Process or Product Name: Responsible:

Water Treatment Management

Prepared by: Debuque, Flores, Gesta, Rodrigo FMEA Date (Orig): July 1, 2013 (Rev): July 6, 2013

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Process Step/Input

Potential Failure Mode

Potential Failure Effects SEVERITY

Potential Causes

Current Controls DETECTION RPN

Actions Recommended

Resp.

OCCURRENCE

What is the process step/ Input under investigation?

In what ways does the key input go wrong?

What is the impact on the key output variables (customer requirements) or internal requirements?

What causes the key input to go wrong?

What are the existing controls that prevent either the cause or the failure mode?

What are the actions for reducing the RPN. Should have actions only on high RPN's or easy fixes.

Who is responsible for the recommend ed action?

Raw Water Well and Screens

Death, skin injuries and other detrimental health effects Chlorine Leakage

High pressure of input flow

The flowrate and concentration of the chlorine gas is monitored and adjusted according to the amount of raw water feed Manual inspection of instruments as problem arises

135

Installation of pressure measurement and control Checking of the status of pipes, tanks and vessels daily

Process Engineer

Corrode instruments

Weakened tank and pipe structure

162

Corrosive HCl environment

Water vapor reacts with chlorine gas to produce HCl

Monitorng and control of the Cl2 flowrate

162

The amount of moisture above the vessel should be maintained and Cl2 should be in contact directly with the feed streams Variable speed pump shoul be installed The generated output should be under critical evaluation other than the pH, alkalinity and turbidity. A variable speed motor on the flocculator and turbidity analyzer must be installed

Low output

Low production of treated water

Pump and the source water deficiency

The centrifugal pump is installed that is under constant rating The flowrate of PAC and Cl2 are controlled according to the flowrate of raw water and the analysis of pH, alkalinity and turbidity of exiting streams

72

Inadequacy of amount of PAC and Cl2

Low agglomeration of particles and dirt removal

The mixing is inefficient and the analysis & control of the amount of input streams do not reflect the enough amount needed. flocculator mixing intensity is too fast flocculator mixing intensity is too slow

42

Flocculation

insufficient agglomeration of flocs

floc particles will be broken up there will be too few particle collisions

4 The speed of the flocculator is adjust accordingly with the level in the flocculating tank. 4

112

Operator, Process Engineer

112

Distribution

clogged pipelines

flow of the water to the distribution network is hindered and blocked

scaling of pipelines due to the hardening of water

the hardness of water is tested at different points of the distribution network

140

An analyzer for determining the hardness of water should be installed prior to distribution Bacterial presence in the pipeline should be analyzed and pipelines should be checked for leakages Replacement of the corroded pipelines The time of sludge removal must be known depending on the amount of sludge formed Removing of less sludge more often Clean the filter regularly and monitor backwashing

Maintenan ce Officer

consumer complaints Clear Well / Contact Tank bad tasting water

bacterial growth in the pipe system

there no current controls

210

Quality Control Officer

consumer complaints

pipelines are corroded

no current controls

210

sludge remains in the settling tank Sedimentation inefficient sludge removal

overflow of settling tank

withdrawal of sludge is hindered

the quantity of sludge formed is based on the amount of coagulant and characteristics of raw water there are no controls available no current controlls are available as to when the filters are cleaned

150

Process Engineer

overflow of settling tank

discharging big amounts of sludge more often filter is not backwashed properly

168

Filtration

unclean filter system

clogging of thefilter underdrain system

126

Operator, Process Engineer