UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R00/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI :

Component :-

OCC CRT Failure Effect on

No Item Identification
1 Housing
2 Waterbox manways,
expansion seals, welds,
and liner
3 Expansion joint
4 Tube
Function Failure Mode Failure Cause Component or Functional Next Higher Assembly
Assembly (Equipment)
Sebagai pelindung /casing Leaking Improper Installation Kandungan oksigen tinggi pada
daripada condenser feedwater
Wall/Lining Damaged
Aging Failed welds
Improper or failed cathodic Mechanical damage to
protection liner/coating
Mechanical damage Improper Installation
Scalling or deposit High temperatur with Heat transfer process disturbed
improper chemistry

Improper chemical Heat transfer process disturbed

treatment
Low flow velocity Heat transfer process disturbed

Sand/silt Heat transfer process disturbed

Water quality Heat transfer process disturbed

Corrosion Chemical High water temperature Heat transfer process disturbed Loss of Condenser
with improper chemistry Performance

Water Chemistry Heat transfer process disturbed Loss of Condenser

Performance
Erosion (internal) Flow accelerated corrosin Tube rupture Heat transfer process disturbed
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R00/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI :

Component :-

OCC CRT Failure Effect on

No Item Identification Function Failure Mode Failure Cause Component or Functional Next Higher Assembly
Assembly (Equipment)
High flow velocity Tube rupture Heat transfer process disturbed

Foriegn material Tube rupture Heat transfer process disturbed

Suspended Soilids Tube rupture Heat transfer process disturbed

Microbiological Fouling Improper chemical Heat transfer process disturbed

treatment
Enviromental Heat transfer process disturbed

5 Water box Corrosion Aging Heat transfer process disturbed

Water quality Heat transfer process disturbed

Improper or failed cathodic Heat transfer process disturbed

protection
Aging/wear Aging Heat transfer process disturbed

Water quality Heat transfer process disturbed

Improper or failed cathodic Heat transfer process disturbed

protection
Failed welds Aging Heat transfer process disturbed

Water quality Heat transfer process disturbed

Improper or failed cathodic Heat transfer process disturbed

protection
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R00/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI :

Component :-

OCC CRT Failure Effect on

No Item Identification Function Failure Mode Failure Cause Component or Functional Next Higher Assembly
Assembly (Equipment)
Mechanical damage to Aging Heat transfer process disturbed
liner/coating
Water quality Heat transfer process disturbed

Improper or failed cathodic Heat transfer process disturbed

protection
Gasket leakage Aging

Improper maintenance
Low Level Sea Water Vacuum priming pump
wear out
6 Hotwell structure Cracking of welds vibration Defect dissolved oxygen is high

Boundary : Steam errosion Defect dissolved oxygen is high

Tube support plates

Support hardware
Baffle plates
Diffuser shileds
Feeds water supports
7 Spray Plugged Steam quality

8 Spray pipes Cracking Vibration

Manufacturing defect
9 Water box level indication Dirty Environment Unable to read accurately
(sight glass)
Leakage Aging
Leakage
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R00/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI :

Component :-

OCC CRT Failure Effect on

No Item Identification Function Failure Mode Failure Cause Component or Functional Next Higher Assembly
Assembly (Equipment)
10 Hotwell A Level - Level To detect level of hotwell A Dirty Bad quality of demin water 4 N Unable to read the indicator Unable to detect the level
Gauge (10MAG10CL501) accurately accurately from
10MAG10CL501

Valve Leakage Gasket wear out 4 N House keeping issue

-

11 Hotwell A Level - Level To detect level of hotwell A Dirty Bad quality of demin water 4 N Unable to read the indicator Unable to detect the level
Gauge (10MAG10CL502) accurately accurately from
10MAG10CL502
Valve Leakage Gasket wear out 4 N House keeping issue
-

12 Condenser A Hotwell To detect condenser hotwell Bad wiring and connection Broken, loose, or 4 N Fail to detect hotwell level and Interlock to stop condensate
Level 1 - Differential level dan give interlock signal grounded give LL signal pump when '2/3' logic is met
Pressure Transmitter when the level is LL
(10MAG10CL104)

Bad sensing component of Component failure 4 N Fail to detect hotwell level and Interlock to stop condensate
transmitter give LL signal pump when '2/3' logic is met
Bad sensing lines Valve leakage 4 N Fail to detect hotwell level Interlock to stop condensate
pump when '2/3 LL signal' logic
is met

13 Condenser A Hotwell To detect condenser hotwell Bad wiring and connection Broken, loose, or 4 N Fail to detect hotwell level and Interlock to stop condensate
Level 2 - Differential level dan give interlock signal grounded give LL signal pump when '2/3' logic is met
Pressure Transmitter when the level is LL
(10MAG10CL105)

Bad sensing component of Component failure 4 N Fail to detect hotwell level and Interlock to stop condensate
transmitter give LL signal pump when '2/3' logic is met
Bad sensing lines Valve leakage 4 N Fail to detect hotwell level Interlock to stop condensate
pump when '2/3 LL signal' logic
is met
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R00/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI :

Component :-

OCC CRT Failure Effect on

No Item Identification Function Failure Mode Failure Cause Component or Functional Next Higher Assembly
Assembly (Equipment)
14 Condenser A Hotwell To detect condenser hotwell Bad wiring and connection Broken, loose, or 4 N Fail to detect hotwell level and Interlock to stop condensate
Level 3 - Differential level dan give interlock signal grounded give LL signal pump when '2/3' logic is met
Pressure Transmitter when the level is LL
(10MAG10CL106)

Bad sensing component of Component failure 4 N Fail to detect hotwell level and Interlock to stop condensate
transmitter give LL signal pump when '2/3' logic is met
Bad sensing lines Valve leakage 4 N Fail to detect hotwell level Interlock to stop condensate
pump when '2/3 LL signal' logic
is met
 Finishing Date :

Workshop Date :

Revision : 00

on SEV DET RPN

Failure Detection Method Recommended Action PIC
System

Dapat menyebabkan kerusakan pada Operator check, housekeeping Inspeksi SpS. Har. Mekanik
boiler tube
Maintenance check Inspeksi SpS. Har. Mekanik
Loss of Turbine Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Turbine Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Turbine Performance Maintenance check Inspeksi SpS. Har. Mekanik

Maintenance check Chemical treatment SpS. KLK3

Cleaning SpS. Har. Mekanik

Maintenance check Chemical treatment SpS. KLK3

Maintenance check Inspeksi SpS. Har. Mekanik

Cleaning SpS. Har. Mekanik

Maintenance check Inspeksi SpS. Har. Mekanik

Cleaning SpS. Har. Mekanik

Labor check Chemical treatment SpS. KLK3

Labor check Chemistry monitoring SpS. KLK3

Maintenance check Leak testing (trace gas) SpS. Har. Mekanik

Labor check Chemistry monitoring SpS. KLK3

Loss of Condenser Performance Maintenance check Eddy Current Test SpS. Har. Mekanik
 Finishing Date :

Workshop Date :

Revision : 00

on SEV DET RPN

Failure Detection Method Recommended Action PIC
System

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Cleaning SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Cleaning SpS. Har. Mekanik

Labor check Chemistry monitoring SpS. KLK3

Labor check Chemistry monitoring & SpS. KLK3
treatment
Labor check Chemistry treatment SpS. KLK3

Maintenance check Cleaning SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

 Finishing Date :

Workshop Date :

Revision : 00

on SEV DET RPN

Failure Detection Method Recommended Action PIC
System

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance Maintenance check Inspeksi SpS. Har. Mekanik

Flooded, housekeeping issue Operator check Operator rounds Operator Lokal

Maintenance check Inspeksi SpS. Har. Mekanik
Flooded, housekeeping issue Maintenance check Inspeksi SpS. Har. Mekanik
Loss of cooling performance Operator check Operator rounds Operator Lokal

Possibility of damaging the tubr boiler Maintenance check Inspeksi SpS. Har. Mekanik

Possibility of damaging the tubr boiler Maintenance check Inspeksi SpS. Har. Mekanik

Loss of condenser performance Operator check Online monitoring vacuum Operator CR.
Maintenance check Inspeksi SpS. Har. Mekanik
Loss of condenser performance Maintenance check Inspeksi SpS. Har. Mekanik
Loss of condenser performance Maintenance check Inspeksi SpS. Har. Mekanik
Operator check Operator rounds Operator Lokal

Housekeeping issue Operator check Operator rounds Operator Lokal

Housekeeping issue Operator check Operator rounds Operator Lokal
 Finishing Date :

Workshop Date :

Revision : 00

on SEV DET RPN

Failure Detection Method Recommended Action PIC
System

2 Visual check 2 16 Cleaning by preventive SPS Har K&I

- maintenance

2 Visual check 2 16 Routine replacement by annual SPS Har K&I

- inspection
2 Visual check 2 16 Cleaning by preventive SPS Har K&I
- maintenance

2 Visual check 2 16 Routine replacement by annual SPS Har K&I

- inspection
Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
loop test)

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
loop test)
Trip unit when '2/3 LL signal' logic is 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
met loop test)

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
loop test)

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
loop test)
Trip unit when '2/3 LL signal' logic is 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
met loop test)
 Finishing Date :

Workshop Date :

Revision : 00

on SEV DET RPN

Failure Detection Method Recommended Action PIC
System

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
loop test)

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
loop test)
Trip unit when '2/3 LL signal' logic is 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, SPS Har K&I
met loop test)
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R01/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI : 396.337
Component :-

No Item Identification
1 Housing
2 Waterbox manways,
expansion seals, welds,
and liner
3 Expansion joint
4 Tube
Failure Effect on
Function Failure Mode Failure Cause OCC CRT Component or Functional Next Higher Assembly
Assembly (Equipment)
Sebagai pelindung /casing Leaking Improper Installation 3 Kandungan oksigen tinggi pada
daripada condenser feedwater
Wall/Lining Damaged 4
Fasilitas untuk inspeksi Aging Failed welds 1
condenser
Improper or failed cathodic Mechanical damage to 1
protection liner/coating
Sebagai pengaman Mechanical damage Improper Installation 3
Sebagai media untuk Scalling or deposit High temperatur with 6 Heat transfer process disturbed
condensasi dan pendingin improper chemistry

Improper chemical 3 Heat transfer process disturbed

treatment
Low flow velocity 3 Heat transfer process disturbed

Sand/silt 4 Heat transfer process disturbed

Water quality 3 Heat transfer process disturbed

Corrosion Chemical High water temperature 3 Heat transfer process disturbed Loss of Condenser
with improper chemistry Performance

Water Chemistry 3 Heat transfer process disturbed Loss of Condenser

Performance
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R01/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI : 396.337
Component :-

Failure Effect on
No Item Identification Function Failure Mode Failure Cause OCC CRT Component or Functional Next Higher Assembly
Assembly (Equipment)
Erosion (internal) Flow accelerated corrosin 3 Tube rupture Heat transfer process disturbed

High flow velocity 3 Tube rupture Heat transfer process disturbed

Foriegn material 3 Tube rupture Heat transfer process disturbed

Suspended Soilids 3 Tube rupture Heat transfer process disturbed

Microbiological Fouling Improper chemical 6 Heat transfer process disturbed

treatment
Enviromental Heat transfer process disturbed

5 Water box Sebagai penampung air Corrosion Aging 2 Heat transfer process disturbed
pendingin
Water quality 2 Heat transfer process disturbed

Improper or failed cathodic 2 Heat transfer process disturbed

protection
Aging/wear Aging 2 Heat transfer process disturbed

Water quality 2 Heat transfer process disturbed

Improper or failed cathodic 2 Heat transfer process disturbed

protection
Failed welds Aging 2 Heat transfer process disturbed
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R01/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI : 396.337
Component :-

Failure Effect on
No Item Identification Function Failure Mode Failure Cause OCC CRT Component or Functional Next Higher Assembly
Assembly (Equipment)
Water quality 2 Heat transfer process disturbed

Improper or failed cathodic 2 Heat transfer process disturbed

protection
Mechanical damage to Aging 2 Heat transfer process disturbed
liner/coating
Water quality 2 Heat transfer process disturbed

Improper or failed cathodic 2 Heat transfer process disturbed

protection
Gasket leakage Aging 4

Improper maintenance 3
Low Level Sea Water Vacuum priming pump 3
wear out
6 Hotwell structure Konstruksi dari condenser Cracking of welds vibration 2 Defect dissolved oxygen is high

Boundary : Steam errosion 2 Defect dissolved oxygen is high

Tube support plates

Support hardware
Baffle plates
Diffuser shileds
Feeds water supports
7 Spray Agar pengaman condenser Plugged Steam quality 2
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R01/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI : 396.337
Component :-

Failure Effect on
No Item Identification Function Failure Mode Failure Cause OCC CRT Component or Functional Next Higher Assembly
Assembly (Equipment)
8 Spray pipes Supply media spray Cracking Vibration 2 N

Manufacturing defect 2 N

9 Water box level indication Faslilitas untuk mengetahui Dirty Environment 6 N Unable to read accurately
(sight glass) kondisi level secara visual
Leakage Aging 5 N
Leakage 6 N
10 Hotwell A Level - Level To detect level of hotwell A Dirty Bad quality of demin water 4 N Unable to read the indicator Unable to detect the level
Gauge (10MAG10CL501) accurately accurately from
10MAG10CL501

Valve Leakage Gasket wear out 4 N House keeping issue

-

11 Hotwell A Level - Level To detect level of hotwell A Dirty Bad quality of demin water 4 N Unable to read the indicator Unable to detect the level
Gauge (10MAG10CL502) accurately accurately from
10MAG10CL502

Valve Leakage Gasket wear out 4 N House keeping issue

-

12 Condenser A Hotwell To detect condenser hotwell Bad wiring and connection Broken, loose, or 4 N Fail to detect hotwell level and Interlock to stop condensate
Level 1 - Differential level dan give interlock signal grounded give LL signal pump when '2/3' logic is met
Pressure Transmitter when the level is LL
(10MAG10CL104)

Bad sensing component of Component failure 4 N Fail to detect hotwell level and Interlock to stop condensate
transmitter give LL signal pump when '2/3' logic is met
Bad sensing lines Valve leakage 4 N Fail to detect hotwell level Interlock to stop condensate
pump when '2/3 LL signal' logic
is met
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R01/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI : 396.337
Component :-

Failure Effect on
No Item Identification Function Failure Mode Failure Cause OCC CRT Component or Functional Next Higher Assembly
Assembly (Equipment)
13 Condenser A Hotwell To detect condenser hotwell Bad wiring and connection Broken, loose, or 4 N Fail to detect hotwell level and Interlock to stop condensate
Level 2 - Differential level dan give interlock signal grounded give LL signal pump when '2/3' logic is met
Pressure Transmitter when the level is LL
(10MAG10CL105)

Bad sensing component of Component failure 4 N Fail to detect hotwell level and Interlock to stop condensate
transmitter give LL signal pump when '2/3' logic is met
Bad sensing lines Valve leakage 4 N Fail to detect hotwell level Interlock to stop condensate
pump when '2/3 LL signal' logic
is met
14 Condenser A Hotwell To detect condenser hotwell Bad wiring and connection Broken, loose, or 4 N Fail to detect hotwell level and Interlock to stop condensate
Level 3 - Differential level dan give interlock signal grounded give LL signal pump when '2/3' logic is met
Pressure Transmitter when the level is LL
(10MAG10CL106)

Bad sensing component of Component failure 4 N Fail to detect hotwell level and Interlock to stop condensate
transmitter give LL signal pump when '2/3' logic is met
Bad sensing lines Valve leakage 4 N Fail to detect hotwell level Interlock to stop condensate
pump when '2/3 LL signal' logic
is met

No Reference
1 Title : N-600-16.67/538/538 Type 600 MW Condensing Reheat Steam Turbine
Sub-Title : Control and Protect System Manual
Doc. No. : 71.A158-1E
Man. : Shanghai Electric Power Generation Equipment Co., Ltd. (Shanghai Turbine Works)
2 PM Basis (EPRI)
3 FMEA Workshop UBP Suralaya
 UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FMEA Form 1 No. : FMEA-0001-R01/2011/BSR

System : CONDENSING SYSTEM KKS : CS10MAG10AC010

Equipment : CONDENSER A MPI : 396.337
Component :-

Failure Effect on
No Item Identification Function Failure Mode Failure Cause OCC CRT Component or Functional Next Higher Assembly
Assembly (Equipment)
4 Suralaya Power Plant 600 MW Generating Unit
Profesional Overhaul Regulations for Turbin, CNTIC Consortiom
 Finishing Date : 22 Agustus 2011
Workshop Date : 27 Oktober 2011
Revision : 01

Failure Effect on
SEV Failure Detection Method DET RPN Recommended Action PIC
System

Dapat menyebabkan kerusakan 3 Operator check, housekeeping 6 54 Inspeksi SpS. Har. Mekanik
pada boiler tube
3 Maintenance check 6 72 Inspeksi SpS. Har. Mekanik
Loss of Turbine Performance 3 Maintenance check 6 18 Inspeksi SpS. Har. Mekanik

Loss of Turbine Performance 3 Maintenance check 6 18 Inspeksi SpS. Har. Mekanik

Loss of Turbine Performance 3 Maintenance check 6 54 Inspeksi SpS. Har. Mekanik

3 Maintenance check 6 108 Chemical treatment SpS. KLK3

Cleaning SpS. Har. Mekanik

3 Maintenance check 6 54 Chemical treatment SpS. KLK3

3 Maintenance check 6 54 Inspeksi SpS. Har. Mekanik

Cleaning SpS. Har. Mekanik

5 Maintenance check 4 80 Inspeksi SpS. Har. Mekanik

Cleaning SpS. Har. Mekanik

3 Labor check 6 54 Chemical treatment SpS. KLK3

3 Labor check 6 54 Chemistry monitoring SpS. KLK3

Maintenance check Leak testing (trace gas) SpS. Har. Mekanik

3 Labor check 6 54 Chemistry monitoring SpS. KLK3
 Finishing Date : 22 Agustus 2011
Workshop Date : 27 Oktober 2011
Revision : 01

Failure Effect on
SEV Failure Detection Method DET RPN Recommended Action PIC
System

Loss of Condenser Performance 3 Maintenance check 6 54 Eddy Current Test SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 54 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 54 Cleaning SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 54 Cleaning SpS. Har. Mekanik

3 Labor check 4 36 Chemistry monitoring SpS. KLK3

5 Labor check 4 120 Chemistry monitoring & treatment SpS. KLK3

5 Labor check 4 120 Chemistry treatment SpS. KLK3

Maintenance check 6 180 Cleaning SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

 Finishing Date : 22 Agustus 2011
Workshop Date : 27 Oktober 2011
Revision : 01

Failure Effect on
SEV Failure Detection Method DET RPN Recommended Action PIC
System

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 4 24 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 5 Maintenance check 6 60 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Loss of Condenser Performance 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

Flooded, housekeeping issue 3 Operator check 6 72 Operator rounds Operator Lokal

Maintenance check 6 72 Inspeksi SpS. Har. Mekanik
Flooded, housekeeping issue 3 Maintenance check 6 54 Inspeksi SpS. Har. Mekanik
Loss of cooling performance 3 Operator check 6 54 Operator rounds Operator Lokal

Possibility of damaging the tubr 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik
boiler
Possibility of damaging the tubr 3 Maintenance check 6 36 Inspeksi SpS. Har. Mekanik
boiler

Loss of condenser performance 3 Operator check 6 36 Online monitoring vacuum Operator CR.

Maintenance check 6 36 Inspeksi SpS. Har. Mekanik

 Finishing Date : 22 Agustus 2011
Workshop Date : 27 Oktober 2011
Revision : 01

Failure Effect on
SEV Failure Detection Method DET RPN Recommended Action PIC
System

Loss of condenser performance 3 Maintenance check 4 24 Inspeksi SpS. Har. Mekanik

Loss of condenser performance 3 Maintenance check 4 24 Inspeksi SpS. Har. Mekanik

5 Operator check 6 180 Operator rounds Operator Lokal

Housekeeping issue 3 Operator check 6 90 Operator rounds Operator Lokal

Housekeeping issue 3 Operator check 6 108 Operator rounds Operator Lokal
2 Visual check 2 16 Cleaning by preventive maintenance SPS Har K&I
-

2 Visual check 2 16 Routine replacement by annual SPS Har K&I

- inspection
2 Visual check 2 16 Cleaning by preventive maintenance SPS Har K&I
-

2 Visual check 2 16 Routine replacement by annual SPS Har K&I

- inspection
Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
test)

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
test)
Trip unit when '2/3 LL signal' 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
logic is met test)
 Finishing Date : 22 Agustus 2011
Workshop Date : 27 Oktober 2011
Revision : 01

Failure Effect on
SEV Failure Detection Method DET RPN Recommended Action PIC
System

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
test)

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
test)
Trip unit when '2/3 LL signal' 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
logic is met test)

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
test)

Trip unit when '2/3' logic is met 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
test)
Trip unit when '2/3 LL signal' 8 HMI trend check by operator 2 64 Inspection (repaired, calibration, loop SPS Har K&I
logic is met test)

Name Position Date Sign

Aditya Timur
Prepared by AMA ENG K&I
Baladika

AMA ENG Boiler &

Prepared by Danny Yunarta
Aux.

Reviewed by Erik Pujianto SPS Reliability

 Finishing Date : 22 Agustus 2011
Workshop Date : 27 Oktober 2011
Revision : 01

Failure Effect on
SEV Failure Detection Method DET RPN Recommended Action PIC
System

Reviewed by Erik Pujianto SPS Reliability

Approved by Andiek Tri Ferianto MEMA

UNIT BISNIS OPERASI DAN PEMELIHARAAN PLTU BANTEN 1 SURALAYA

FAILURE MODE & EFFECT ANALISYS TURBIN UBOH PLTU BANTEN 1 SURALAYA
FMEA Form 1 No. : FMEA-MEC-0002-R00/2011/BSR

System : Condensing System KKS : CS10MAG10AC010/CS10MAG10AC020

Subsystem : Condenser MPI : 317.070
Subsytem Element

O Potential D Potential Cause(s) S R

Potential Failure Task Recommende
Item Function C Effect(s) of E Mechanism of E P
Mode Action(s)
C Failure T Failure V N

Tube Mengalirkan air Bocor 6 Conductivity 7 Life Time 7 294 1. Performace monitoring
pendingin (sea feedwater tinggi
water) Korosi
Unit Derating Erosi
Unit Trip 2. NDE Inspection
3. Waterbox or Hotwell insp
4. Cleaning
5. Patroli Operator
Vacuum Pump Membuat dan Vacuum Low 3 Pressure LP exhaust 6 Vacuum Pump tidak 7 126 1. Performance monitoring
mempertahankan tinggi beroperasi maksimal
kondisi vacuum 2. Menurunkan beban
pada condenser Unit Derating Level Air laut turun 3. Patroli Operator
Unit Trip Kebocoran pada
Condensor

Ball Cleaning Membersihkan tube Bola taproge hilang 3 Tube condenser 7 Ball Cacther yang tidak full 6 126 1. Pemeriksaan line saat star
condenser kurang bersih close ball cleaning
Tube condenser Ukuran bola taproge yang 2. Continuos injection chlori
tersumbat tidak sesuai
 Banyak tritip yang
berkembang

Note : belum di workshop kan No. Refer

1 PM BASIS (EPRI)
2 FMEA Workshop UBP PGT
3 Suralaya Power Plant 600 MW Gene
Proffesional Overhaul Regulations; C

Name Position
Prepared by Danny Yunarta AMA ENG. Boiler &
Aux.
Reviewed by Erik Pujianto SPS. Reliability

Approved by Andiek Tri Ferianto MEMA

UBOH PLTU BANTEN 1 SURALAYA

Date : 10 Mei 2011

Revision 00
Page : 01

Task Recommended
PIC
Action(s)

1. Performace monitoring SPS Rendal Op

2. NDE Inspection SPS Rendal Har

3. Waterbox or Hotwell inspectioSPS Rendal Har
SPS Rendal Har
5. Patroli Operator SPS Rendal Op
1. Performance monitoring SPS Rendal Har
2. Menurunkan beban SPS Rendal Op
3. Patroli Operator SPS Rendal Op

1. Pemeriksaan line saat start SPS Rendal Op

ball cleaning

2. Continuos injection chlorin SPS Rendal Op

 Reference

FMEA Workshop UBP PGT

Suralaya Power Plant 600 MW Generating Unit
Proffesional Overhaul Regulations; CNTIC Consortiom

Date Sign