<![CDATA[Tugboats play an essential role in port activities, but their cooling systems are vulnerable to failures that can potentially trigger serious accidents. This study aims to analyze the risks of tugboat cooling systems through a Formal Safety Assessment (FSA) using the Failure Mode and Effects Analysis (FMEA) method based on field surveys and accident data. Data collection was conducted via questionnaires to 12 engine room crew (including the Chief Engine Room Officer, Engineer, and Technician) and the accident investigation report of TB. Kawan Kita XI (2025), which was used as external validation by cross-refencing the documented failure causes with the high-priority FMEA result. This study identified 14 failure modes in 9 key components of the cooling system, assessed based on severity (Severity), frequency (Occurrence), and detection (Detection) on a scale of 1–10. The average value of the 12 respondents was used to calculate the Risk Priority Number (RPN) and Pareto analysis. Key findings revealed six priority risks: mechanical seal leakage (RPN=405), cylinder head cooling jacket cracking (RPN=300), freshwater pump bearing failure (RPN=243), sea chest strainer corrosion (RPN=216), temperature control valve sticking (RPN=216), and internal cooler leakage (RPN=168). These six modes accounted for 82.6% of the total risk, consistent with the Pareto principle. The uniqueness of this study lies in the integration of multi-vessel survey data, a more accurate 1–10 rating scale, and validation from actual accidents. Recommendations include preventive seal replacement, installation of leak sensors, regular valve maintenance, and anti-corrosion protection. This study contributes to strengthening the operational safety of tugboats in Indonesia.]]>
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