Implementasi FMECA (Failure Mode Effect and Criticality Analysis) Sebagai Dasar Penilaian Risiko dan Perencanaan Strategi Preventive Maintenance Pada Boiler PT Surya Pamenang

IMPLEMENTATION OF FMECA (FAILURE MODE EFFECTS AND CRITICALITY ANALYSIS) AS THEBASISOF RISK ASSESSMENT ANDPREVENTIVE MAINTENANCE STRATEGY PLANNING IN BOILER PTSURYA PAMENANG

Hendra Wijaya Kusuma (6510040063)


Abstrak

ABSTRAK Boiler memiliki peranan yang sangat penting bagiPT Surya Pamenang sebagai penyedia steam yang digunakan untuk pengering kertas (dryer). Terjadi kegagalan atau kerusakan pada komponen boiler plant dapat menyebabkan proses produksi steam tidak maksimal atau terganggu. Apabila kondisi ini dibiarkantidak dilakukan identifikasi terhadap kegagalandan penanganan yang tepat akan dapat menimbulkankerugian yang besar pada PT Surya Pamenang. Dalam penelitian ini metode FMECA digunakan untuk menganalisa kegagalan dan nilai kekritisan/criticality number pada setiap komponen yang mengalami kegagalan. Selajutnya metode cost based criticality yang terdiri dari production loss dan capital loss akibat kerusakan dan probabilitas terjadinya kerusakan. Dengan hasil criticality analysis dan cost based criticality dapat mempermudah dalam memprioritaskan perawatan komponen boiler plant. Perencanaan preventive maintenance berdasarkan perhitungan waktu perawatan optimal dan penyusunan RCM II dicision worksheet. Dari hasil analisa data kerusakan komponen boiler plant selama periode 3 tahun (tahun 2011,2012 dan 2013) terdapat 9 komponen (safety valve, burner, water tank demin, feed water level, oil preheater, feed water tank, steam header, economizer ,flowmeter steam) dengan 10 mode kegagalan yang pernah terjadi yang dapat berpengaruh terhadap keselamatan dan operasi atau performa kerja boiler plant. Berdasarkan nilai criticality number dan cost based criticality maka urutan prioritasnya meliputi oil preheater, feed water tank, flowmeter steam, feed water level, economizer, safety valve, water tank demin, steam header, burner. Perencaan preventive maintenance hasil perhitungan waktu perawatan optimal didapat hasil maintenance interval lebih kecil daripada MTTF (mean time to failure) dan pada penyusunan RCM II dicision worksheet terbagi dalam beberapa kegiatan perawatan yaitu scheduled on condition task meliputi steam header, flange oil preheater, feed water tank, economizer, feed water level, flowmeter steam. Untuk scheduled restoration task meliputi water tank demin sedangkan untuk scheduled discard task meliputi thermostat oil preheater, safety valve, burner. Kata Kunci : Boiler plant, Cost Based Criticality, FMECA (failure mode effect and criticality analysis),RCM II Dicision worksheet.


Abstract

ABSTRACT Boilers have a very important role for PT Surya Pamenang as a provider of steam that is used for paper dryer. Event of failure or damage to the boiler plant components can lead to the production process does not steam up or disturbed. If this condition is not allowed the identification of the failure and the proper handling can lead to large losses in PT Surya Pamenang. In this study FMECA method is used to analyze the failure and criticality value/criticality number on each component failure. Following that method of cost-based criticality consisting of production loss and capital loss due to damage and the probability of occurrence of damage. With the results of the criticality analysis and cost based criticality may be easier to prioritize treatment plant boiler components. Planning preventive maintenance based on the calculation of the optimal treatment time and the preparation of RCM II dicision worksheet. From the data analysis component of the boiler plant damage over a period of 3 years (in 2011, 2012 and 2013) there are 9 parts (safety valve, burner, demin water tanks, feed water level, oil preheater, feed water tanks, steam headers, economizer, flowmeter steam) with 10 failure modes that have occurred that may affect the safety and operation of the boiler plant or job performance. Based on the criticality number and cost based criticality, the order of priority include oil preheater, feed water tanks, steam flowmeter, feed water level, economizer, safety valve, demin water tanks, steam header, burner. Planning preventive maintenance on the calculation results obtained optimal treatment time maintenance intervals smaller than the MTTF (mean time to failure) and the preparation of RCM II dicision worksheet divided into several activities scheduled on-condition maintenance tasks that include steam header, flange oil preheater, feed water tank, economizer, feed water level, steam flowmeter. For scheduled restoration task includes demin water tank for scheduled discard task while covering oil preheater thermostat, safety valve, burner. Keywords : Boiler plant, Cost Based Criticality, FMECA (failure mode effect and criticality analysis), RCM II Dicision worksheet.


Detil Peneliti

Dosen Pembimbing 1 :Rachmad Tri Soelistijono
Dosen Pembimbing 2 : Muhammad Shah

Program Studi : D4 - TEKNIK KESELAMATAN DAN KESEHATAN KERJA
Angkatan : 2010


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