Kharisma, Adellia Refi (2026) Laporan Magang Analisis Potensi Penerapan Predictive Maintenance Berdasarkan Data Operasional dan Parameter Burner pada Sistem Furnace Unit Phonska III PT Petrokimia Gresik. Project Report. [s.n.]. (Unpublished)
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Abstract
Sistem furnace Unit Phonska III PT Petrokimia Gresik masih mengandalkan strategi preventive dan corrective maintenance yang memiliki keterbatasan dalam mendeteksi gangguan secara dini. Penelitian ini bertujuan menganalisis data operasional eksisting untuk mengevaluasi potensi penerapan strategi predictive maintenance (PdM). Metode yang digunakan adalah analisis data parameter proses kontinu dari DCS periode Mei 2026 dan data historis kumulatif dari Burner Management System (BMS) Siemens LMV51.100C2. Hasil analisis data BMS menunjukkan running hours sebesar 9.584 jam, start counter 856 kali, dan lockout counter 497 kali, merepresentasikan rasio kegagalan operasi pembakaran mencapai 58%. Sementara itu, data DCS berhasil merekam anomali riil berupa insiden burner trip total pada Minggu IV serta fenomena thermal overshoot hingga 877°C pada Minggu V. Penelitian ini menyimpulkan bahwa kombinasi data operasional eksisting dari DCS dan BMS memiliki potensi besar untuk mendeteksi gejala kerusakan dini tanpa memerlukan investasi sensor baru. Tekanan Draf Furnace (PI1340) diidentifikasi sebagai prediktor primer (early warning trigger), didukung oleh Temperatur Chamber (TI1302) dan Temperatur Inlet Dryer (TI1301) sebagai variabel verifikasi termal untuk meminimalkan risiko unplanned downtime.
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The furnace system at PT Petrokimia Gresik’s Phonska III Unit still relies on preventive and corrective maintenance strategies, which have limitations in detecting malfunctions early on. This study aims to analyze existing operational data to evaluate the potential for implementing a predictive maintenance (PdM) strategy. The methods used include analysis of continuous process parameter data from the DCS for the period of May 2026 and cumulative historical data from the Siemens LMV51.100C2 Burner Management System (BMS). Analysis of the BMS data revealed 9,584 running hours, 856 start counts, and 497 lockout counts, representing a combustion operation failure rate of 58%. Meanwhile, the DCS data successfully recorded actual anomalies in the form of a total burner trip incident in Week IV and a thermal overshoot phenomenon reaching 877°C in Week V. This study concludes that the combination of existing operational data from the DCS and BMS has great potential for detecting early signs of failure without requiring investment in new sensors. Furnace Draft Pressure (PI1340) was identified as the primary predictor (early warning trigger), supported by Chamber Temperature (TI1302) and Dryer Inlet Temperature (TI1301) as thermal verification variables to minimize the risk of unplanned downtime.
| Item Type: | Monograph (Project Report) |
|---|---|
| Uncontrolled Keywords: | Predictive Maintenance, Furnace, Burner Management System, Distributed Control System, Early Warning Indicators. |
| Subjects: | T Technology > TS Manufactures > TS155 Production control. Production planning. Production management T Technology > TS Manufactures > TS173 Reliability of industrial products T Technology > TS Manufactures > TS174 Maintainability (Engineering) . Reliability (Engineering) |
| Divisions: | Faculty of Vocational > Instrumentation Engineering |
| Depositing User: | Adellia Refi Kharisma |
| Date Deposited: | 27 Jul 2026 01:17 |
| Last Modified: | 27 Jul 2026 01:17 |
| URI: | http://repository.its.ac.id/id/eprint/137153 |
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