GRAPHICAL REPRESENTATION OF RISK PRIORITY NUMBER 2019-2022

AIR INLET SYSTEM P-1.0 RPN 2019 RPN 2020 RPN 2021 RPN 2022
17 9 9 9 9 AIR INLET SYSTEM P-1.0
18 100
48 12 12 12
19 48 12 24 12 90
20 9 9 9 9 80
21 9 9 9 9
22 9 9 9 9 70
23 9 9 9 9 R 60
24 9 9 18 9 2019
P 50
LUBE OIL SYSTEM P-1.1 RPN 2019 RPN 2020 RPN 2021 RPN 2022 2020
40
31
N
9 9 9 9 30 2021
32 25 25 25 25
33 12 12 12 12 20 2022
34 9 9 9 9 10
35 30 30 30 30
0
36 9 9 9 9
17 18 19 20 21 22 23 24
37 20 20 20 20
38 9 9 9 9 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
39 9 9 9 9
40 18 18 18 18
41 9 9 9 9 LUBE OIL SYSTEM P-1.1
42 28 28 28 28 100
43 56 28 28 28
90
44 28 28 28 28
45 12 12 12 12 80
46 12 12 12 12
47 70
20 20 20 20
48 12 12 12 12 R 60
49 24 24 24 24 2019
50 24 24 24 24 P 50
51 18 18 18 18 40 2020
52 18 18 18 18
N
30 2021
53 16 16 16 16
54 15 15 15 15 20 2022
55 24 24 24 24
56 9 27 9 9 10
57 24 24 24 24 0
58 40 40 40 40 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59
59 25 50 75 25
START SYSTEM P-1.2 RPN 2019 RPN 2020 RPN 2021 RPN 2022 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
66 9 9 9 9
67 9 9 9 9 START SYSTEM P-1.2
68 9 18 9 9 100
69 12 12 12 12
70 9 9 9 9 90
71 9 9 9 9 80
72 12 12 12 12
73 20 20 20 20 70
74 9 9 9 9 R 60
75 12 12 12 12 2019
FUEL SYSTEM P-1.3 RPN 2019 RPN 2020 RPN 2021 RPN 2022
P 50
40 2020
82 9 9 9 9
N
30 2021
83 9 9 9 9
84 9 9 9 9 20 2022
85 12 12 12 12
10
86 9 9 9 9
87 9 9 9 9 0
88 9 9 9 9 66 67 68 69 70 71 72 73 74 75
89 9 9 9 9
90 9 9 9 9 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
91 9 9 9 9
92 9 9 9 9
93 9 9 9 9
94 16 16 32 16
95 12 12 12 12
96
97
12
16
12
16
12
16
12
16
FUEL SYSTEM P-1.3
98 72 36 18 54 100
99 9 9 9 9 90
100 15 15 15 15
101 45 30 30 15 80
102 24 12 12 12
103 12 12 12 12 70
104 15 15 15 15
R 60
105 12 12 12 12
106 12 12 12 12 2019
107 9 18 9 9
P 50
2020
108 16 16 16 16 N 40
109 12 12 12 12 2021
110 20 40 20 20 30
2022
111 15 15 15 15 20
112 15 15 15 15
113 9 9 9 9 10
114 18 9 9 9
115 12 12 12 12 0
116 12 12 12 12 82 84 86 88 90 92 94 96 98 100 102 104 106 108 110 112 114 116 118 120 122 124 126
117 12 12 12 12
118 12 12 12 12 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
119 16 16 16 16
120 12 12 12 12
121 20 20 20 20
122 18 9 9 9
123 9 9 9 9
124 12 12 12 12
125 12 12 12 12
126 12 12 12 12 SEAL SYSTEM P-1.4
127 48 48 96 48
100
SEAL SYSTEM P-1.4 RPN 2019 RPN 2020 RPN 2021 RPN 2022
90
135 12 12 12 12
136 9 9 9 9 80
137 9 9 9 9
138 9 9 9 9 70
139 9 9 9 9
60
140 12 12 12 12 R
141 9 9 9 9 2019
142 20 20 20 20
P 50
2020
143 9 9 9 9 N 40
144 9 18 9 9 2021
145 9 9 9 9 30
2022
146 9 9 9 9
20
147 9 9 9 9
148 9 9 9 9 10
149 12 12 12 12
150 12 12 12 12 0
151 20 20 20 20 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159
152 9 9 9 9
153 20 20 20 20 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
154 9 9 9 9
155 40 20 20 20
156 9 9 9 9
157 16 16 16 16
158 12 12 12 24
159 12 12 12 12
 VIBRATION SYSTEM P-1.5 RPN 2019 RPN 2020 RPN 2021 RPN 2022
166 24 24 24 24
VIBRATION SYSTEM P-1.5
100
167 24 72 48 24
168 48 24 24 24 90
169 24 24 24 24 80
170 24 24 24 24
70
171 24 24 24 24
172 24 24 24 24 R 60
173 24 24 24 24 2019
P 50
YARD VALVE P-1.6 RPN 2019 RPN 2020 RPN 2021 RPN 2022 40 2020
N
181 6 6 6 6 30 2021
182 24 12 12 6 20 2022
183 12 6 12 6
10
184 6 6 6 12
185 6 6 6 6 0
186 6 6 6 12 166 167 168 169 170 171 172 173
187 6 6 6 6
188 18 18 12 12 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
189 6 6 12 12
190 6 6 6 6 YARD VALVE/HPC SYSTEM P-1.6
191 8 8 8 8 50
192 8 8 8 8
193 6 6 6 6
40
194 32 32 16 32
195 12 12 12 12
196 9 9 9 9 R 30
197 12 6 6 6 2019
198 9 9 9 9
P
20 2020
199 9 9 9 9 N
200 9 9 9 9 2021
201 16 16 16 16 10 2022
202 16 16 16 16
203 20 20 20 20
204 12 12 12 12 0
205 12 12 12 12 181 183 185 187 189 191 193 195 197 199 201 203 205 207 209 211 213 215 217 219 221
206 12 12 12 12 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
207 12 12 12 12
208 12 12 12 12
209 12 12 12 12 100
ANTI SURGE SYSTEM P-1.7
210 12 12 12 12
90
211 12 12 12 12
212 12 12 12 12 80
213 12 12 12 12 70
214 12 12 12 12 R 60
215 12 12 12 12 2019
216 12 12 12 12 P 50
217 40 2020
12 12 12 12 N
218 12 12 12 12 30 2021
219 12 12 12 12 20 2022
220 12 12 12 12
10
221 16 16 16 16
0
ANTI SURGE P-1.7 RPN 2019 RPN 2020 RPN 2021 RPN 2022 228 229 230 231 232
228 9 9 9 9 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
229 20 20 20 20
230
231
48
9
24
9
36
9
12
9 100
BACKUP SYSTEM P-1.8
232 16 16 16 16
90
BACKUP SYSTEM P-1.8 RPN 2019 RPN 2020 RPN 2021 RPN 2022 80
239 20 20 20 20 70
240 12 12 12 12 R 60
241 16 16 16 16 2019
242 24 24 24 24 P 50
40 2020
243 12 12 12 12 N
244 12 12 12 12 30 2021
245 12 12 12 12 20 2022
246 24 12 12 12 10
247 12 12 12 12
248 40 40 40 40 0
249 40 40 40 40 239 241 243 245 247 249 251 253 255
250 25 25 25 25 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#
251 21 21 21 21
252
253
21
21
21
21
21
21
21
21 180
CONTROL SYSTEM P-1.9
170
254 12 12 12 12 160
255 6 6 6 6 150
140
CONTROL SYSTEM P-1.9 RPN 2019 RPN 2020 RPN 2021 RPN 2022 130
120
R 110
262 9 9 9 9 100 2019
263 9 9 9 9 P 90
80
264 21 21 21 21 70 2020
265 9 9 9 9 N 60
50 2021
266 9 9 9 9 40
267 18 9 9 45 30 2022
20
268 9 9 9 9 10
0
269 6 12 6 12
270 262 263 264 265 266 267 268 269 270 271
40 100 140 60
271 4 4 4 4 PROCESS FAULT NUMBERS FOLLOW EXCEL ROW#

MFI COMPARISION (YEAR WISE) 25.00

SYSTEM CODE MFI 2019 MFI 2020 MFI 2021 MFI 2022
P 1.0 AIR INLET SYSTEM 1 12.00 2.00 4.00 2.00 20.00
P 1.1 LUBE OIL SYSTEM 2 4.00 8.00 6.00 2.00
P 1.2 START SYSTEM 3 1.00 3.00 1.00 1.00 2019
15.00
P 1.3 FUEL SYSTEM 4 23.00 12.00 9.00 8.00 2020
P 1.4 SEAL OIL/GAS, BUFFER
5 3.00 7.00 0.00 2.00 2021
AIR/GAS SYSTEM 10.00
P 1.5 VIBRATION SYSTEM 6 5.00 4.00 3.00 2.00 2022
P 1.6 YARD VALVE & HPC
7 18.00 11.00 12.00 16.00 5.00
MONITORING SYS.
P 1.7 ANTI SURGE SYSTEM 8 7.00 3.00 5.00 1.00
P-1.8 BACKUP/ F&G SYSTEM 9 4.00 1.00 0.00 1.00
0.00
P 1.9 CONTROL SYSTEM 10 6.00 12.00 21.00 19.00
1 2 3 4 5 6 7 8 9 10
TOTAL MFI 83.00 63.00 61.00 54.00
UNITS RUNNING HOUR (YEAR WISE)
RUNNING HOURS R.H 2019 R.H 2020 R.H 2021 R.H 2022 5000
UNIT 1A 3529 3884 2633 996 4500
UNIT 2A 5124 423 468 1057
UNIT 3A 1162 45 2688 375 4000
UNIT 4A 4456 2891 1477 789
UNIT 1B 66 205 149 171 3500
UNIT 2B 485 116 523 106 2019
3000
UNIT 3B 4659 1131 2041 1657
UNIT 4B 1925 688 278 191 2020
2500
UNIT 5B 3253 2626 2892 911 2021
UNIT 6B 4335 1738 1517 442 2000
2022
TOTAL RUNNING HOUR 28994 13747 14666 6695 1500

1000

500

0
UNIT 1A UNIT 2A UNIT 3A UNIT 4A UNIT 1B UNIT 2B UNIT 3B UNIT 4B UNIT 5B UNIT 6B
 FAILURE MODES AND EFFECTS ANALYSIS (2021)
PARENT PROCESS NAME AND IDENTIFICATION # P-1 TURBINE PACKAGE (MD)
AC-4
SUB-PROCESS MFI TOTAL MFI OVER THE YEAR 61
P 1.0 AIR INLET SYSTEM 4.00 P 1.5 VIBRATION SYSTEM 3.00 STATION OFF STREAM PERIOD
3-6-21 TO 17-6-21
P 1.1 LUBE OIL SYSTEM 6.00 P 1.6 YARD VALVE & HPC MONITORING SYS. 12.00
29-6-21 TO 3-12 -21
P 1.2 START SYSTEM 1.00 P 1.7 ANTI SURGE SYSTEM 5.00 5-12-21 TO 31-12-21 GO TO PROCESS FLOW DIAGRAM
P 1.3 FUEL SYSTEM 9.00 P-1.8 BACKUP/ F&G SYSTEM 0.00
P 1.4 SEAL OIL/GAS, BUFFER AIR/GAS SYSTEM 0.00 P 1.9 CONTROL SYSTEM 21.00

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.0 AIR INLET SYSTEM

RUNNING HOURS FOR THE PERIOD OF JAN,21 TO DEC,21 2633 468 2688 1477 149 523 2041 278 2892 1517 Total # of Starts 186
14666
START/STOP 26/27 18/18 21/20 19/19 9/9 12/12 23/23 14/14 26/26 18/19 Total # of Stops 187

FAILURE MODE U#1A U#2A U#3A U#4A U# 1B U#2B U#3B U#4B U#5B U#6B TOTAL SEV OCC DET RPN

Turbine Air Inlet Filter DP Transmitter Failure 0 3 1 3 9

Turbine Air Inlet Filter DP High 0 3 1 4 12

Turbine Enclosure Vent Fans 1 and 2 Failure 1 1 2 3 2 4 24

Turbine Enclosure Temperature High 0 3 1 3 9

Turbine Enclosure Vent Flow Switch Failure Start Permissive 0 3 1 3 9

Turbine Enclosure Pressure Transmitter Failure 0 3 1 3 9

Turbine Air Inlet Temperature RTD Failure 0 3 1 3 9

Turbine Enclosure Pressure Low 2 2 3 2 3 18

Contribution Of MFIS %AGE UNIT WISE 0.0% 25.0% 50.0% 0.0% 0.0% 0.0% 0.0% 0.0% 25.0% 0.0% 100.000%

TOTAL MFI 4

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.1 LUBE OIL SYSTEM SEV OCC DET RPN

Lube Oil Header Temperature RTD Failure 0 3 1 3 9

Lube Oil Header Temperature High 0 5 1 5 25

Lube Oil Header Temperature Low, Start Inhibited 0 3 1 4 12

Lube Oil Tank Level Transmitter Failure 0 3 1 3 9

Lube Oil Tank Level Low 0 5 1 6 30

Lube Oil Tank DP Transmitter Failure 0 3 1 3 9

Lube Oil Tank DP High 0 5 1 4 20

Lube Pump Output Module Failure 0 3 1 3 9

Lube Oil Header Pressure Transmitter Failure 0 3 1 3 9

Lube Oil Header Pressure Low 0 6 1 3 18

Lube Oil Tank Temperature RTD Failure 0 3 1 3 9

Engine Bearing 2 Drain Delta Temperature High 0 7 1 4 28

Engine Bearing 3 Drain Delta Temperature High 0 7 1 4 28

Engine Bearing 4&5 Drain Delta Temperature High 0 7 1 4 28

Engine Bearing 2&3 Drain Temperature RTD Failure 0 3 1 4 12

Engine Bearing 4&5 Drain Temperature RTD Failure 0 3 1 4 12

Backup Lube Oil Pump Test Failure 0 5 1 4 20

Lube Pressure Decay Check Failure 0 4 1 3 12

Pre/Post Lube Oil Pump Failure 0 8 1 3 24

Backup Lube Oil Pump Failure 0 8 1 3 24

Backup Lube Oil Pump Pressure Failure 0 6 1 3 18

Backup Lube Pressure Decay Check Failure 0 6 1 3 18

Lube Oil Tank Temperature Low Start Permissive 0 4 1 4 16

Low Start Pressure Lube Oil Inhibit 0 5 1 3 15

Possible Engine Bearing Failure Due to Interrupted Post Lube 0 8 1 3 24

Lube Oil Cooler Fans Vibration High 1 1 3 1 3 9

Possible Engine Bearing Failure Due to Low Header Pressure While

Rotating 0 8 1 3 24

S/D due to High Lube Oil consumption 0 8 1 5 40

ShutDown Due TO Lube Oil Leakge (Common) 1 2 1 1 5 5 3 5 75

Contribution Of MFIS %AGE UNIT WISE 16.7% 0.0% 33.3% 33.3% 0.0% 0.0% 0.0% 0.0% 0.0% 16.7% 100.000%

TOTAL 6
 SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.2 START SYSTEM SEV OCC DET RPN

Test Crank Sequence Timeout 0 3 1 3 9

Loss of Gas Producer Speed Signal 0 3 1 3 9

Fail To Crank 0 3 1 3 9

Fail To Accelerate 0 3 1 4 12

Crank Speed High 0 3 1 3 9

Crank Speed Low 0 3 1 3 9

Starter Motor Temperature High 1 1 3 1 4 12

Bleed Valve Duct Damaged/Leakge 0 4 1 5 20

Start VFD Fault 0 3 1 3 9

Start VFD Turbine CNet Node Fault 0 4 1 3 12

Contribution Of MFIS %AGE UNIT WISE 0.0% 0.0% 0.0% 100.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 100.000%

TOTAL 1

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.3 FUEL SYSTEM SEV OCC DET RPN

Main Gas Fuel Valve Manual Test Active during Turbine Start 0 3 1 3 9

Gas Fuel Vent Pressure High 0 3 1 3 9

Gas Producer Maximum Momentary Speed Exceeded 0 3 1 3 9

Power Turbine Maximum Momentary Speed Exceeded 0 3 1 4 12

Gas Producer Compressor Discharge Pressure Dual Transmitter

Failure 0 3 1 3 9

Gas Fuel Control DP Transmitter Failure 0 3 1 3 9

Gas Fuel Supply Pressure Transmitter Failure 0 3 1 3 9

Gas Fuel Supply Pressure High 0 3 1 3 9

Gas Fuel Valve Check Pressure Transmitter Failure 0 3 1 3 9

Gas Fuel Shutoff Valves Pressure High 0 3 1 3 9

Primary Gas Fuel Shutoff Valve Output Module Failure 0 3 1 3 9

Secondary Gas Fuel Shutoff Valve Output Module Failure 0 3 1 3 9

T5 Instantaneous Temperature High 1 1 2 4 2 4 32

Delayed Single T5 Thermocouple High 0 3 1 4 12

Single T5 Thermocouple High 0 3 1 4 12

T5 Thermocouples Fail to Completely Light Around 0 4 1 4 16

Main Gas Fuel Valve Actuator Fault 0 6 1 3 18

Main Gas Fuel Valve Position Transmitter Failure 0 3 1 3 9

Engine Flameout Detected By High Fuel Command 1 1 5 1 3 15

Engine Flameout Detected By High Fuel Flow 2 1 3 5 2 3 30

Engine Flameout Detected By Low Engine Temperature 0 4 1 3 12

Engine Under Speed Possibly Due to Flameout 0 4 1 3 12

Main Gas Fuel Valve Position Failure 0 5 1 3 15

Gas Fuel Valve Check Failure 0 4 1 3 12

High Start Gas Fuel Flow 0 4 1 3 12

Ignition Failure 1 1 3 1 3 9

Gas Producer Acceleration Rate Low 0 4 1 4 16

Gas Producer Over Speed 0 3 1 4 12

Gas Producer Under Speed 0 5 1 4 20

Power Turbine Fail to Break Away 0 5 1 3 15

Power Turbine Over Speed 0 5 1 3 15

Power Turbine Under Speed 0 3 1 3 9

Flameout Switch failure to transfer on shutdown 0 3 1 3 9

Thermocouple Input Module Multiple Thermistor Failure 0 3 1 4 12

Gas Producer Compressor Discharge Pressure Signal Difference

High 0 3 1 4 12

Gas Producer Compressor Discharge Pressure Transmitter Failure 0 3 1 4 12

Gas Producer Compressor Discharge Pressure Transmitter #2 Failure 0 3 1 4 12

Multiple T5 Thermocouple Failure 0 4 1 4 16

T5 Delayed Temperature High 0 3 1 4 12

Failure To Unload Driver 0 5 1 4 20

T5 Cold Junction Temperature RTD Failure 0 3 1 3 9

Gas Fuel Temperature High 0 3 1 3 9

Main Gas Fuel Valve Actuator Over Temeprature 0 4 1 3 12

Gas Fuel Control Valve Pressure High 0 4 1 3 12

Gas Fuel Control Temperature RTD Failure 0 3 1 4 12

Shutdown Due to GAS Leakge/ Abnormal sound/ Exhaust Below 1 1 2 8 2 6 96

Contribution Of MFIS %AGE UNIT WISE 0.0% 11.1% 11.1% 0.0% 22.2% 0.0% 0.0% 0.0% 44.4% 11.1% 100.000%

TOTAL 9

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.4 SEAL OIL/GAS, BUFFER AIR/GAS SYSTEM SEV OCC DET RPN

Seal Oil Main Pump Delayed Low Pressure Shutdown 0 3 1 4 12

Aux Seal Pump Discharge Pressure Transmitter Failure 0 3 1 3 9

Backup Seal Pump Motor Motive Force Pressure Transmitter Failure 0 3 1 3 9

Backup Seal Pump Discharge Pressure Transmitter Failure 0 3 1 3 9

HPC Buffer Gas DP Transmitter Failure 0 3 1 3 9

HPC Buffer Gas DP Low 0 3 1 4 12

HPC Seal Oil DP Transmitter Failure 0 3 1 3 9

HPC Seal Oil DP Low 0 5 1 4 20

Auxiliary Seal Oil Pump Failure 0 3 1 3 9

Back Up Seal Oil Pump Failure 0 3 1 3 9

Backup Seal Oil Pressure Decay Check Fail 0 3 1 3 9

Backup Seal Oil Pump Restart Fail 0 3 1 3 9

Aux Seal Pump Motive Force Loss [AC Power] 0 3 1 3 9

BU Seal Pump Motive Force Loss 0 3 1 3 9

Seal Oil Pressure Decay Check Fail 0 3 1 4 12

HPC Discharge Primary Seal Vent Transmitter Failure 0 3 1 4 12

HPC Discharge Primary Seal Flow High 0 5 1 4 20

HPC Suction Primary Seal Vent Transmitter Failure 0 3 1 3 9

HPC Suction Primary Seal Flow High 0 5 1 4 20

HPC Seal Gas Transmitter Failure 0 3 1 3 9

HPC Seal Gas DP Low 0 5 1 4 20

HPC Buffer Air Transmitter Failure 0 3 1 3 9

HPC Buffer Air DP Low 0 4 1 4 16

HPC Secodary Seal Flow High, Prior to Start 0 3 1 4 12

Seal System Start Premissive Failure 0 3 1 4 12

Contribution Of MFIS %AGE UNIT WISE #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

TOTAL 0
 SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.5 VIBRATION SYSTEM SEV OCC DET RPN

Engine GP Velocity Vibration High 1 1 6 1 4 24

Engine PT Velocity Vibration High 2 2 6 2 4 48

HPC Suction X-Axis Radial Vibration High 0 6 1 4 24

HPC Suction Y-Axis Radial Vibration High 0 6 1 4 24

HPC Discharge X-Axis Radial Vibration High 0 6 1 4 24

HPC Discharge Y-Axis Radial Vibration High 0 6 1 4 24

HPC Axial Displacement # 1 High 0 6 1 4 24

HPC Axial Displacement # 2 High 0 6 1 4 24

Contribution Of MFIS %AGE UNIT WISE 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 100.0% 0.0% 0.0% 0.0% 100.000%

TOTAL 3

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.6 YARD VALVE & HPC MONITORING SYSTEM SEV OCC DET RPN

Process Gas Discharge Valve Limit Switch Fail 0 2 1 3 6

Discharge Valve Command Disagree 1 1 1 3 2 2 3 12

Hot Bypass Valve Command Disagree 1 1 2 2 2 3 12

Hot Bypass Valve Limit Switch Fail 0 2 1 3 6

Process Gas Loading Valve Limit Switch Fail 0 2 1 3 6

Loading Valve Command Disagree 1 1 2 1 3 6

Process Gas Suction Valve Limit Switch Fail 0 2 1 3 6

Suction Valve Command Disagree 1 1 2 2 2 3 12

Vent Valve Command Disagree 1 2 3 2 2 3 12

Process Gas Vent Valve Limit Switch Fail 0 2 1 3 6

HPC Case Pressure Switch Failed 0 2 1 4 8

Compressor Fail to Pressurize 0 2 1 4 8

HPC Discharge Gas Pressure Transmitter Failure 0 2 1 3 6

HPC Discharge Gas Pressure High 1 1 4 1 4 16

Compressor Failed to Load 0 3 1 4 12

HPC Suction Gas Pressure Transmitter Failure 0 3 1 3 9

HPC Suction Gas Pressure Low 0 2 1 3 6

HPC Suction Gas Temperature RTD Failure 0 3 1 3 9

Discharge Flow Control Process Variable Transmitter Fail 0 3 1 3 9

HPC Discharge Gas Temperature RTD Failure 0 3 1 3 9

Possible Check Valve Failure - Unexpected NPT Detected 0 4 1 4 16

Process Gas Valve Position Failure 0 4 1 4 16

High Pressure Compressor In Surge 0 5 1 4 20

HPC Discharge Gas Temperature High 0 4 1 3 12

HPC Outboard Thrust Bearing Lower Pad Temperature RTD Failure 0 4 1 3 12

HPC Outboard Thrust Bearing Upper Pad Temperature RTD Failure 0 4 1 3 12

HPC Inboard Thrust Bearing Lower Pad Temperature RTD Failure 0 4 1 3 12

HPC Inboard Thrust Bearing Upper Pad Temperature RTD Failure 0 4 1 3 12

HPC Suction Journal Bearing Lower Pad Temperature RTD Failure 0 4 1 3 12

HPC Suction Journal Bearing Upper Pad Temperature RTD Failure 0 4 1 3 12

HPC Discharge Journal Bearing Lower Pad Temperature RTD Failure 0 4 1 3 12

HPC Discharge Journal Bearing Upper Pad Temperature RTD Failure 0 4 1 3 12

HPC Impeller Eye DP Transmitter Fail 0 4 1 3 12

HPC Outboard Thrust Bearing Lower Pad Temperature High 0 4 1 3 12

HPC Outboard Thrust Bearing Upper Pad Temperature High 0 4 1 3 12

HPC Inboard Thrust Bearing Lower Pad Temperature High 0 4 1 3 12

HPC Inboard Thrust Bearing Upper Pad Temperature High 0 4 1 3 12

HPC Suction Journal Bearing Lower Pad Temperature High 0 4 1 3 12

HPC Suction Journal Bearing Upper Pad Temperature High 0 4 1 3 12

HPC Discharge Journal Bearing Lower Pad Temperature High 0 4 1 3 12

HPC Discharge Journal Bearing Upper Pad Temperature High 0 4 1 4 16

Contribution Of MFIS %AGE UNIT WISE 0.0% 0.0% 8.3% 16.7% 16.7% 0.0% 8.3% 0.0% 8.3% 41.7% 100.000%

TOTAL 12

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.7 ANTI SURGE SYSTEM SEV OCC DET RPN

HPC Anti-Surge Control Differential Pressure Transmitter Fail 0 3 1 3 9

HPC Possible Reverse Flow Condition Check 0 5 1 4 20

HPC Anti-Surge Valve Position Fail 2 1 2 5 4 3 3 36

HPC Anti-Surge Valve Limit Switch Fail 0 3 1 3 9

Failure To Unload Turbine 0 4 1 4 16

Contribution Of MFIS %AGE UNIT WISE 0.0% 40.0% 0.0% 0.0% 0.0% 20.0% 0.0% 40.0% 0.0% 0.0% 100.000%

TOTAL 5

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.8 BACKUP/ F&G SYSTEM SEV OCC DET RPN

Backup Overspeed 0 5 1 4 20

Backup Speed Probe Failure 0 4 1 3 12

Backup Overspeed Detected vs Backup System Latch Active

Mismatch 0 4 1 4 16

Micro Processor Fail vs Backup System Latch Active Mismatch 0 6 1 4 24

Backup Overspeed Monitor Analog Overspeed 0 3 1 4 12

Backup Overspeed Monitor Processor Test Fail 0 3 1 4 12

Backup Overspeed Monitor System Test Fail 0 3 1 4 12

Backup Overspeed Monitor Speed Tracking Error 0 3 1 4 12

Backup Overspeed Monitor Speed Transmitter Failure 0 3 1 4 12

Turbine Enclosure Combustible Gas Level High 0 8 1 5 40

Enclosure Fire Detected 0 8 1 5 40

Enclosure Fire Detected vs Backup System Latch Active Mismatch 0 5 1 5 25

Enclosure Fire System Discharged 0 7 1 3 21

Turbine Enclosure Gas Detected vs Backup System Latch Active

Mismatch 0 7 1 3 21

Turbine Enclosure Combustible Gas Detection Level High During

Prestart 0 7 1 3 21

Backup System Relay Failure 0 4 1 3 12

Fast Stop From Aux/Remote/Customer 0 3 1 2 6

Contribution Of MFIS %AGE UNIT WISE #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0! #DIV/0!

TOTAL 0
 SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.9 CONTROL SYSTEM SEV OCC DET RPN

24 Vdc Battery Charger Failure 0 3 1 3 9

External Watchdog Fault 0 3 1 3 9

Fast Stop Latch 0 7 1 3 21

Controller Executed First Pass 0 3 1 3 9

Control System 24 Vdc Supply Voltage Low 0 3 1 3 9

Flex I/O Module Fault 1 1 3 1 3 9

Turbine CNET Node Fault 1 1 3 1 3 9

HMI and HMI-S Non Responsive Issues 0 2 1 3 6

Power Failure/BlackOut 2 2 1 4 1 4 4 1 19 5 7 4 140

System Off Lockout 0 2 1 2 4

Contribution Of MFIS %AGE UNIT WISE 14.3% 9.5% 4.8% 19.0% 4.8% 0.0% 19.0% 0.0% 19.0% 9.5% 100.000%

TOTAL 21

PROCESS VALUE
P 1.0 AIR INLET SYSTEM 4.00 PROCESS CONTRIBUTION IN MFI
P 1.1 LUBE OIL SYSTEM 6.00
P 1.2 START SYSTEM 1.00
P 1.3 FUEL SYSTEM 9.00
P 1.4 SEAL OIL/GAS, BUFFER 4.00
0.00
AIR/GAS SYSTEM
P 1.5 VIBRATION SYSTEM 6.00
3.00 1.00
P 1.6 YARD VALVE & HPC
12.00 21.00
MONITORING SYS.
P 1.7 ANTI SURGE SYSTEM 5.00

P-1.8 BACKUP/ F&G SYSTEM 0.00 9.00

P 1.9 CONTROL SYSTEM 21.00

3.00 0.00
0.00 5.00

12.00

P 1.0 AIR INLET SYSTEM P 1.1 LUBE OIL SYSTEM

P 1.2 START SYSTEM P 1.3 FUEL SYSTEM
P 1.4 SEAL OIL/GAS, BUFFER AIR/GAS SYSTEM P 1.5 VIBRATION SYSTEM
P 1.6 YARD VALVE & HPC MONITORING SYS. P 1.7 ANTI SURGE SYSTEM
P-1.8 BACKUP/ F&G SYSTEM P 1.9 CONTROL SYSTEM
 FAILURE MODES AND EFFECTS ANALYSIS (2022)
PARENT PROCESS NAME AND IDENTIFICATION
# P-1 TURBINE PACKAGE (MD)
AC-4
SUB-PROCESS MFI TOTAL MFI OVER THE YEAR 54
P 1.0 AIR INLET SYSTEM 2.00 P 1.5 VIBRATION SYSTEM 2.00 SSTATION OFF STREAM PERIOD
5-3-22 TO 28-6-22
P 1.1 LUBE OIL SYSTEM 2.00 P 1.6 YARD VALVE & HPC MONITORING SYS. 16.00
30-6-22 TO 4-11-22
P 1.2 START SYSTEM 1.00 P 1.7 ANTI SURGE SYSTEM 1.00 10-11-22 TO 23-12-22 GO TO PROCESS FLOW DIAGRAM
P 1.3 FUEL SYSTEM 8.00 P-1.8 BACKUP/ F&G SYSTEM 1.00
P 1.4 SEAL OIL/GAS, BUFFER AIR/GAS SYSTEM 2.00 P 1.9 CONTROL SYSTEM 19.00

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.0 AIR INLET SYSTEM

RUNNING HOURS FOR THE PERIOD OF JAN,22 TO DEC,22 996 1057 375 789 171 106 1657 191 911 442 Total # of Starts 136
6695
START/STOP 14/15 17/16 10/11 15/15 12/11 13/13 16/16 11/10 13/13 15/16 Total # of Stops 136

FAILURE MODE U#1A U#2A U#3A U#4A U# 1B U#2B U#3B U#4B U#5B U#6B TOTAL SEV OCC DET RPN

Turbine Air Inlet Filter DP Transmitter Failure 0 3 1 3 9

Turbine Air Inlet Filter DP High 0 3 1 4 12

Turbine Enclosure Vent Fans 1 and 2 Failure 0 3 1 4 12

Turbine Enclosure Temperature High 1 1 3 1 3 9

Turbine Enclosure Vent Flow Switch Failure Start Permissive 0 3 1 3 9

Turbine Enclosure Pressure Transmitter Failure 0 3 1 3 9

Turbine Air Inlet Temperature RTD Failure 1 1 3 1 3 9

Turbine Enclosure Pressure Low 0 3 1 3 9

Contribution Of MFIS %AGE UNIT WISE 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 50.0% 50.0% 0.0% 0.0% 100.000%

TOTAL MFI 2

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.1 LUBE OIL SYSTEM SEV OCC DET RPN

Lube Oil Header Temperature RTD Failure 0 3 1 3 9

Lube Oil Header Temperature High 0 5 1 5 25

Lube Oil Header Temperature Low, Start Inhibited 0 3 1 4 12

Lube Oil Tank Level Transmitter Failure 0 3 1 3 9

Lube Oil Tank Level Low 0 5 1 6 30

Lube Oil Tank DP Transmitter Failure 0 3 1 3 9

Lube Oil Tank DP High 0 5 1 4 20

Lube Pump Output Module Failure 0 3 1 3 9

Lube Oil Header Pressure Transmitter Failure 0 3 1 3 9

Lube Oil Header Pressure Low 0 6 1 3 18

Lube Oil Tank Temperature RTD Failure 0 3 1 3 9

Engine Bearing 2 Drain Delta Temperature High 0 7 1 4 28

Engine Bearing 3 Drain Delta Temperature High 0 7 1 4 28

Engine Bearing 4&5 Drain Delta Temperature High 1 1 7 1 4 28

Engine Bearing 2&3 Drain Temperature RTD Failure 0 3 1 4 12

Engine Bearing 4&5 Drain Temperature RTD Failure 0 3 1 4 12

Backup Lube Oil Pump Test Failure 0 5 1 4 20

Lube Pressure Decay Check Failure 0 4 1 3 12

Pre/Post Lube Oil Pump Failure 0 8 1 3 24

Backup Lube Oil Pump Failure 0 8 1 3 24

Backup Lube Oil Pump Pressure Failure 0 6 1 3 18

Backup Lube Pressure Decay Check Failure 0 6 1 3 18

Lube Oil Tank Temperature Low Start Permissive 0 4 1 4 16

Low Start Pressure Lube Oil Inhibit 0 5 1 3 15

Possible Engine Bearing Failure Due to Interrupted Post Lube 0 8 1 3 24

Lube Oil Cooler Fans Vibration High 0 3 1 3 9

Possible Engine Bearing Failure Due to Low Header Pressure

While Rotating 0 8 1 3 24

S/D due to High Lube Oil consumption 1 1 8 1 5 40

ShutDown Due TO Lube Oil Leakge (Common) 0 5 1 5 25

Contribution Of MFIS %AGE UNIT WISE 0.0% 0.0% 0.0% 0.0% 0.0% 100.0% 0.0% 0.0% 0.0% 0.0% 100.000%

TOTAL 2
 SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.2 START SYSTEM SEV OCC DET RPN

Test Crank Sequence Timeout 0 3 1 3 9

Loss of Gas Producer Speed Signal 0 3 1 3 9

Fail To Crank 0 3 1 3 9

Fail To Accelerate 0 3 1 4 12

Crank Speed High 0 3 1 3 9

Crank Speed Low 0 3 1 3 9

Starter Motor Temperature High 0 3 1 4 12

Bleed Valve Duct Damaged/Leakge 0 4 1 5 20

Start VFD Fault 1 1 3 1 3 9

Start VFD Turbine CNet Node Fault 0 4 1 3 12

Contribution Of MFIS %AGE UNIT WISE 100.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 100.000%

TOTAL 1

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.3 FUEL SYSTEM SEV OCC DET RPN

Main Gas Fuel Valve Manual Test Active during Turbine Start 0 3 1 3 9

Gas Fuel Vent Pressure High 0 3 1 3 9

Gas Producer Maximum Momentary Speed Exceeded 0 3 1 3 9

Power Turbine Maximum Momentary Speed Exceeded 0 3 1 4 12

Gas Producer Compressor Discharge Pressure Dual Transmitter

Failure 0 3 1 3 9

Gas Fuel Control DP Transmitter Failure 0 3 1 3 9

Gas Fuel Supply Pressure Transmitter Failure 1 1 3 1 3 9

Gas Fuel Supply Pressure High 1 1 3 1 3 9

Gas Fuel Valve Check Pressure Transmitter Failure 0 3 1 3 9

Gas Fuel Shutoff Valves Pressure High 0 3 1 3 9

Primary Gas Fuel Shutoff Valve Output Module Failure 0 3 1 3 9

Secondary Gas Fuel Shutoff Valve Output Module Failure 0 3 1 3 9

T5 Instantaneous Temperature High 0 4 1 4 16

Delayed Single T5 Thermocouple High 0 3 1 4 12

Single T5 Thermocouple High 0 3 1 4 12

T5 Thermocouples Fail to Completely Light Around 0 4 1 4 16

Main Gas Fuel Valve Actuator Fault 3 1 4 6 3 3 54

Main Gas Fuel Valve Position Transmitter Failure 0 3 1 3 9

Engine Flameout Detected By High Fuel Command 0 5 1 3 15

Engine Flameout Detected By High Fuel Flow 0 5 1 3 15

Engine Flameout Detected By Low Engine Temperature 0 4 1 3 12

Engine Under Speed Possibly Due to Flameout 0 4 1 3 12

Main Gas Fuel Valve Position Failure 0 5 1 3 15

Gas Fuel Valve Check Failure 1 1 4 1 3 12

High Start Gas Fuel Flow 0 4 1 3 12

Ignition Failure 1 1 3 1 3 9

Gas Producer Acceleration Rate Low 0 4 1 4 16

Gas Producer Over Speed 0 3 1 4 12

Gas Producer Under Speed 0 5 1 4 20

Power Turbine Fail to Break Away 0 5 1 3 15

Power Turbine Over Speed 0 5 1 3 15

Power Turbine Under Speed 0 3 1 3 9

Flameout Switch failure to transfer on shutdown 0 3 1 3 9

Thermocouple Input Module Multiple Thermistor Failure 0 3 1 4 12

Gas Producer Compressor Discharge Pressure Signal Difference

High 0 3 1 4 12

Gas Producer Compressor Discharge Pressure Transmitter

Failure 0 3 1 4 12

Gas Producer Compressor Discharge Pressure Transmitter #2

Failure 0 3 1 4 12

Multiple T5 Thermocouple Failure 0 4 1 4 16

T5 Delayed Temperature High 0 3 1 4 12

Failure To Unload Driver 0 5 1 4 20

T5 Cold Junction Temperature RTD Failure 0 3 1 3 9

Gas Fuel Temperature High 0 3 1 3 9

Main Gas Fuel Valve Actuator Over Temeprature 0 4 1 3 12

Gas Fuel Control Valve Pressure High 0 4 1 3 12

Gas Fuel Control Temperature RTD Failure 0 3 1 4 12

Shutdown Due to GAS Leakge 0 8 1 6 48

Contribution Of MFIS %AGE UNIT WISE 0.0% 37.5% 0.0% 0.0% 0.0% 12.5% 0.0% 37.5% 12.5% 0.0% 100.000%

TOTAL 8

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.4 SEAL OIL/GAS, BUFFER AIR/GAS SYSTEM SEV OCC DET RPN

Seal Oil Main Pump Delayed Low Pressure Shutdown 0 3 1 4 12

Aux Seal Pump Discharge Pressure Transmitter Failure 0 3 1 3 9

Backup Seal Pump Motor Motive Force Pressure Transmitter

Failure 0 3 1 3 9

Backup Seal Pump Discharge Pressure Transmitter Failure 0 3 1 3 9

HPC Buffer Gas DP Transmitter Failure 0 3 1 3 9

HPC Buffer Gas DP Low 0 3 1 4 12

HPC Seal Oil DP Transmitter Failure 0 3 1 3 9

HPC Seal Oil DP Low 0 5 1 4 20

Auxiliary Seal Oil Pump Failure 0 3 1 3 9

Back Up Seal Oil Pump Failure 0 3 1 3 9

Backup Seal Oil Pressure Decay Check Fail 0 3 1 3 9

Backup Seal Oil Pump Restart Fail 0 3 1 3 9

Aux Seal Pump Motive Force Loss [AC Power] 0 3 1 3 9

BU Seal Pump Motive Force Loss 0 3 1 3 9

Seal Oil Pressure Decay Check Fail 0 3 1 4 12

HPC Discharge Primary Seal Vent Transmitter Failure 0 3 1 4 12

HPC Discharge Primary Seal Flow High 0 5 1 4 20

HPC Suction Primary Seal Vent Transmitter Failure 0 3 1 3 9

HPC Suction Primary Seal Flow High 0 5 1 4 20

HPC Seal Gas Transmitter Failure 0 3 1 3 9

HPC Seal Gas DP Low 0 5 1 4 20

HPC Buffer Air Transmitter Failure 0 3 1 3 9

HPC Buffer Air DP Low 0 4 1 4 16

HPC Secodary Seal Flow High, Prior to Start 2 2 3 2 4 24

Seal System Start Premissive Failure 0 3 1 4 12

Contribution Of MFIS %AGE UNIT WISE 0.0% 0.0% 0.0% 100.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 100.000%

TOTAL 2
SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.5 VIBRATION SYSTEM SEV OCC DET RPN

Engine GP Velocity Vibration High 0 6 1 4 24

Engine PT Velocity Vibration High 1 1 6 1 4 24

HPC Suction X-Axis Radial Vibration High 0 6 1 4 24

HPC Suction Y-Axis Radial Vibration High 1 1 6 1 4 24

HPC Discharge X-Axis Radial Vibration High 0 6 1 4 24

HPC Discharge Y-Axis Radial Vibration High 0 6 1 4 24

HPC Axial Displacement # 1 High 0 6 1 4 24

HPC Axial Displacement # 2 High 0 6 1 4 24

Contribution Of MFIS %AGE UNIT WISE 0.0% 50.0% 0.0% 0.0% 0.0% 50.0% 0.0% 0.0% 0.0% 0.0% 100.000%

TOTAL 2

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.6 YARD VALVE & HPC MONITORING SYSTEM SEV OCC DET RPN

Process Gas Discharge Valve Limit Switch Fail 0 2 1 3 6

Discharge Valve Command Disagree 1 1 2 1 3 6

Hot Bypass Valve Command Disagree 0 2 1 3 6

Hot Bypass Valve Limit Switch Fail 2 2 2 2 3 12

Process Gas Loading Valve Limit Switch Fail 0 2 1 3 6

Loading Valve Command Disagree 1 2 3 2 2 3 12

Process Gas Suction Valve Limit Switch Fail 0 2 1 3 6

Suction Valve Command Disagree 1 1 2 2 2 3 12

Vent Valve Command Disagree 1 1 1 3 2 2 3 12

Process Gas Vent Valve Limit Switch Fail 0 2 1 3 6

HPC Case Pressure Switch Failed 0 2 1 4 8

Compressor Fail to Pressurize 0 2 1 4 8

HPC Discharge Gas Pressure Transmitter Failure 0 2 1 3 6

HPC Discharge Gas Pressure High 1 1 2 4 2 4 32

Compressor Failed to Load 0 3 1 4 12

HPC Suction Gas Pressure Transmitter Failure 0 3 1 3 9

HPC Suction Gas Pressure Low 0 2 1 3 6

HPC Suction Gas Temperature RTD Failure 0 3 1 3 9

Discharge Flow Control Process Variable Transmitter Fail 0 3 1 3 9

HPC Discharge Gas Temperature RTD Failure 0 3 1 3 9

Possible Check Valve Failure - Unexpected NPT Detected 0 4 1 4 16

Process Gas Valve Position Failure 1 1 4 1 4 16

High Pressure Compressor In Surge 1 1 5 1 4 20

HPC Discharge Gas Temperature High 1 1 4 1 3 12

HPC Outboard Thrust Bearing Lower Pad Temperature RTD

Failure 0 4 1 3 12

HPC Outboard Thrust Bearing Upper Pad Temperature RTD

Failure 0 4 1 3 12

HPC Inboard Thrust Bearing Lower Pad Temperature RTD

Failure 0 4 1 3 12

HPC Inboard Thrust Bearing Upper Pad Temperature RTD

Failure 0 4 1 3 12

HPC Suction Journal Bearing Lower Pad Temperature RTD

Failure 0 4 1 3 12

HPC Suction Journal Bearing Upper Pad Temperature RTD

Failure 0 4 1 3 12

HPC Discharge Journal Bearing Lower Pad Temperature RTD

Failure 0 4 1 3 12

HPC Discharge Journal Bearing Upper Pad Temperature RTD

Failure 0 4 1 3 12

HPC Impeller Eye DP Transmitter Fail 0 4 1 3 12

HPC Outboard Thrust Bearing Lower Pad Temperature High 0 4 1 3 12

HPC Outboard Thrust Bearing Upper Pad Temperature High 0 4 1 3 12

HPC Inboard Thrust Bearing Lower Pad Temperature High 0 4 1 3 12

HPC Inboard Thrust Bearing Upper Pad Temperature High 0 4 1 3 12

HPC Suction Journal Bearing Lower Pad Temperature High 0 4 1 3 12

HPC Suction Journal Bearing Upper Pad Temperature High 0 4 1 3 12

HPC Discharge Journal Bearing Lower Pad Temperature High 0 4 1 3 12

HPC Discharge Journal Bearing Upper Pad Temperature High 0 4 1 4 16

Contribution Of MFIS %AGE UNIT WISE 6.3% 0.0% 0.0% 25.0% 6.3% 0.0% 0.0% 6.3% 50.0% 6.3% 100.000%

TOTAL 16

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.7 ANTI SURGE SYSTEM SEV OCC DET RPN

HPC Anti-Surge Control Differential Pressure Transmitter Fail 0 3 1 3 9

HPC Possible Reverse Flow Condition Check 0 5 1 4 20

HPC Anti-Surge Valve Position Fail 1 1 4 1 3 12

HPC Anti-Surge Valve Limit Switch Fail 0 3 1 3 9

Failure To Unload Turbine 0 4 1 4 16

Contribution Of MFIS %AGE UNIT WISE 0.0% 0.0% 0.0% 0.0% 100.0% 0.0% 0.0% 0.0% 0.0% 0.0% 100.000%

TOTAL 1

SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.8 BACKUP/ F&G SYSTEM SEV OCC DET RPN

Backup Overspeed 0 5 1 4 20

Backup Speed Probe Failure 0 4 1 3 12

Backup Overspeed Detected vs Backup System Latch Active

Mismatch 0 4 1 4 16

Micro Processor Fail vs Backup System Latch Active Mismatch 0 6 1 4 24

Backup Overspeed Monitor Analog Overspeed 0 3 1 4 12

Backup Overspeed Monitor Processor Test Fail 0 3 1 4 12

Backup Overspeed Monitor System Test Fail 0 3 1 4 12

Backup Overspeed Monitor Speed Tracking Error 0 3 1 4 12

Backup Overspeed Monitor Speed Transmitter Failure 0 3 1 4 12

Turbine Enclosure Combustible Gas Level High 0 8 1 5 40

Enclosure Fire Detected 0 8 1 5 40

Enclosure Fire Detected vs Backup System Latch Active

Mismatch 0 5 1 5 25

Enclosure Fire System Discharged 0 7 1 3 21

Turbine Enclosure Gas Detected vs Backup System Latch Active

Mismatch 0 7 1 3 21

Turbine Enclosure Combustible Gas Detection Level High During

Prestart 0 7 1 3 21

Backup System Relay Failure 1 1 4 1 3 12

Fast Stop From Aux/Remote/Customer 0 3 1 2 6

Contribution Of MFIS %AGE UNIT WISE 100.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 100.000%

TOTAL 1
SUBSYSTEM PROCESS AND IDENTIFICATION # P-1.9 CONTROL SYSTEM SEV OCC DET RPN

24 Vdc Battery Charger Failure 1 1 3 1 3 9

External Watchdog Fault 0 3 1 3 9

Fast Stop Latch 0 7 1 3 21

Controller Executed First Pass 0 3 1 3 9

Control System 24 Vdc Supply Voltage Low 1 1 3 1 3 9

Flex I/O Module Fault 2 2 2 1 2 9 3 5 3 45

Turbine CNET Node Fault 0 3 1 3 9

HMI and HMI-S Non Responsive Issues 2 1 3 2 2 3 12

Power Failure/BlackOut/Short Circuit 1 2 1 1 5 5 3 4 60

System Off Lockout 0 2 1 2 4

Contribution Of MFIS %AGE UNIT WISE 10.5% 5.3% 31.6% 10.5% 5.3% 0.0% 10.5% 5.3% 5.3% 15.8% 100.000%

TOTAL 19

PROCESS VALUE PROCESS CONTRIBUTION IN MFI

P 1.0 AIR INLET SYSTEM 2.00
P 1.1 LUBE OIL SYSTEM 2.00
P 1.2 START SYSTEM 1.00
P 1.3 FUEL SYSTEM 8.00 1.00
P 1.4 SEAL OIL/GAS, BUFFER 2.00
2.00 2.00
AIR/GAS SYSTEM
P 1.5 VIBRATION SYSTEM 2.00
P 1.6 YARD VALVE & HPC
16.00
MONITORING SYS.
P 1.7 ANTI SURGE SYSTEM 1.00 8.00
19.00
P-1.8 BACKUP/ F&G
1.00
SYSTEM
P 1.9 CONTROL SYSTEM 19.00

2.00

2.00

1.00
1.00
16.00

P 1.0 AIR INLET SYSTEM P 1.1 LUBE OIL SYSTEM

P 1.2 START SYSTEM P 1.3 FUEL SYSTEM
P 1.4 SEAL OIL/GAS, BUFFER AIR/GAS SYSTEM P 1.5 VIBRATION SYSTEM
P 1.6 YARD VALVE & HPC MONITORING SYS. P 1.7 ANTI SURGE SYSTEM
P-1.8 BACKUP/ F&G SYSTEM P 1.9 CONTROL SYSTEM
 FAILURE MODES AND EFFECTS ANALYSIS (2021)
PARENT PROCESS NAME AND
GEN SET CONTRIBUTION IN MFI
IDENTIFICATION # P-5 POWER GENERATION
AC-4
GEN SET MFI TOTAL MFI OVER THE YEAR 36
GEN SET A Contributtion 14.00 GEN SET B Contributtion 22.00
SUBSYSTEM PROCESS AND
IDENTIFICATION # P-5.1,5.2,5.3,5.4 Elect. /Driver/Driven/Aux Systems
14.00
RUNNING HOURS FOR THE PERIOD OF 3627 5116 Total # of Starts 83
8743
JAN,21 TO DEC,21 START/STOP
46/49 37/36 Total # of Stops 85

FAILURE MODE GEN SET A GEN SET B TOTAL SEV OCC DET RPN
22.00
Hardware Failure (Modules, ECM, etc)/
0 7 2 6 84
Synchronization

MFI Due To Circuit Breakers /Load Sharing 0 5 1 6 30

Battery Charger/ Batteries 0 4 3 6 72 Gen Set A Gen Set B

Under/Over Voltage, RPM Fluctuations 6 4 10 6 1 5 30

Electronic Ignition System/Ignition Failure 1 1 2 6 6 5 180

Engine/Lube Oil Temperature High/Low 1 1 2 5 2 5 50

Vibration High/ Abnormal Noises 1 4 5 7 5 6 210

Water Circulating System 5 5 5 4 4 80

Oil Leakges 1 1 2 7 1 6 42

Ventilation System 0 3 1 4 12

Start System/Under/Over Speed 0 4 3 5 60

HMI Non Resposive/Fail 0 3 3 4 36

ShutDown With No Indication 4 5 9 3 2 7 42

Fuel System 1 1 5 3 5 75

Total MFIs Gen Set Wise 14.0 22.0

TOTAL MFI 36
 FAILURE MODES AND EFFECTS ANALYSIS (2022)
PARENT PROCESS NAME AND
GEN SET CONTRIBUTION IN MFI
IDENTIFICATION # P-5 POWER GENERATION
AC-4
GEN SET MFI TOTAL MFI OVER THE YEAR 21
GEN SET A Contributtion 10.00 GEN SET B Contributtion 11.00
SUBSYSTEM PROCESS AND
IDENTIFICATION # P-5.1,5.2,5.3,5.4 Elect. /Driver/Driven/Aux Systems
RUNNING HOURS FOR THE PERIOD OF 3360 5389 Total # of Starts 78
8749 10.00
JAN,22 TO DEC,22 START/STOP
46/40 32/30 Total # of Stops 70
11.00
FAILURE MODE GEN SET A GEN SET B TOTAL SEV OCC DET RPN

Hardware Failure (Modules, ECM, etc)/

0 7 2 6 84
Synchronization

MFI Due To Circuit Breakers /Load Sharing 0 5 1 6 30

Battery Charger/ Batteries 3 3 4 3 6 72 Gen Set A Gen Set B

Under/Over Voltage, RPM Fluctuations 1 1 6 1 5 30

Electronic Ignition System/Ignition Failure 1 1 6 6 5 180

Engine/Lube Oil Temperature High/Low 0 5 2 5 50

Vibration High/ Abnormal Noises 2 2 7 5 6 210

Water Circulating System 1 1 2 5 4 4 80

Oil Leakges 1 1 2 7 1 6 42

Ventilation System 0 3 1 4 12

Start System/Under/Over Speed 0 4 3 5 60

HMI Non Resposive/Fail 0 3 3 4 36

ShutDown With No Indication 6 2 8 3 2 7 42

Fuel System 1 1 2 5 3 5 75

Total MFIs Gen Set Wise 10.0 11.0

TOTAL MFI 21