ANALYZING EFFECTIVENESS OF BADAK LNG PREVENTIVE MAINTENANCE (PM) WORK ORDER FOR ELECTRICAL EQUIPMENT
Badak LNG is one of the largest LNG plant in the world consist of 8 trains and has been running for more than 4 decades to produce LNG and LPG. In early 2000, Badak LNG was the largest LNG producers in the world in around 22.5 MTPA and the rest of the product was LPG. There are 110,000 equipment ins...
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| Format: | Theses |
| Language: | Indonesia |
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| Online Access: | https://digilib.itb.ac.id/gdl/view/44079 |
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| Institution: | Institut Teknologi Bandung |
| Language: | Indonesia |
| Summary: | Badak LNG is one of the largest LNG plant in the world consist of 8 trains and has been running for more than 4 decades to produce LNG and LPG. In early 2000, Badak LNG was the largest LNG producers in the world in around 22.5 MTPA and the rest of the product was LPG. There are 110,000 equipment installed in 8 LNG trains at Badak LNG plant consist of electrical, instrumentation, rotating and stationary equipment. From such amount, some equipment still uses old or conventional technology, meanwhile instrument is major equipment installed in Badak LNG plant.
The priority of maintenance activites using Equipment Criticality Rating (ECR) where safety and production as the most dominant factor. All installed equipment shall be maintained with many methods such as Preventive Maintenance (PM), Predictive Maintenance (PdM), Corrective Maintenance (CM), Shutdown (SD) or Turnaround (TA) and Overhaul (OH). In maintenance terminology known as MRO (Maintenance, Repair and Overhaul). We will discuss only 1 method, PM and analyze in detail whether PM activities in Badak LNG to increase plant reliability, follow standard and optimize the cost.
We have identified some issues related to Badak LNG in maintaining the plant such as: ageing of the plant after running for more than 4 decades (fatigue and wear out period issue), some PM Task (SJP) still can be improved to increase reliability and optimize cost, some PM facilities still need to be improved and added.
PM activity is done by Maintenance Department using Maintenance Work Order (MWO) which fully integrated in the Computerized Maintenance Management System (CMMS). Each section in Maintenance Department has responsibility in maintaining LNG plant, and the section that plan PM MWO is Maintenance Planning and Turnaround (MPTA). There are 4 sections in Maintenance Department that execute the jobs: Electrical, conducting PM for electrical equipment such as transformer, motor etc; Instrument, conducting PM for insrumentation equipment such as control valve, transmitter etc; Stationary Equipment and Construction (SEC), conducting PM for stationary equipment such as pressure vessel, boilers, pipes, tanks etc; Machinary and Heavy Equipment (MHE), conducting PM for rotating and heavy equipment such as turbine, compressor, pumps, mobile cranes, tug boat etc.
By downloading all PM MWO for the last 4 years from CMMS, there are around 1400-1700 in a month, we have some data to be analysed to check and evaluate PM effectiveness. Total of PM around 10011 equipment and 5813 for electrical, 1152 for instrument, 803 for SEC, Heavy equipment and fire 459 and MHE plant related 1784 equipment. We analyse based on their SJP and MST and compare to some frequency of failure from database of failure in SHEQ Incident Notification, then we use some methods and data analysis using Business Model Canvas, SWOT and House of Quality Matrix Analysis. After analysing the whole data, we can define main root causes and plan to improve them technically and from management Badak LNG point of view such as getting management approval related to the budget to retrofit old and obsolete plant, improving PM SJP and MST and its facility as well.
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