1 Process Flow for Classification Required the for the Philosophy and Scope and Ground Scope and Physical Boundaries (Global and Local).

4 Criteria and Types of of Ranking (FMECA).. Naming Convention within this Coast Guard Supplemental Requirements forQualitative Failure Analyses (QFA)..193 FMEA s Workshop FMEA Practitioner(s).. Participation in the FMEA 214 Ideal Timing to Conduct Notes ONFAILURE MODE AND Effects Analysis (FMEA) FORCLASSIFICATIONABS Guidance Notes ON Failure MODE AND Effects Analysis (FMEA) FOR CLASSIFICATION 2015iiiTABLE 1 Typical Corrective Actions to Control Failure 2 Examples of System/Subsystem s Physical Boundaries(for a DP System)..14 FIGURE 1 Typical Risk Matrix for 19 SECTION3 Developing the the Collection to Support the Risk Analysis as Input to the the the Analysis Failure Failure Detection Existing Risk Control Ranking (for FMECA).

5 Corrective 1 Risk Analyses that could Provide Input Information toan 2 Sample FMEA/FMECA 3 Sample Failure Modes of Mechanical and 1 FMEA Study 26 FIGURE 2 Reliability Block Diagram (or Dependency Diagrams)..27 FIGURE 3 Example of External/Operational Forces That MayImpact FMEA Report and Classification Review of 361 FMEA Internal Review Review of the and Common Problems in ClassificationSubmitted and Supporting Documentation 1 Sample FMEA Report Guidance Notes ON Failure MODE AND Effects Analysis (FMEA) FOR CLASSIFICATION 2015ivFIGURE 1 Sample Cause and Effect Verification of FMEA Verification Program Test FMEA Verification and Verification Program States Coast Guard Design Verification 1 Sample FMEA Verification Program Report Structure(for a DP FMEA).

6 46 FIGURE 1 FMEA Trial Test Sheet Lifecycle 491 Best Practices for FMEA as a Living Practices for FMEA as an Operations Practices for FMEA Lifecycle to the Classed System and FMEAR evisions and and Management of 1 Suggested Entries in Management of Change Form 51 FIGURE 1 FMEA Lifecycle FMEA for System-Specific FMEA (General Control, Safety-RelatedFunctions of Computer-Based Systems, WirelessData Communication, Integrated Automation Systems).. Controlled Diesel Control Propulsion [Automatic CentralizedControl (ACC), Automatic Centralized ControlUnmanned (ACCU), Automatic Bridge CentralizedControl Unmanned (ABCU)].. Propulsion and Pod Positioning Systems (DPS)..77 ABS Guidance Notes ON Failure MODE AND Effects Analysis (FMEA) FOR CLASSIFICATION Control Heavy Systems/Subsystems/Individual Drilling Fuel Diesel Engines (DFDE).

7 Compensation and Rope Tensioning Systemsfor 1 Index of FMEA Requirements in ABS Rules and 53 TABLE 2 Structure of the Guidance for Each FMEA 3 Sample DP FMEA Worksheet , Acronyms and and FMEA/FMECA FMEA/FMECA Worksheet Example (for ISQM and for CDS).. 135 TABLE 1 Example of BOP Control Functional 2 FMECA Worksheet Example (Select Sections of aFMECA for BOP Control System)..137 ABS Guidance Notes ON Failure MODE AND Effects Analysis (FMEA) FOR CLASSIFICATION 2015viSECTION 1 Introduction1 BackgroundIn the marine and offshore industry, design and equipment configurations vary from one system to thenext, and systems are in many cases increasingly complex. There are gaps in codes and standards whichmay lag technological innovations and there are issues related to interfaces between systems.

8 Risk analysessuch as Failure Modes and Effects Analysis (FMEAs) provide a formalized approach to identify hazardoussituations, address the gaps and interconnection variances, and improve safety, environmental performanceand operational requires clients to develop and submit FMEAs as part of Classification requirements for certainsystems and to obtain certain special notations. This document provides Guidance and insight into thedevelopment process for FMEAs to comply with ABS Classification Rule requirements for various specialnotations. The utilization of this Guidance will provide tangible benefits as the marine and offshoreindustry is able to realize the positive results of FMEAs that are developed correctly and managedappropriately throughout the lifecycle of a system.

9 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 Expedite the FMEA review process Reduce failures, downtimes, and incidents2 Purpose of FMEAsWhenever a system Failure could result in undesirable consequences such as loss of propulsion, loss ofpropulsion control, etc., best practices advise carrying out a risk Analysis , such as an FMEA, as an integralpart of the design and operational development process. This Analysis can be a powerful aid in identifyingpossible failures which could potentially leave a vessel, an offshore installation or its crew in ultimate goal of an FMEA from the point of view of Classification is to use it as supportingdocumentation to demonstrate compliance with the ABS design philosophy and related Classificationnotation requirements and design intent for the particular are instances where the goal of the vessel or asset owner is to have a comprehensive and systematicrisk-based approach to the design.

10 When such approach is taken, design choices are prioritized based onthe assessment of risks, thus the much broader FMEA goal is to identify and reduce a wider range of risksthat could arise from failures. The ISQM (Integrated Software Quality Management) for softwaredevelopment is an example of such risk-based design Guidance Notes ON Failure MODE AND Effects Analysis (FMEA) FOR CLASSIFICATION 201573 FMEA OverviewAn FMEA is a design and engineering tool which analyzes potential Failure modes within a system todetermine the impact of those failures. It was first developed by the US Department of Defense for use insystems design. The FMEA technique has since been adopted by commercial industries in an attempt tominimize failures and reduce safety, and environmental and economic impacts that could result from have more recently become a preferred risk Analysis tool in the marine industry.