Component failure modes & failure rates

Per-component reference pages: typical λ values from SN 29500 / IEC 62380 / OREDA, the dominant failure modes with root causes, detection and mitigation, and notes on how to represent each component in a fault tree. Click any card to drill in.

Electronic

Aluminium electrolytic capacitor

Polarised, large-value capacitor used for bulk filtering and energy storage.

Electronic

Multi-layer ceramic capacitor (MLCC)

Non-polarised, surface-mount capacitor used for decoupling and high-frequency filtering.

Electronic

Power MOSFET

Voltage-controlled switching transistor dominant in modern power conversion.

Electronic

Microcontroller (ARM Cortex-M class)

Programmable logic device that runs the safety-related software.

Electronic

Optocoupler (LED-phototransistor isolator)

Galvanic-isolation device combining an LED and phototransistor in a single package.

Electromechanical

Electromechanical relay

Mechanical contact switched by a solenoid coil.

Electromechanical

Brushed DC motor

DC motor using carbon brushes and a commutator to deliver current to the rotating armature.

Electromechanical

Solenoid valve

Coil-actuated valve for on/off process flow.

Sensor

Pressure transmitter (smart, 4-20 mA)

Process-mounted differential or gauge pressure sensor with integral electronics outputting 4-20 mA + HART.

Sensor

PT100 RTD temperature sensor

Platinum-resistance thermometer with 100 Ω resistance at 0 °C following the IEC 60751 curve.

Process / rotating

Centrifugal pump (general service)

Rotating impeller in a volute casing; the workhorse of process plants for moving liquid.

Process / rotating

Pressure relief valve (PRV)

Spring-loaded valve that opens at a set pressure to vent overpressure to a safe location.

Process / rotating

Shell-and-tube heat exchanger

Static heat-transfer device with one fluid in tubes and another in the shell.

Mechanical

Rolling-element ball bearing

Universal element wherever a shaft rotates with low friction.

Mechanical

Industrial gearbox

Power-transmission unit reducing motor speed to driven-equipment speed (or stepping up where needed).