No.

Name /
Function
Requireme
nts

Potential
Failure
Mode

Potential
Effect(s) of
Failure

SE
Vi

Potential Cause(s)
of Failure

OC
Ci

Current
Process
Controls
(Preventio
n)

Current
Process
Controls
(Detection
)

DET RPN
i
i

Recommen
ded
Action(s)

Responsibi
lity &
Planned
Completio
n Date

Action
Results

Actions
Taken &
Actual
Completi
on Date
321
00
or
341
00

510
00
or
610
00
or
740
00
or
760
00

Bearing
(CE or TE)

Casing

minor
cracks

Reduction
in speed

Deformatio
n

Overheatin
g of
bearings

cracks

Leaks in
the casing
leading to
loss of
lubricant

loss of free
passage capacity
of the ducts
carrying oil to
turbocharger
bearings and in
consequence their
seizure.

Change
bearing
every
16000h

Oil pump
emergency shutdown or sudden
drop in the oil
pressure
accompanied by
an improper
operation of the
emergency
lubrication of the
turbocharger
bearings
Loss of balance of
rotor

Thermal tension

Noises on
running
down,
time to
short,
reluctant
starting

Replace
bearing and
seek
possible
cause

Replace
casing

Excessive
Vibrations

Visual
inspection
every 24h
for leakage

Leaks in
the casing

SEV
r

OCCr

DETr

RPNr

200
00

Turbine

contaminati
on

deformatio
n

Reduction
of the
turbine
throughpu
t capacity.

Increases
exhaust
gas flow
resistance,
reduces
turbine
power,
increases
specific
fuel
consuption
and
decreases
turbine
efficiency
Reduction
of the
turbine
throughpu
t capacity.

Insufficient
ventilation

Provide
better
ventilation

Insufficient cooling
water

Check and
top up

dirt in cooling
water space
During operation,
tarry substances
and carbon
deposit in the
turbine flow ducts
at labyrinth
sealings. There is
an increase in
deposit if there is
incomplete fuel
burning in engine
cylinders.

Clean

broken piston
rings and valves
or small particles

Wet
cleaning
every
week,
Visual
inspection
every
8000h and
every
100000h
change

Exhaust
gas
temperatu
re too
high,
engine
performan
ce and
speed
unaltered

Exhaust
gas
temperatu
re too
high,
engine
performan
ce and
speed
unaltered

Clean

Replace

cracks

Reduction
of the
turbine
throughpu
t capacity.

Pressure pulsation
of the exhaust gas
supplying the
turbine. They
occur more
frequently as the
engine is
reversed. In such
cases, large
volumes of cold
starting air and
hot exhaust gas
flow alternately
through the
turbine, which in
consequence
increases the
thermal strain and
generates microcracks.

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Replace

Blade tip
wear

Reduction
of the
turbine
efficiency

Particles passing
through the
filtering system

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Replace

Erosion

Reduction
of the
turbine
throughpu
t capacity,
Increases
exhaust
gas flow
resistance,
reduces
turbine
power,
increases
specific
fuel
consuption

Hard and
chemically
corrosive
components from
combustion
residues can
initiate erosion.

Exhaust
gas
temperatu
re too
high,
engine
performan
ce and
speed
unaltered

Replace

and
decreases
turbine
efficiency

Dirt
accumulati
on

Compresso
r

Contaminat
ion

Reduction
of the
turbine
throughpu
t capacity,
Increases
exhaust
gas flow
resistance,
reduces
turbine
power,
increases
specific
fuel
consuption
and
decreases
turbine
efficiency
Decrease
in
Compress
or
efficiency
and
compresso
r surging

Bad filtering
system

Dust laden air

from outside or air
mixed with oil
vapours

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Wet
cleaning
every
week,
Visual
inspection
every
8000h and
every
100000h
change

Exhaust
gas
temperatu
re too
high,
engine
performan
ce and
speed
unaltered

Clean

Clean

Dirt
accumulati
on

Heavy dirt
accumulati
on

570
00

Cover ring

Erosion

Increases
inlet gas
flow
resistance,
reduces
compresso
r power,
increases
specific
fuel
consumpti
on and
decreases
compresso
r efficiency
Increases
inlet gas
flow
resistance,
reduces
compresso
r power,
increases
specific
fuel
consumpti
on and
decreases
compresso
r efficiency
Enlarges
the
clearance
between
the
moving
blades and
the cover
ring,
causing a
drop in
turbine
efficiency
as well as
turbocharg
er speed.

Dust laden air

from outside or air
mixed with oil
vapours

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Dust laden air

from outside or air
mixed with oil
vapours

Constant
surging of
the
turbochar
ger

Hard and
chemically
corrosive
components from
combustion
residues can
initiate erosion.

Every
8000h
visual
inspection.

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Clean

Replace

812
50

560
01

Filter

Contaminat
ion

Labyrinth
seal

Damaged

Nozzle ring

Corrosion

Increase in
flow
resistance
which
leads to a
decrease
in air-mass
flux
through
the engine
which
increases
specific
fuel
consumpti
on.
Increases
flow
resistance
which
increases
fuel
consumpti
on

Decrease
in
efficiency
of the
turbocharg
er

Air taken in by the

compressor is
often mixed with
oil vapour or laden
with dust which
contaminates the
filter.

Exhaust
gas
temperatu
re too
high,
engine
performan
ce and
speed
unaltered

Clean

Prior wear of
thrust bearings

???

Every
8000h,
visual
inspections
are made

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Consult
service
station for
replacemen
t

Hard and
chemically
corrosive
components from
combustion
residues can
initiate erosion.

Every
8000h,
visual
inspections
are made
and every
100000h it
is
changed.

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Replace

360
00
or
390
00

Oil Pump

Erosion

Decrease
in
efficiency
of the
turbocharg
er

Hard and
chemically
corrosive
components from
combustion
residues can
initiate corrosion.

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Replace

Contaminat
ion

Surging
occuring
due to
reduction
in air flow

Residues formed
depending on the
quality of the fuel
burnt in the
engine and the
constituents of the
lubricating oil
passes together
with the exhaust
gases into the
turbine. This
determines
whether a layer of
dirt is deposited or
not

Charge air
pressure
too low,
engine
performan
ce and
speed
unaltered;
air intake
normal

Clean

Wear

Decrease
in
lubricant

Leaks

Decrease
in
lubricant
Loss of
lubricant

760
02

Sealing
bush

Damaged

810
00

Silencer
filter

Contaminat
ion

Surging
occuring
due to
reduction
in air flow

Every
8000h
pump is
changed or
recondition
ed

Replace

Replace

Decrease in
efficiency due to
reduction in air
flow

Every
8000h
inspection
is made

Loss of
lubrication
oil

Replace

Every
8000h
inspection
is made

Constant
surging of
the
turbochar
ger

Clean