Perencanaan Pemeliharaan Pabrik Amonia Dengan Reliability Centered Maintenance 3

Islam, Muhammad Hafidzul (2025) Perencanaan Pemeliharaan Pabrik Amonia Dengan Reliability Centered Maintenance 3. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Amonia merupakan produk krusial sebagai bahan baku pupuk, sehingga produktivitas pabrik amonia harus dijaga guna mencegah gangguan produksi berantai dan kerugian perusahaan. Proses produksinya melibatkan kondisi suhu dan tekanan ekstrem membuat peralatan rentan terhadap kegagalan. Tercatat, kegagalan peralatan telah menyebabkan rata-rata 37,21 hari downtime per tahun pada periode 2021-2023. Di samping itu, kegagalan peralatan dalam proses produksi amonia memiliki risiko ledakan pada tabung bertekanan tinggi yang dapat berdampak pada operasional, finansial, keselamatan, dan lingkungan. Oleh karena itu, penelitian ini bertujuan untuk merencanakan pemeliharaan menggunakan kerangka kerja Reliability Centered Maintenance 3 (RCM 3) yang mempertimbangkan risiko dari kegagalan peralatan. Penelitian ini diawali dengan identifikasi subsistem kritis dengan menggunakan prinsip pareto. Selanjutnya, seluruh peralatan dalam subsistem kritis dianalisis menggunakan RCM 3 Information Worksheet untuk diidentifikasi fungsinya, mode kegagalannya, dampak kegagalannya, serta tingkat risiko yang ditimbulkannya. Kemudian, dengan mempertimbangkan dampak kegagalannya, ditentukan jenis tindakan pemeliharaan setiap peralatan menggunakan RCM 3 Decision Diagram hingga menjadi RCM 3 Decision Worksheet. Penelitian ini menemukan bahwa subsistem Secondary Reformer merupakan subsistem kritis di perusahaan berdasarkan catatan unscheduled downtime. Empat komponen utama di dalamnya adalah Secondary Reformer (103-D), Secondary Reformer Waste Heat Boiler (101-C), H.P. Steam Superheater (102-C), Temperature Valve (TV-1010), dan Pressure Valve (PV-1018). Dari 26 risiko mode kegagalan yang teridentifikasi, 1 mode kegagalan memiliki risiko high risk, 6 mode kegagalan significant risk, 17 mode kegagalan medium risk, dan 2 mode kegagalan low risk. Hasil akhir RCM 3 menghasilkan 21 tindakan perawatan scheduled on-condition task dan 5 tindakan scheduled discard untuk equipment di subsistem kritis Secondary Reformer.
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Ammonia is a crucial product as a raw material for fertilizers, so the productivity of ammonia plants must be maintained to prevent chain production disruptions and company losses. The production process involves extreme temperature and pressure conditions, making equipment prone to failure. It has been found that equipment failures have caused an average of 37.21 days of downtime per year in the 2021-2023 period. In addition, equipment failure in the ammonia production process has a risk of explosion in high-pressure tubes that can have operational, financial, safety, and environmental impacts. Therefore, this study aims to plan maintenance using the Reliability Centered Maintenance 3 (RCM 3) framework that considers the risk of equipment failure. This research begins with the identification of critical subsystems using the pareto principle. Afterwards, all equipment in the critical subsystem was analyzed using RCM 3 Information Worksheet to identify its function, failure mode, failure impact, and the level of risk it poses. Then, by considering the impact of failure, the type of maintenance action for each equipment is determined by using RCM 3 Decision Diagram to become RCM 3 Decision Worksheet. This research found that the Secondary Reformer subsystem is a critical subsystem in the company based on unscheduled downtime records. The four main equipments in it include Secondary Reformer (103-D), Secondary Reformer Waste Heat Boiler (101-C), H.P. Steam Superheater (102-C), Temperature Valve (TV-1010), and Pressure Valve (PV-1018). Of the 26 identified failure mode risks, 1 failure mode has a high risk, 6 failure modes have a significant risk, 17 failure modes have a medium risk, and 2 failure modes have a low risk. The outcome of RCM 3 resulted in 21 scheduled on-condition task maintenance actions and 5 scheduled discard actions for equipment in the Secondary Reformer critical subsystem.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Pabrik Amonia, Pemeliharaan, Perencanaan, RCM 3. Ammonia Plant, Maintenance, Planning, RCM 3.
Subjects:	T Technology > TA Engineering (General). Civil engineering (General) > TA169 Reliability (Engineering) T Technology > TA Engineering (General). Civil engineering (General) > TA169.5 Failure analysis T Technology > TJ Mechanical engineering and machinery > TJ174 Maintenance and repair of machinery T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26201-(S1) Undergraduate Thesis
Depositing User:	Muhammad Hafidzul Islam
Date Deposited:	01 Aug 2025 08:50
Last Modified:	01 Aug 2025 08:50
URI:	http://repository.its.ac.id/id/eprint/124355

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