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Dividing, Rosario

Loyao, Alger Jr.


Tandingan, Wayne Lorenz
Villasica, Serge Lorenz
Fault Mode and Effect Analysis
Detection
Occurrence
End Effects on Detection

Severity
Potential Failure Potential Causes of
Function/Requirement Local Effects Product, User, Method/ RPN
Modes Failure
Other Systems Current Controls

Raw Water Well and


Screen
Visual
Leakage Vessel Failure 1 Spill Economic loss 9 4 36
inspection
Store water
Plant operation is Visual
Leakage Loose Fittings 6 Spill 9 4 216
stopped inspection
Foreign object in Damage to Visual
Screen damaged 6 None 9 3 162
Remove foreign effluent equipment inspection
objects Visual
No effluent flow Screen clogged 8 No flow Economic loss 6 4 192
inspection
Low Lift Transfer
Pump
No electricity to Broken pump Plant operation is
3 No Flow 8 None 7 168
pump motor switch stopped
No electricity to Loose switch Plant operation is
1 No Flow 8 None 7 56
pump motor connection stopped
Supply electricity to No electricity to Plant operation is
Short in power line 2 No Flow 8 None 7 112
pump pump motor stopped
No electricity to Plant operation is
No power source 4 No Flow 8 None 7 224
pump motor stopped
Low current to Reduced Decreased
Low power source 2 7 None 7 98
pump motor Flow efficiency
Plant operation is
No rotation Motor Failure 4 No Flow 8 None 7 224
stopped
Plant operation is
Convert electric No rotation Obstruction 5 No Flow 8 None 7 280
stopped
power to rotation
Motor
No rotation Obstruction 5 Pump Damage 8 None 7 280
overheat
Rotor/shaft Reduced Decreased
Low Rotation 2 7 None 7 98
misalignment Flow efficiency
Rotor/shaft Reduced Decreased
Low Rotation 2 7 None 7 98
misalignment Flow efficiency
Foreign material Reduced Decreased
Low Rotation 4 7 None 7 196
trapped in pump Flow efficiency
Flocculation Tank
Plant operation is Visual
Leakage Vessel Failure 1 Spill 9 4 36
stopped inspection
Contain water
Plant operation is Visual
Leakage Loose Fittings 6 Spill 9 4 216
stopped inspection
Visual
No Flow Scaling 3 No Flow No liquid in tank 8 4 96
inspection
Liquid Inlet
Foreign material Visual
No Flow 6 No Flow No liquid in tank 8 4 192
trapped in pipe inspection
Visual
No Flow Scaling 2 No Flow No liquid in tank 8 4 64
inspection
Liquid Outlet
Foreign material Visual
No Flow 6 No Flow No liquid in tank 8 4 192
trapped in pipe inspection
Settling Tanks
Plant operation is Visual
Leakage Vessel Failure 1 Spill 9 4 36
stopped inspection
Tank Structure
Plant operation is Visual
Leakage Loose Fittings 6 Spill 9 4 216
stopped inspection
No liquid in settling Visual
No Flow Scaling 3 No Flow 8 4 96
tank inspection
Liquid Inlet
Foreign material No liquid in settling Visual
No Flow 6 No Flow 8 4 192
trapped in pipe tank inspection
No liquid in settling Visual
Liquid Outlet No Flow Scaling 2 No Flow 8 4 64
tank inspection
Foreign material No liquid in settling Visual
No Flow 6 No Flow 8 4 192
trapped in pipe tank inspection

Sediments not Buildup of 1


Tank 4 Overflow Cloudy Liquid 6 None 240
Collected sediments 0
Filters
Buildup of filter Pressure Increased pump Visual
No Flow 8 5 4 160
cake Buildup requirement inspection
Remove flocs from Pressure Increased pump Visual
No Flow Inefficient filters 6 5 4 120
water Buildup requirement inspection
Decreased Visual
More Flow Filter failure 7 Overflow 9 4 252
efficiency inspection
No liquid in settling Visual
No Flow Scaling 3 No Flow 7 4 84
tank inspection
Liquid Inlet
Foreign material No liquid in settling Visual
No Flow 6 No Flow 7 4 168
trapped in pipe tank inspection
Overflow of Visual
No Flow Scaling 3 No Flow 7 4 84
settling tank inspection
Liquid Outlet
Foreign material Overflow of Visual
No Flow 6 No Flow 7 4 168
trapped in pipe settling tank inspection
High Lift Pump
No electricity to Broken pump Plant operation is
3 No Flow 8 None 7 168
pump motor switch stopped
No electricity to Loose switch Plant operation is
1 No Flow 8 None 7 56
pump motor connection stopped
Supply electricity to No electricity to Plant operation is
Short in power line 2 No Flow 8 None 7 112
pump pump motor stopped
No electricity to Plant operation is
No power source 4 No Flow 8 None 7 224
pump motor stopped
Low current to Reduced Decreased
Low power source 2 7 None 7 98
pump motor Flow efficiency
Plant operation is
No rotation Motor Failure 4 No Flow 8 None 7 224
stopped
Plant operation is
No rotation Obstruction 5 No Flow 8 None 7 280
stopped
Motor
No rotation Obstruction 5 Pump Damage 8 None 7 280
Convert electric overheat
power to rotation Rotor/shaft Reduced Decreased
Low Rotation 2 7 None 7 98
misalignment Flow efficiency
Rotor/shaft Reduced Decreased
Low Rotation 2 7 None 7 98
misalignment Flow efficiency
Foreign material Reduced Decreased
Low Rotation 4 7 None 7 196
trapped in pump Flow efficiency
Backwash Pump
No electricity to Broken pump Plant operation is
3 No Flow 8 None 7 168
pump motor switch stopped
No electricity to Loose switch Plant operation is
1 No Flow 8 None 7 56
pump motor connection stopped
Supply electricity to No electricity to Plant operation is
Short in power line 2 No Flow 8 None 7 112
pump pump motor stopped
No electricity to Plant operation is
No power source 4 No Flow 8 None 7 224
pump motor stopped
Low current to Reduced Decreased
Low power sauce 2 7 None 7 98
pump motor Flow efficiency
Plant operation is
No rotation Motor Failure 4 No Flow 8 None 7 224
stopped
Plant operation is
No rotation Obstruction 5 No Flow 8 None 7 280
stopped
Convert electric Motor
No rotation Obstruction 5 Pump Damage 8 None 7 280
power to rotation overheat
Rotor/shaft Reduced Decreased
Low Rotation 2 7 None 7 98
misalignment Flow efficiency
Rotor/shaft Reduced Decreased
Low Rotation 2 7 None 7 98
misalignment Flow efficiency
Foreign material Reduced Decreased
Low Rotation 4 7 None 7 196
trapped in pump Flow efficiency
Clear Well/Contact
Tank
Plant operation is Visual
Leakage Vessel Failure 1 Spill 9 4 36
stopped inspection
Tank Structure
Plant operation is Visual
Leakage Loose Fittings 6 Spill 9 4 216
stopped inspection
Visual
No Flow Scaling 3 No Flow No liquid in tank 8 4 96
inspection
Liquid Inlet
Foreign material Visual
No Flow 6 No Flow No liquid in tank 8 4 192
trapped in pipe inspection
Visual
No Flow Scaling 2 No Flow Overflow in tank 8 4 64
inspection
Liquid Outlet
Foreign material Visual
No Flow 6 No Flow Overflow in tank 8 4 192
trapped in pipe inspection
High Level Reservoir
Significant DO in Adverse health Analytical
5 2 60
water effects Control
Rusting of the High PH in water Bad Water
6
pipeline due to excess Quality Adverse health Analytical
7 3 126
amount of Chloride effects Control
Pumping to Reservoir
ions
Leakage of the Mechanical Failure Waste of
4 Economic losses 5 Level Control 2 40
pipeline of pipeline water
Liquid hold-
No flow Failure of Pump 3 Spillage 6 Level Control 2 36
up
Leakage of the Mechanical failure Waste of
5 Economic losses 6 Level control 3 90
tank of tank Water
Storage in the
Particles High PH in water Harmful
Reservoir Analytical
apparent on the due to excess 1 spread of Corrosion 8 2 16
Control
water amount of PAC acid
Particles
Inadequate Bad Water Flow Control/
apparent on the 5 Off-spec product 4 4 80
filtration Quality Observation
water
Particles Malfunction in
Adverse health Flow Control/
apparent on the both settling and 1 Toxic effects 9 2 18
effects Observation
water filter processes
Air penetrates the Pressure
Bad Water
Bubbles present pump and through 4 Pump damage 2 Control/ 1 8
Quality
the pipeline Observation
Inadequate
Waste of
Low tank level pumping due to 3 Economic losses 3 Level Control 2 18
water
height
Low Level Reservoir
Significant DO in Adverse health Analytical
5 2 60
water effects Control
Rusting of the High PH in water Bad Water
6
pipeline due to excess Quality Adverse health Analytical
7 3 126
amount of Chloride effects Control
Pumping to Reservoir
ions
Leakage of the Mechanical Failure Waste of
4 Economic losses 5 Level Control 2 40
pipeline of pipeline water
Liquid hold-
No flow Failure of Pump 3 Spillage 6 Level Control 2 36
up
Leakage of the Mechanical failure Waste of
5 Economic losses 6 Level control 3 90
tank of tank Water
High PH in water Harmful
Leakage of the Analytical
Storage in the due to excess 1 spread of Corrosion 8 2 16
tank Control
Reservoir amount of PAC acid
Particles
Inadequate Bad Water Flow Control/
apparent on the 5 Off-spec product 4 4 80
filtration Quality Observation
water
Particles Malfunction in
Adverse health Flow Control/
apparent on the both settling and 1 Toxic effects 9 2 18
effects Observation
water filter processes
Air penetrates the Pressure
Bad Water
Bubbles present pump and through 4 Pump damage 2 Control/ 1 8
Quality
the pipeline Observation

Hazard and Operability Study


Deviation Cause Consequence Safeguards Action
Raw Water Well and
Screens
Effluent
No Flow Screen fully clogged Plant operation is stopped None Clean screen
Less Flow Screen clogged Economic Loss None Clean screen
Also Flow Screen damaged Damage to downstream equipment None Install second screen
Disinfectants
No flow Pump damaged Off-spec None Install secondary pump
No flow Source-related Off-spec None Monitoring
High flow Source-related Health hazard None Monitoring
PAC
No Flow Pump damaged Off-spec None Install secondary pump
Less Flow Source-related Off-spec None Monitoring
More Flow Source-related Health hazard None Monitoring
Influent/Tank
More flow Source-related Off-spec None Install secondary pump/ Inspect pumps
High level Overfilling Spills None Install secondary pump
Low level Source-related Economic Loss None Monitoring
Low Lift Transfer Pump
No Flow Foreign material trapped in pipe Pump damage None Install filter
No Flow Pump is off - no electricity Stopped operation None Inspect electrical connections
No Flow No venting Pump damage None Vent before startup
Less Flow Leakage Economic Loss None Repair leak source
Less Flow Low power supplied to pump Economic Loss None Inspect electrical connections
Less Flow Scale build-up Economic Loss None Clean pump
Fluctuation Flow Air binding Unreliable operation None Check for leakage
Flocculation Tanks
Influent/Tank
No flow Upstream pump problem Economic loss None Install secondary pump
Less flow Upstream pump problem Economic loss None Maintenance
Also flow Foreign object in stream Damage to downstream equipment None Check screen
High level Downstream pump problem Spills None Maintenance
Low level Upstream pump problem Agitator power wastage None Maintenance
Effluent
No flow Upstream pump problem Economic loss None Install secondary pump
Less flow Upstream pump problem Economic loss None Maintenance
Settling Tanks
No Flow Foreign material trapped in pipe Plant operation is stopped None Widen pipes
No Flow Pump is off Plant operation is stopped None Install secondary pump
No Settling Flow is turbulent Cloudy water None Reduce Flow
Less Flow Foreign material trapped in pipe Plant operation is stopped None Widen pipes
Less Flow Pump not working properly Plant operation is stopped None Install secondary pump
Less Settling Flow is turbulent Cloudy water/ Economic Loss None Reduce Flow
Less Level Leak Economic Loss None Regular maintenance
Less Level Less flow to tank Economic Loss None Inspect pumps
More Flow Pump damage Economic Loss None Install secondary pump/ Inspect pumps
More Flow Pump damage Economic Loss None Install secondary pump/ Inspect pumps
More Level Overfilling Economic Loss None INTAL high level alarm
More sediments No sediment collection Overflow/ Economic Loss None Regular maintenance
Also level Unexpected material in tank Economic Loss None Foreign material trap
Fluctuation Flow Pump malfunction Economic Loss None Inspect pumps
Flection Level Pump malfunction Economic Loss None Inspect pumps
Filters
No Flow Filter cake build-up Economic Loss None Inspect filters
Less Flow Filter cake build-up Economic Loss None Inspect filters
More Flow Filter malfunction Economic Loss None Inspect filters
Also Flow Filter malfunction Economic Loss None Inspect filters
Other Flow Filter malfunction Economic Loss None Inspect filters
Other Composition Filter malfunction Economic Loss None Inspect filters
Early Flow Filter malfunction Economic Loss None Inspect filters
Late Flow Filter cake build-up Economic Loss None Inspect filters
Clear Well/ Contact Tank
No Flow Foreign material trapped in pipe Plant operation is stopped None Widen pipes
No Flow Pump is off Plant operation is stopped None Install secondary pump
Less Flow Foreign material trapped in pipe Plant operation is stopped None Widen pipes
Less Flow Pump not working properly Plant operation is stopped None Install secondary pump
Less Level Leak Economic Loss None Regular maintenance
Less Level Less flow to tank Economic Loss None Inspect pumps
More Flow Pump damage Economic Loss None Install secondary pump/ Inspect pumps
More Flow Pump damage Economic Loss None Install secondary pump/ Inspect pumps
More Level Overfilling Economic Loss None INTAL high level alarm
Also level Unexpected material in tank Economic Loss None Foreign material trap
Fluctuation Flow Pump malfunction Economic Loss None Inspect pumps
Flection Level Pump malfunction Economic Loss None Inspect pumps
Backwash Pump
No Flow Foreign material trapped in pipe Plant operation is stopped None Widen pipes
No Flow Pump is off - no electricity Economic Loss None Inspect electrical connections
No Flow Damaged Pump Economic Loss None Install secondary pump
Less Flow Damaged Pump Economic Loss None Install secondary pump
Less Flow Low power supplied to pump Economic Loss None Install secondary pump
More Flow Damaged Pump Economic Loss None Install secondary pump
Reverse Flow Damaged Pump Economic Loss None Install secondary pump
Fluctuation Flow Damaged Pump Economic Loss None Install secondary pump
Fluctuation Flow Fluctuating current Economic Loss None Inspect power connection
High Lift Pump
No Flow Foreign material trapped in pipe Plant operation is stopped None Widen pipes
No Flow Pump is off - no electricity Economic Loss None Inspect electrical connections
No Flow Damaged Pump Economic Loss None Install secondary pump
Less Flow Damaged Pump Economic Loss None Install secondary pump
Less Flow Low power supplied to pump Economic Loss None Install secondary pump
More Flow Damaged Pump Economic Loss None Install secondary pump
Reverse Flow Damaged Pump Economic Loss None Install secondary pump
Fluctuation Flow Damaged Pump Economic Loss None Install secondary pump
Fluctuation Flow Fluctuating current Economic Loss None Inspect power connection

Suction Well
Other Flow Contact tank was not cleaned The water might be contaminated Operator must check Stopping of operation once in a while
properly. the contact tank to clean the tank properly
regularly for possible
contaminations and
sediments
Flow Meter
There must be some clogging or The production of water will be Operator must log the Ensure that the operator is always
Less Flow
fouling in the pipes slowed flow rates every hour keeping in check of the flow rate