Power Management Failure Mode & Defect Analysis

Introduction

FMEA Training, Failure Mode and Effects Analysis training program will cover the procedures, tools, and methods on how to identify potential modes of failure prior to the launch of a new product/system or modifying an existing one. Attendees will learn how to choose tools and manage projects and teams to effectively carry out FMEA processes. FMEA training will teach the attendees how to reduce the organization’s risk of costly mistakes and how to identify potential modes of failure before launching a new product or modifying an existing one. FMEA is used to anticipate modes of failure and mitigate potential risks. This training course will be conducted as per standard IEC60812 and cover how to plan, perform, document, and maintain Failure modes and effects analysis (FMEA) including the failure modes, effects, and criticality analysis. This course will cover FMEA of electric generators, power transformers, distribution systems/switchgear, power cables/overhead lines, motors, & electric Capacitor banks.

Objectives

At the end of the course, participants will be able to:

• Increase quality, reliability, manufacturability, serviceability, and safety of products
• Ensure the linkage between components, systems and vehicles
• Maintain defect-free product launches
• Prove product and process-related risk analysis in the case of product reliability.
• Reduce warranty and goodwill cost
• Learn FMEA of Electric Generator
• Learn FMEA of Power transformer
• Learn FMEA of Underground Cables & Overhead Lines
• Understand the FMEA of Switchgear
• Understand FMEA of Electric Motors  Understand FMEA of Capacitor Bank

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practices. Participants will have the opportunity to share with the facilitator and other participants what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS Teams/ClickMeeting.

Who Should Attend?

FMEA training is a recommended training course designed for:

• System and software engineers
• System designers
• Electrical Engineers
• Electrical Technicians
• Process Engineer
• Manufacturing supervisor
• Operators
• Quality Engineers &Technicians
• Safety Engineers & Technicians
• Product engineer

Course Outline

Day 1: Introduction to FMEA

• Definition and description of terms and classification
• Risk priority numbers calculation
• Scaling of Severity, Occurrence, and Detection
• Algorithm/methodology of FMEA
• Carrying out an FMEA
• FMEA Standards
• How FMEA is used
• FMEA Process
• FMEA Reporting
• Evaluating the Effects of Each Failure Mode on Your System
• Failure Detection Methods and Corrective Actions Steps in the FMEA Process
• Failure modes (What could go wrong?)
• Failure causes (Why would the failure happen?)
• Failure effects (What would be the consequences of each failure?)
• FMEA Matrix
• Severity
• Probability of occurrence
• Probability of detection

Day 2: Inside FMEA Matrix

• How to Complete a Process FMEA
• Failure Mode
• What could go wrong?
• Failure Causes
• Why would the failure happen?
• Failure Effects
• What would be the consequences of failure?
• Likelihood of Occurrence
• Likelihood of Detection
• Severity Risk Priority Number (RPN)
• Likelihood of Occurrence
  • Likelihood of Detection
  • Severity FMEA Applied
• Typical Tools Used in FMEA
• Teams and Team Mechanics of FMEA
• Concept FMEA
• System FMEA
• Design FMEA Service FMEA
• Machine FMEA

Day 3: FMEA Case Studies and Workshops FMEA of Electric Generators

• Rotor tooth-top cracking and dovetail cracking
• Rotor turn insulation migration
• Stator core damage
• Partial discharge and vibration sparking
• Stator end turn vibration
• Bearing
• Field failure
• Other
• FMEA of Power Transformer
• Solid Insulation
• Oil insulation
• Windings
• Tank
• Bushing
• Core
• Diverter Switch

Day 4: FMEA of Circuit Breaker & Switchgear

• Open or shorted trip coil
• Inappropriate or adequate lubrication
• Loss of stored interrupting energy
• Mechanical failure
• Loss of vacuum
• Low gas pressure or density (air or SF6)
• Other
• FMEA of Underground Cables & Overhead Lines
• Interruption of current flow
• Short to ground
• Hot short
• Insulation resistance degradation
• Joint failure
• Termination failure
• Others

Day 5: FMEA of Electric Motors

• Noisy operation
• Motor overheating
• Overload tripping
• Bearing failure
• Stator Failure
• Rotor Failure
• Starting Failure
• Other
• FMEA of Capacitor Bank
• Open Circuit
• Insulating Liquid Leakage
• Bushing Degradation
• Fuse Failure
• Electrical Flashover of Support Insulators
• Others