Peningkatan Keandalan Melalui Strategi Pemeliharaan Pada Make Up Gas Compressor (MUGC) Menggunakan Metode Reliability Centered Maintenance (RCM) II

Masruri, Syukron Masruri (2026) Peningkatan Keandalan Melalui Strategi Pemeliharaan Pada Make Up Gas Compressor (MUGC) Menggunakan Metode Reliability Centered Maintenance (RCM) II. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Dalam industri perminyakan, keandalan peralatan merupakan faktor kunci dalam menjaga kelancaran operasional, efisiensi biaya, dan keselamatan kerja. Gangguan pada peralatan kritis dapat menyebabkan stop produksi dan kerugian finansial yang signifikan. PT X menghadapi tantangan dalam menjaga keandalan subsistem kompresor T-3-02ABC pada Hydrocracker Unit A dan B yang berfungsi memasok gas hidrogen untuk proses hydrocracking, dengan riwayat kegagalan tinggi akibat temperature tinggi pada valve dan kerusakan intermediate shaft gearbox. Pada periode 2012–2023, beberapa kegagalan menyebabkan gangguan produksi, sehingga sejak 2019 diterapkan preventive maintenance (PM) berkala setiap 2–6 bulan, meskipun belum berbasis kajian teknis komprehensif dan memerlukan biaya sekitar Rp 753 juta per unit. Penelitian ini bertujuan menentukan tingkat keandalan komponen kritis, mengidentifikasi mode kegagalan, serta merumuskan interval dan strategi pemeliharaan yang optimal. Metode yang digunakan meliputi analisis Failure Mode and Effect Analysis (FMEA) dan Reliability Centered Maintenance (RCM) II Decision Diagram, dilanjutkan dengan pengolahan data historis Time to Failure (TTF) dan Time to Repair (TTR), uji goodness of fit, perhitungan reliability, serta simulasi Monte Carlo untuk menentukan interval pemeliharaan optimum. Hasil penelitian menunjukkan tujuh komponen kritis, yaitu Intermediate Shaft, Rubber Damper, Suction Valve Stage 3, Discharge Valve Stage 3, Packing Rod Stage 1–3 dan Shoe Thrust, dengan nilai reliability baseline masih di bawah standar perusahaan (41,61%–55%). Simulasi Monte Carlo menghasilkan interval pemeliharaan optimum masing-masing 67 hari, 56 hari, 70 hari, 332 hari, 280 hari, 270 hari dan 250 hari. Strategi pemeliharaan yang diusulkan meliputi scheduled discard task, scheduled on-condition task melalui pemantauan temperatur, serta proactive maintenance dengan pemasangan sistem online temperature monitoring untuk meningkatkan keandalan dan efisiensi biaya operasional.
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In the petroleum industry, equipment reliability is a key factor in maintaining operational continuity, cost efficiency, and occupational safety. Failures in critical equipment may lead to production shutdowns and significant financial losses. PT X faces challenges in maintaining the reliability of the T-3-02ABC compressor subsystem in Hydrocracker Units A and B, which functions to supply hydrogen gas for the hydrocracking process. The subsystem has experienced a high failure history caused by elevated valve temperatures and intermediate shaft gearbox failures. During the period of 2012–2023, several failures resulted in production disturbances. Consequently, since 2019, periodic preventive maintenance (PM) has been implemented every 2–6 months, although the maintenance interval has not been determined based on a comprehensive technical assessment and requires approximately IDR 753 million per unit.This study aims to determine the reliability level of critical components, identify failure modes, and formulate optimal maintenance intervals and strategies. The methods employed include Failure Mode and Effect Analysis (FMEA) and the Reliability Centered Maintenance (RCM) II Decision Diagram, followed by the analysis of historical Time to Failure (TTF) and Time to Repair (TTR) data, goodness-of-fit testing, reliability calculations, and Monte Carlo simulation to determine the optimum maintenance interval.The results identified seven critical components, namely the Intermediate Shaft, Rubber Damper, Suction Valve Stage 3, Discharge Valve Stage 3, Packing Rod Stages 1– 3, and Shoe Thrust, with baseline reliability values still below the company standard, ranging from 41.61% to 55%. Monte Carlo simulation produced optimum maintenance intervals of 67 days, 56 days, 70 days, 332 days, 280 days, 270 days, and 250 days, respectively. The proposed maintenance strategies include scheduled discard tasks, scheduled on-condition tasks through temperature monitoring, and proactive maintenance by installing an online temperature monitoring system to improve reliability and operational cost efficiency.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	: keandalan, kompresor, Reliability Centered Maintenance II (RCM II), strategi pemeliharaan optimal Reliability, Compressor, Reliability Centered Maintenance II (RCM II), Optimal Maintenance Strategy
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:	Syukron Masruri
Date Deposited:	19 Jun 2026 00:43
Last Modified:	19 Jun 2026 00:43
URI:	http://repository.its.ac.id/id/eprint/133914

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