Perencanaan Preventif Maintenance Menggunakan Reliability-Centered Maintenance II Untuk Mencegah Kegagalan Peralatan Di Pembangkit Listrik Tenaga Uap

Risnatha, I Gede Sukma Setia (2024) Perencanaan Preventif Maintenance Menggunakan Reliability-Centered Maintenance II Untuk Mencegah Kegagalan Peralatan Di Pembangkit Listrik Tenaga Uap. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Loss production akibat breakdown peralatan kritis sangat dihindari dalam bisnis pembangkitan tenaga listrik karena pendapatan produksi akan turun. Pada tahun 2023, Total Loss Production di Pembangkit Listrik Tenaga Uap (PLTU) ADP yang dikelola oleh PT. XYZ mencapai 1.010.432,7 MWh, salah satunya akibat breakdown peralatan coal feeder sehingga target kinerja Equivalen Availability Factor (EAF) tidak tercapai dengan realisasi sebesar 81,24% dari target 86,74%. Salah satu penyebab breakdown adalah penerapan strategi pemeliharaan yang belum tepat dan efektif. Penelitian ini bertujuan untuk merencanakan preventif maintenance (PM) pada peralatan kritis coal feeder di PLTU ADP menggunakan metode Reliability-Centered Maintenance II (RCM II) serta menganalisa data failure peralatan untuk menentukan interval waktu pelaksanaan PM yang tepat dan efektif. Tahapan penelitian dimulai dengan mengumpulkan data, dan perhitungan nilai kehandalan peralatan sesuai dengan konfigurasi reliability block diagram. Selanjutnya menentukan interval waktu pelaksanaan PM yang tepat dengan kriteria Reliability Function R(t)<60%. Tahap selanjutnya, mendefinisian Function Equipment, mengidentifikasi Function Failure Equipment, kegagalan fungsi menggunakan Failure Mode Equipment Analysis (FMEA) dan mengevaluasi Failure Consequences untuk mendapatkan tindakan pemeliharaan yang tepat dengan pendekatan RCM II. Hasil penelitian ini diperoleh strategi perencanaan PM peralatan Coal feeder dengan tindakan pemeliharaan Scheduled discard task atau Scheduled restoration task sesuai interval waktu optimum PM dengan kriteria reliability 60% pada setiap komponen, diantaranya Feeder Belt Assembly dilakukan pada interval waktu 2738,85 jam, Microprocessor Feeder Electronics pada 3312,1 jam, Cleanout Conveyor pada 8601,56 jam, Weighing Component pada 3200,42 jam, Protection Device pada 12938,05 jam, Frame pada 4421 jam, dan Inlet Outlet Valve pada 2900,56 jam. Peningkatan nilai kehandalan peralatan Coal feeder dari 11,21% menjadi 74,19% dapat dilakukan dengan memprioritaskan pelaksanaan PM melalui penggantian atau perbaikan komponen coal feeder yang mempunyai nilai kehandalan kurang dari atau mendekati 60% yaitu komponen Inlet Outlet Valve, Cleanout Conveyor, Microprocessor feeder electronics dan Proteksi sehingga dapat mencegah terjadinya kegagalan peralatan Coal feeder.
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Loss of production due to breakdowns of critical equipment is highly avoided in the electricity generation business, as it directly reduces production revenue. In 2023, the total loss of production at the ADP Coal-Fired Power Plant (PLTU ADP) managed by PT. XYZ reached 1,010,432.7 MWh, one cause being the breakdown of the coal feeder equipment. This failure resulted in the performance target for the Equivalent Availability Factor (EAF) not being achieved, with an actual value of 81.24% compared to the target of 86.74%. One contributing factor to these breakdowns is the implementation of maintenance strategies that are neither appropriate nor effective. This study aims to plan preventive maintenance (PM) for critical coal feeder equipment at PLTU ADP using the Reliability-Centered Maintenance II (RCM II) method and to analyze equipment failure data to determine an accurate and effective PM schedule. The research process begins with data collection and calculation of equipment reliability values based on the reliability block diagram configuration. Next, the optimal PM interval is determined using the reliability function criterion R(t)<60%. Subsequent steps include defining the function of the equipment, identifying functional failures, analyzing failures using Failure Mode and Effects Analysis (FMEA), and evaluating the consequences of failures to propose appropriate maintenance actions using the RCM II approach. The study results provide a PM strategy for coal feeder equipment through scheduled discard or scheduled restoration tasks, based on optimal PM intervals with a reliability criterion of 60% for each component. These intervals include Feeder Belt Assembly: 2,738.85 hours, Microprocessor Feeder Electronics: 3,312.1 hours, Cleanout Conveyor: 8,601.56 hours, Weighing Component: 3,200.42 hours, Protection Device: 12,938.05 hours, Frame: 4,421 hours, Inlet Outlet Valve: 2,900.56 hours. The reliability of coal feeder equipment can be increased from 11.53% to 74.19% by prioritizing PM tasks, including replacing or repairing components with reliability values below or close to 60%. These components include the Inlet Outlet Valve, Cleanout Conveyor, Microprocessor Feeder Electronics and Protection, thereby preventing coal feeder equipment failures.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Preventive Maintenance, Peralatan Kritis, Reliability-Centered Maintenance II, Kehandalan, Critical Equipment, Reliability Centered Maintenance, Reliability, Coal feeder
Subjects:	T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering)
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	I Gede Sukma Setia Risnatha
Date Deposited:	07 Jan 2025 07:25
Last Modified:	07 Jan 2025 07:25
URI:	http://repository.its.ac.id/id/eprint/116205

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