Sinaga, Lobeny Markus Hezekiel (2026) Proposed Framework Evaluasi Dan Perencanaan Strategi Pemeliharaan Coal Pulverizing Sub-System Berbasis RCM II Dan Maintenance Bundling: Studi Kasus PLTU Asam Asam Unit 3 Dan 4. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Coal Pulverizing Sub-System PLTU Asam Asam Unit 3 dan 4 menjadi penyumbang losses akibat forced derating terbesar periode 2017–2025, dengan total kehilangan produksi 23.272,86 MWh (Unit 3) dan 15.253,17 MWh (Unit 4). Strategi pemeliharaan eksisting berbasis rekomendasi OEM dan metode analisis seperti SERP, FMEA, dan RCFA berdiri sendiri dan tidak terintegrasi, sehingga tidak memberikan hubungan langsung antara failure mode, konsekuensi kegagalan, dan tindakan pemeliharaan. Penelitian ini mengevaluasi strategi pemeliharaan menggunakan pendekatan Reliability Centered Maintenance (RCM) II dan mengembangkan maintenance bundling berbasis data histori kegagalan untuk rekomendasi strategi pemeliharaan baru. RCM II Worksheet mengidentifikasi 34 functional failures dan 43 failure modes, dengan distribusi rekomendasi tindakan 25 Schedule on-condition task, 14 Schedule restoration task, dan 4 Schedule discard task. Analisis terhadap 19 komponen kritis dari data kegagalan periode 2017–2025 menggunakan distribusi Weibull-2P dengan estimasi MLE, merupakan best fit untuk seluruh komponen berdasarkan uji Anderson-Darling. Dominasi pola Decreasing Failure Rate (DFR) pada 79% komponen mengindikasikan permasalahan keandalan lebih bersifat early-life failure daripada degradasi usia, dengan R(t) komponen terendah 0,208 saat pemeliharaan dilakukan pada strategi eksisting. Maintenance bundling disusun menggunakan 10 katalog interval standar, menghasilkan 7 Work Package (WP) dengan R(t) komponen terendah 0,272 pada bundling berbasis MTTF, 9 WP setelah penyempurnaan ke basis B10 Life, dengan R(t) komponen terendah 0,801. Analisis Total Annual Cost (TAC) dengan model biaya ternormalisasi pada interval berbasis B10 Life secara simultan memenuhi persyaratan keandalan, namun akan meningkatkan biaya pemeliharaan hingga 2,9× dibanding strategi eksisting. Kerangka kerja usulan (proposed framework) evaluasi dan perencanaan pemeliharaan dari penelitian ini dapat diusulkan sebagai alternatif baru.
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The Coal Pulverizing Sub-System at PLTU Asam Asam Units 3 and 4 was the largest contributor to forced-derating losses during 2017–2025, totaling 23,272.86 MWh (Unit 3) and 15,253.17 MWh (Unit 4) in lost production. The existing maintenance strategy, based on OEM recommendations and standalone analytical methods such as SERP, FMEA, and RCFA, remains fragmented, failing to link failure modes, failure consequences, and maintenance actions. This research evaluates the maintenance strategy using Reliability Centered Maintenance (RCM) II and develops a maintenance bundling strategy based on historical failure data to formulate a new recommendation. The RCM II Worksheet identified 34 functional failures and 43 failure modes, with recommended actions distributed as 25 Scheduled On-Condition Tasks, 14 Scheduled Restoration Tasks, and 4 Scheduled Discard Tasks. Analysis of 19 critical components using 2017–2025 failure data, fitted with the 2-Parameter Weibull distribution via Maximum Likelihood Estimation, showed this distribution as the best fit for all components per the Anderson-Darling test. The dominance of Decreasing Failure Rate (DFR) patterns in 79% of components indicates that reliability issues stem more from early-life failure than age-related degradation, with the lowest component R(t) at 0.208 under the existing strategy. Maintenance bundling using 10 standard interval catalogs initially produced 7 Work Packages (WP) with a lowest R(t) of 0.272 based on MTTF, refined to 9 WPs based on B10 Life with a lowest R(t) of 0.801. Total Annual Cost (TAC) analysis using a normalized cost model on B10 Life-based intervals simultaneously satisfies reliability requirements, albeit increasing maintenance costs up to 2.9× compared to the existing strategy. The proposed framework for maintenance evaluation and planning developed in this study can be proposed as a novel alternative.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | Reliability Centered Maintenance (RCM) II, Maintenance Bundling, B10 Life, Weibull-2P Reliability Centered Maintenance (RCM) II, Maintenance Bundling, B10 Life, Weibull-2P |
| Subjects: | T Technology > TA Engineering (General). Civil engineering (General) > TA169 Reliability (Engineering) |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Industrial Engineering > 26101-(S2) Master Thesis |
| Depositing User: | Lobeny Markus Hezekiel Sinaga |
| Date Deposited: | 20 Jul 2026 06:10 |
| Last Modified: | 20 Jul 2026 06:10 |
| URI: | http://repository.its.ac.id/id/eprint/135591 |
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