Penentuan Interval Pemeliharaan Pencegahan Dengan System Equipment Reliability Prioritization (Serp) Dan Optimasi Keandalan Padaturbin Gas Seri M701d (Studi Kasus Di PT. Z)

Jatmiko, Eko Darmawan (2019) Penentuan Interval Pemeliharaan Pencegahan Dengan System Equipment Reliability Prioritization (Serp) Dan Optimasi Keandalan Padaturbin Gas Seri M701d (Studi Kasus Di PT. Z). Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. Z merupakan salah satu pemasok listrik terbesar di area Jawa Madura Bali (Jamali). Perusahaan ini mengelola Pembangkit Listrik Tenaga Gas dan Uap (PLTGU) dengan kapasitas total produksi sebesar 1.500 MegaWatt. Salah satu mesin utama PLTGU yaitu turbin gas, yang mana memegang peran vital dalam proses produksi listrik. Apabila terjadi kegagalan pada salah satu peralatan turbin gas, maka keandalan mesin tersebut menjadi berkurang. Selain itu dampak yang tidak diinginkan adalah breakdown pada turbin gas. Hal ini menyebabkan kerugian besar, yaitu biaya pemeliharaan yang semakin besar dan berkurangnya kesempatan memproduksi listrik. Turbin gas blok 2 memiliki pola operasi dengan jumlah start-stop lebih tinggi dibandingkan dengan lainnya, sehingga potensi kegagalan lebih sering terjadi. Perusahaan ini telah memiliki jadwal pemeliharaan pencegahan, namun masih sering terjadi kegagalan sebelum dilakukan pemeliharaan pencegahan. Oleh karena itu perlu ditentukan interval waktu pemeliharaan pencegahan yang tepat agar keandalan turbin gas terjaga dan meminimalkan total biaya pemeliharaan. Penelitian ini dimulai dengan menentukan top ten dari maintenance priority index (MPI) peralatan-peralatan turbin gas dengan metode System Equipment Reliability Prioritization (SERP), selanjutnya dilakukan pengujian distribusi data dan ditentukan parameter sesuai dengan jenis distribusinya dengan menggunakan perangkat lunak Weibull++6. Kemudian menentukan keandalan sisa masing-masing peralatan turbin gas dan keandalan sistem turbin gas, serta dilakukan penentuan biaya pemeliharaan sebelum dilakukan optimasi keandalan. Setelah itu dilakukan optimasi keandalan dengan target sesuai kinerja manajemen PT. Z dengan menggunakan perangkat lunak Lingo 17.0. Kemudian ditentukan interval waktu pemeliharaan pencegahan dan biaya pemeliharaan setelah dilakukan optimasi keandalan. Dari hasil penelitian diperoleh peralatan turbin gas yang masuk peringkat sepuluh besar MPI adalah turbin, rotor cooling air, exciter set, generator, combuster shell, main transformer, piping fuel gas supply, main lube oil system, compressor dan digital controller. Kemudian total biaya penghematan pemeliharaan pencegahan selama satu tahun dengan target keandalan sistem turbin gas 0,9 terbesar pada peralatan turbin dengan total penghematan biaya pemeliharaan sebesar IDR 145.174.877,40. Dengan target keandalan yang sama diperoleh interval waktu pemeliharaan pencegahan terpanjang pada peralatan Main lube oil system yaitu 1101,5112 jam. ================================================================================================ PT. Z is one of the largest electricity suppliers in the Java Madura Bali (Jamali) area. The company manages the Combined Cycle Power Plant (CCPP) with a total production capacity of 1,500 MegaWatts. One of the main engines of the CCPP is the gas turbine, which plays a vital role in the electricity production process. If there any failure in one of the gas turbine equipment, the reliability of the engine will be reduced. In addition, the unwanted impact is a breakdown of the gas turbine. This caused huge losses in the form greater maintenance costs and reduced opportunities to produce electricity. Gas turbine on Block 2 has an operating pattern with a higher number of start-stops than others, so that the potential for failure is more often. This company has a preventive maintenance schedule, but failure often occurs before preventive maintenance is carried out. Therefore it is necessary to determine the appropriate preventive maintenance interval so that the reliability of the gas turbine is maintained and minimizes the total maintenance costs. This research begins by determining the top ten from maintenance priority index (MPI) gas turbine equipment using the System Equipment Reliability Prioritization (SERP) method, then testing the data distribution and determining the parameters according to the type of distribution using Weibull++ 6 software. Then determine the reliability of the remainder of each gas turbine equipment and the reliability of the gas turbine system, along with determination of maintenance costs before reliability optimization is carried out. After that, reliability optimization was carried out with the target according to the management performance of PT. Z by using Lingo 17.0 software. Then the preventive maintenance time interval and maintenance costs are determined after reliability optimization. The results of the research show gas turbine equipment which is ranked in the top ten MPI is turbine, rotor cooling air, exciter set, generator, combuster shell, main transformers, piping fuel gas supply, main lube oil system, compressor and digital controller. Then the total cost of preventive maintenance for one year on the gas turbine system reliability target of 0.9 is the largest in turbine equipment with a total savings of maintenance costs of IDR 145,174,877.40. With the same reliability target, the longest preventive maintenance interval is obtained on the Main lube oil system equipment is 1101.5112 hours.

Item Type: Thesis (Masters)
Additional Information: RTMT 658.202 Jat p-1 2019
Uncontrolled Keywords: Preventive maintenance time interval, maintenance priority index, system equipment reliability prioritization
Subjects: T Technology > TA Engineering (General). Civil engineering (General) > TA169 Reliability (Engineering)
Divisions: Faculty of Business and Management Technology > Management Technology > 61101-(S2) Master Thesis
Depositing User: Eko Darmawan Jatmiko
Date Deposited: 23 Jul 2021 09:12
Last Modified: 23 Jul 2021 09:12
URI: https://repository.its.ac.id/id/eprint/60959

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