FAILURE MODES ANALYSIS TO MINIMIZE UNSCHEDULED SHUTDOWN OF AMMONIA 4 PLANT PT PUPUK KALIMANTAN TIMUR

• Main Author: Setiawan, Budi
• Format: Theses
• Language: Indonesia
• Subjects: Manajemen umum
• Online Access: https://digilib.itb.ac.id/gdl/view/36248
• Institution: Institut Teknologi Bandung

Ammonia 4 plant is one of five Ammonia plants at PT Pupuk Kalimantan Timur the biggest fertilizer industry in one location. Ammonia 4 plant consists of nine operating systems i.e. the reforming system, steam generating system, Carbon Monoxide shift system, Carbon Dioxide removal system, Methane system, natural gas compression system, air compression system, synthesis gas compression system and synthesis loop- refrigeration system. Ammonia 4 plant had seventeen times unscheduled shutdown during 2011-2017. There are some impacts arising by unscheduled shutdown Ammonia plant i.e. Urea plant shall be shutdown because there are not enough Ammonia and CO2 to Urea plant, gas leakage could be explosive, a lot of natural gas will waste during restart-up, cost of natural gas is for one time start up around 4.1 billion Rupiah and total loss production per day is 1.5 billion Rupiah. Ammonia 4 plant has experienced an unscheduled shutdown that requires 7 days for repairing. This has the impact of losing production opportunities around 7,280 tons. By considering high impact of unscheduled shutdown, Ammonia 4 plant entails a strategy to minimize frequency of unscheduled shutdowns. The purpose of this research is to identify failure modes at the Ammonia 4 plant, then proposing solutions to prevent potential equipment failures so that Ammonia 4 plant can prevent the shutdown plant. Research method uses Reliability-Centered Maintenance (RCM) for identifying each failure modes of the equipment by first determining the critical systems at Ammonia 4 plant. RCM determines critical systems to give priority for analyzing. Critical systems are systems in Ammonia 4 plant which have a significant influence as cause of unscheduled shutdowns related to both duration of the shutdown and its impact. This research identifies all failure modes in the critical systems and then determining its the recommended actions which should be taken by the relevant person in charge to prevent the failures by using Reliability-Centered Maintenance (RCM) method. The results of research indicate three critical systems at the Ammonia 4 plant i.e. the reforming system, the steam generation system and the synthesis gas compression system which have 777, 543 and 720 failure modes respectively. Ammonia 4 operation department implements the result of RCM analysis in the form the improved work procedures, operator training programs and critical equipment replacement program. By identifying all failure modes along with recommended actions for prevention at critical systems for all scope maintenance such as instruments, electricity and mechanics and scope of operations, it is expected to minimize the frequency of unscheduled shutdowns so it can obtain an average savings 93% of the average annual loss caused the unscheduled shutdown based on data 2011-2017.