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Documente Cultură
ENJINIRING
1. SERP
2. FMEA
3. RCFA
RENDAL
Task
Identification
Continuous Improvement
4. Baseline
EKSEKUTOR
CR/PD/PM/OH
5. FDT
6.1 PdM
6.1 PM
Design Out
Plan
Schedule
Implement
Run To
Failure
Overhaul
Task Execution
Task
Measurement
(1) F M E A
* FMEA : Failure Mode and Effect Analysis
(Modus Kerusakan dan Analisa Dampak)
* SRCM : Stream line Reliability Centred Maintenace
PENYEBAB KERUSAKAN
Tujuan FMEA
History kerusakan
Pengalaman tempat lain
Rekomendasi vendor
Standarisasi
Feeling expert
Output :
FDT (PdM/PM/
OH/PAaM
GT/HRSG
Turbine
LP BCP
HP BCP
MCC/Breaker
Boiler/HRSG
Motor
Bearing
Fan
Stator Winding
Rotor Winding
Common
EXH. DAMPER
Coupling
Kabel
Panel
Relay
Contactor dll
Generator
Valve &
Piping
Pompa
Flexible C.
Flange
Baut, Nut
Washer
-
Equip. lain
Cooling
Water
Discharge Vlv,
Suction Vlv
Check Vlv
Strainer
Pipa & Isolasi
Casing
Bearing
Impeller
Shaft & Key
Mechanical Seal
Pelumasan
I&C
- Orifice
- FX
- PI
Flow Indicator
Valve
Piping
Cooler/Heat Exchanger
GT/HRSG
Turbine
LP BCP
MCC/Breaker
Target/Goal
Boiler/HRSG
Generator FMEA:
Common
Keandalan
Ketersediaan
HP BCP
EXH. DAMPER
Equip. lain
Efisiensi
Motor
PROSES FMEA:
- Sharing Informasi
- Sharing pengalaman
- Kabel
- Panel
- Relay
- Contactor dll
Bearing
Fan
Stator Winding
Rotor Winding
Coupling
Flexible C.
Flange
Baut, Nut
Washer
SHARING
Valve &
Pompa
Piping
INFORMAS
I
-
Cooling
Water
Discharge Vlv,
Suction Vlv
Check Vlv
Strainer
Pipa & Isolasi
Casing
Bearing
Impeller
Shaft & Key
Mechanical Seal
Pelumasan
I&C
- Orifice
- FX
- PI
Flow Indicator
Valve
Piping
Cooler/Heat Exchanger
Motor
Coupling
Kabel
Panel
Relay
Contactor dll
-
Bearing
Fan
Stator Winding
Rotor Winding
Equip. lain
Valve &
Piping
Pompa
Flexible C.
Flange
Baut, Nut
Washer
Common
Cooling
Water
Discharge Vlv,
Suction Vlv
Check Vlv
Strainer
Pipa & Isolasi
Casing
Bearing
Impeller
Shaft & Key
Mechanical Seal
Pelumasan
I&C
- Orifice
- FX
- PI
Flow Indicator
Valve
Piping
Cooler/Heat Exchanger
Turbine
LP BCP
MCC/Breaker
GT/HRSG
II. Failure
Effect :
Dampak kerusakan terhadap :
1. Keselamatan & Lingkunagn
Boiler/HRSG
Generator
2. Operasi (Trip, Derating, Efisiensi dll)
3. Mengakibatkan kerusakan peralatan
HP BCP
EXH. DAMPER
lain.
Motor
Coupling
Kabel
Panel
Relay
Contactor dll
-
Bearing
Fan
Stator Winding
Rotor Winding
Equip. lain
Valve &
Piping
Pompa
Flexible C.
Flange
Baut, Nut
Washer
Common
Cooling
Water
Discharge Vlv,
Suction Vlv
Check Vlv
Strainer
Pipa & Isolasi
Casing
Bearing
Impeller
Shaft & Key
Mechanical Seal
Pelumasan
I&C
- Orifice
- FX
- PI
Flow Indicator
Valve
Piping
Cooler/Heat Exchanger
GT/HRSG
III. Failure
Cause :
Apa yang menyebabkan
kerusakan dapat terjadi.
Boiler/HRSG
Generator
Turbine
LP BCP
HP BCP
MCC/Breaker
Motor
Bearing
Fan
Stator Winding
Rotor Winding
EXH. DAMPER
Coupling
Kabel
Panel
Relay
Contactor dll
Common
Valve &
Piping
Pompa
Flexible C.
Flange
Baut, Nut
Washer
-
Equip. lain
Cooling
Water
Discharge Vlv,
Suction Vlv
Check Vlv
Strainer
Pipa & Isolasi
Casing
Bearing
Impeller
Shaft & Key
Mechanical Seal
Pelumasan
I&C
- Orifice
- FX
- PI
Flow Indicator
Valve
Piping
Cooler/Heat Exchanger
GT/HRSG
Turbine
LP BCP
MCC/Breaker
Coupling
Kabel
Panel
Relay
Contactor dll
-
Bearing
Fan
Stator Winding
Rotor Winding
Valve &
Piping
Pompa
Flexible C.
Flange
Baut, Nut
Washer
-
Cooling
Water
Discharge Vlv,
Suction Vlv
Check Vlv
Strainer
Pipa & Isolasi
Casing
Bearing
Impeller
Shaft & Key
Mechanical Seal
Pelumasan
I&C
- Orifice
- FX
- PI
Flow Indicator
Valve
Piping
Cooler/Heat Exchanger
GT/HRSG
III. Failure
Cause :
Apa yang menyebabkan
kerusakan dapat terjadi.
Boiler/HRSG
Generator
Turbine
LP BCP
HP BCP
MCC/Breaker
Motor
Bearing
Fan
Stator Winding
Rotor Winding
EXH. DAMPER
Coupling
Kabel
Panel
Relay
Contactor dll
Common
Pompa
Equip. lain
Valve &
Piping
Cooling
Water
Root Cause
FailureVlv,Analysis :
- Discharge
1. Belum
tahuVlv
penyebab
- Suction
- Checkdengan
Vlv
kerusakan
pasti.
- Strainer
2. Belum tahu
penyelesaiannya.
- Pipa & Isolasi
3. Perlu analisa lebih lanjut.
Flexible C.
Flange
Baut, Nut
Washer
-
Casing
Bearing
Impeller
Shaft & Key
Mechanical Seal
Pelumasan
I&C
- Orifice
- FX
- PI
Flow Indicator
Valve
Piping
Cooler/Heat Exchanger
Asset (Equipment)
yang dipilih
DATA
- Riwayat,
- O & M Manual/STD JOB Maint.
-Vendor Manual,
-Pengalaman tempat lain
FMEA PROSES
Failure Mode
1. ________
Failure Effect
1. _______
Failure Cause
1.1. .
1.2. ..
2. ________
2. _______
2.1. .
2.2.
Failure Defense
1.1.1. ______
1.1.2. ______
1.1.3. ______
Failure Mode
Failure Cause
Failure Effect
GT - TURBINE
GT - TURBINE
LP BFP
(2) RCFA
ROOT CAUSE FAILURE ANALYSIS
Tujuan
Mencari akar penyebab masalah, sehingga dapat ditentukan
solusi yang tepat
Merupakan solusi permanen
Mempertimbangkan Biaya & Keuntungan untuk setiap
solusi yang dipilih
Inventory &
Purchasing
UPHar
KLK3
SDTek
Profesional :
Mesin, Listrik, Kontrol
Eliminasi Gap
&
Continuous
Improvement
Sinfo :
Unit lain
User
Assosiation
Vendor/Ma
nufacturer
PdM
Operasi
External
Expert
Lembaga
Serfitikasi
Non-OEM
Supplier
Perguruan
Tinggi/Lembaga
Riset/Konsultasi
Supporting
Document &
Historical Data
Observasi :
Kondisi sekitar
(Panas, berdebu dll)
Tanda-tanda visual
(ada jelaga, korosi dll)
Kejadian / pekerjaan yang terkait
(Pernah dilakukan chemical cleaning dll)
Indikator operasi
(press. High, tren vibrasi dll)
Hasil labor / tes
(Banyak kandungan O2, material tdk homogen dll)
Pengoperasian
(sering start-stop dll)
Buku Manual / Referensi
(Rekomendasi)
Argumentasi
(Penjelasan logis)
Kemungkinan
Root Cause
Prioritas FDT
RCFA
Contoh RCFA
Kemungkinan penyebab :
1. Korosi
Kandungan O2 di feed water tinggi (Kemungkinan ini diambil karena meter pengukuran O2
tidak pernah dikalibrasi) ---------- FDT 1 : Perlu dilakukan kalibrasi
Kemasukan O2 di piping
Flanges pipa tidak rapat (Hasil cek ternyata tidak ada indikasi kebocoran)
Hydrazin kurang (Ternyata konsentrasi injeksi sesuai SOP)
Deaerator abnormal (Hasil pengukuran in-out O2 deaerator menunjukkkan
deaerator normal)
Kemungkinan penyebab :
2. Turbulensi Fluida
Adanya pusaran fluida akibat relief (Ternyata dibagian relief (sisi dalam) ada
indikasi ketebalan pipa banyak berkurang dibandingkan tempat lainnya dan
sering terjadi getaran berlebih) . Menurut keterangan pihak jepang, memang
banyak pipa mengalami kebocoran di daerah relief akibat turbulensi fluida.
Kesimpulan :
FMEA
RCFA
(1). Object
(2). Tujuan
(3) Langkah
(1)
(2)
(3)
(4)
(5)
(6)
FDT PRIORITIZATION
PRIORITAS FDT = Efek x (ROI & Complexity)
ROI (Hasil)
&
Complexity
EFEK
4
Safety
3
Kerusakan Eq.
& Biaya tinggi
Gampang,
Hasil banyak
Sulit,
Hasil banyak
Gampang,
Hasil sedikit
Sulit,
Hasil sedikit
ROI
Trip / Shutdown /
Derating
Tidak berpengaruh
(Minor efek)
Complexity
Component
Failure / Failure
Mode
FDT
EFEK
Nilai
Generator cooling
system
4 (Safety meledak)
2 (Gampang, hasil
rendah)
Cathodic
Protection
Zinc habis
3 (merusak
peralatan-tube
bocor)
4 (Gampang, hasil
banyak)
12
DDC system
Capasitor rusak
Ganti secara
periodik
2 (Trip)
4 (Gampang, hasil
banyak)
FAILURE DEFENSE
TASK EXECUTION
Terima Kasih