SQ29-000002-01

Page 1 of 2

FAILURE MODE AND EFFECT ANALYSIS

(PROCESS FMEA) Item: All PCW System Process Responsibility: Facilities Key Date: 5th July 2006

FMEA Number:

SJ51-000007-01

Prepared By: William Chai FMEA Date (Orig): 5th July 2006 (Rev) 0

Sub-Module/Sub-Department: Core Team:

William Chai, Ganason, Soon Han Chean

Process Function

Potential Failure Mode

Potential Effect(s) of Failure

S e v

Requirements Return Control Valve PCW System fail - full close 1) Production tripped 2) No cooling at machine

C l a s s

Potential Cause(s)/ Mechanism(s) of Failure

O c c u r

Current Process Control

D e t RPN e c

Recommended Action(s)

Responsibility & Target Completion Date

Actions Result Actions Taken S O D e c e v c t RPN

1)PLC fail. 2)Internal parts fail. 3)Loose connection.

1) Half-yearly PM 2) Ten years 1 overhaul 3) Online monitoring 1) Rounds and readings (visual 1 inspection). 2) Replace when detect leaking

27

Tank leak

1) Low flow or production trip 8 2) Flooding at CHEM

1) Hit by object / moving object 2) Gasket leaking

64

Level Transmitter fail

1) Production tripped 2) No cooling at machine

1)Parts fail / error. 2)PLC fail.

1) Use manual level meter. 2) Yearly calibration. 2 2 3) Interlock control. 4) Online monitoring with alarm

36

Chemical Pot Feeder contaminated

1) Production trip 2) Tools cooling not effective.

1) Improper chemical 2 1) Work permit dosing.

1) LOTO the pot 10 160 2) Tighten chemical dosing procedure

William July 06

1) LOTO the pot with authorized person to unLOTO. 8 1 7 2) Tighten chemical dosing procedure

56

SQ29-000002-01

Page 2 of 2

FAILURE MODE AND EFFECT ANALYSIS

(PROCESS FMEA) Item: All PCW System Process Responsibility: Facilities Key Date: 5th July 2006

FMEA Number:

SJ51-000007-01

Prepared By: William Chai FMEA Date (Orig): 5th July 2006 (Rev) 0

Sub-Module/Sub-Department: Core Team:

William Chai, Ganason, Soon Han Chean

Process Function

Potential Failure Mode

Potential Effect(s) of Failure

S e v

Requirements 1) Production tripped 2) No cooling at machine

C l a s s

Potential Cause(s)/ Mechanism(s) of Failure

O c c u r

Current Process Control

D e t RPN e c

Recommended Action(s)

Responsibility & Target Completion Date

Actions Result Actions Taken S O D e c e v c t RPN

Pump fail

1)Internal parts fail. 2)Motor fail.

1) Online monitoring with 1 redundant pumps as standby. 2) Quarterly PM

27

Pump fail

1) Production tripped 2) No cooling at machine

Power dipped.

Normal supply by 4 TNB.

Implement UPS for VFD 10 360 control cable power supply.

C.C. SIM June 06

VFD for Pump 01 to 07 were changed to UPS supply.

9 1 5

45

Heat Exchanger fail

1) Production tripped 2) No cooling at machine

1) No heat exchange 2) Gasket dirty/clogged

1) Online temperature monitoring 1 2) Gasket replacement & cleaning

27

Filter stuck with particles.

1) Change filter when DP at 0.5bar. 3 2) Flow, DP and 3 pressure online monitoring.

81

Filter choked

1) Production tripped Control limit for filter change is not sensitive 1) Change filter when DP at 0.5bar. 2 2) Flow, DP and 3 pressure online monitoring.

54

1) Tighten DP level to trigger filter change.

William July 06

Tighten DP level to 0.15bar for alert and 0.25bar trigger filter change.

9 1 2

18