Safira, Sheren Marsha (2024) Optimisasi Maintenance Cost Berdasarkan Nilai Failure Rate, Analisis Reliability, Availability, dan Maintainability (RAM) dan Reliability Centered Maintenance (RCM) pada Unit 101 Resid Fluid Catalytic Cracking (RFCC) di PT XYZ. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Industri minyak dan gas berpotensi menghasilkan residu dalam proses pengolahan, seperti Low Sulphur Waxy Residue (LSWR) yang dihasilkan oleh Crude Distillation Unit (CDU) PT XYZ. Resid Fluid Catalytic Cracking (RFCC) dapat mengolah LSWR menjadi produk yang lebih bernilai seperti bensin, LPG, dan propilena. Selama beroperasi unit 101 RFCC pada PT XYZ sering mengalami kegagalan yang sebagian besar disebabkan valve sehingga mengakibatkan gangguan produksi, kerugian, dan peningkatan biaya pemeliharaan. Dalam mengatasi hal tersebut, diperlukan analisis RAM dan RCM, serta pengoptimalan maintenance cost. Analisis RAM untuk mengevaluasi nilai failure rate, reliability, availability, dan maintainability. Analisis RCM untuk mengidentifikasi fungsi komponen atau sistem, fungsi kegagalan, mode kegagalan dan analisis dampak, konsekuensi kegagalan, dan tindakan proaktif. Hasil analisis RAM menunjukkan nilai reliability ketika 2160 jam beroperasi pada Governor Control Valve sebesar 57%, Special Check Valve sebesar 79%, Regenerated Catalyst Slide Valve sebesar 76%, dan Recirculation Catalyst Slide Valve 83%. Hasil analisis RCM menunjukkan peralatan memiliki mode kegagalan berbeda-beda setiap valve dengan tindakan proaktif yang diusulkan meliputi Scheduled On-Condition Task dan Scheduled Discard Task. Metode Particle Swarm Optimization (PSO) digunakan untuk mengoptimalkan maintenance cost karena lebih cepat mencapai solusi optimal dibandingkan teknik optimisasi lainnya. Hasil dari optimisasi PSO menunjukkan bahwa PSO dapat mengoptimalkan maintenance cost, yaitu mendapatkan penghematan sebesar $133570,65 selama 4 tahun beroperasi, $166961,70 selama 5 tahun beroperasi, $200352,75 selama 6 tahun beroperasi, dan $233743,80 selama 7 tahun beroperasi
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The oil and gas industry generates residue during processing, such as Low Sulphur Waxy Residue (LSWR) produced by PT XYZ's Crude Distillation Unit (CDU). The Resid Fluid Catalytic Cracking (RFCC) unit effectively converts LSWR into valuable products like gasoline, LPG, and propylene. However, PT XYZ's RFCC unit 101 frequently experiences valve-related failures, leading to production disruptions, losses, and increased maintenance costs. To address these issues, RAM and RCM analysis, along with maintenance cost optimization, are implemented. RAM analysis evaluates failure rate, reliability, availability, and maintainability. RCM analysis identifies component or system functions, failure functions, failure modes and effects analysis (FMEA), failure consequences, and proactive measures. RAM analysis reveals the reliability values of the Governor Control Valve, Special Check Valve, Regenerated Catalyst Slide Valve, and Recirculation Catalyst Slide Valve at 57%, 79%, 76%, and 83%, respectively, after 2160 hours of operation. RCM analysis shows that various valves exhibit distinct failure modes like Fail to Regulate, Fail to Open, and Internal Leakage. The proposed proactive measures include Scheduled On-Condition Task and Scheduled Discard Task. Particle Swarm Optimization (PSO) method is employed to optimize maintenance costs due to its superior ability to reach optimal solutions compared to other optimization techniques. The results of the PSO optimization show that PSO can optimize maintenance costs, achieving savings of $133,570.65 over 4 years of operation, $166,961.70 over 5 years, $200,352.75 over 6 years, and $233,743.80 over 7 years.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | RFCC, RAM, RCM, maintenance cost, Optimisasi, PSO. RFCC, RAM, RCM, maintenance cost, Optimization, PSO. |
| Subjects: | T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering) |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Physics Engineering > 30201-(S1) Undergraduate Thesis |
| Depositing User: | Sheren Marsha Safira |
| Date Deposited: | 01 Aug 2024 08:27 |
| Last Modified: | 01 Aug 2024 08:27 |
| URI: | http://repository.its.ac.id/id/eprint/109460 |
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