Perencanaan Perawatan Pada Mesin Reactor Polypropylene Dengan Metode Reliability Centered Maintenance (RCM)

Andari, Sinta Dahlia (2017) Perencanaan Perawatan Pada Mesin Reactor Polypropylene Dengan Metode Reliability Centered Maintenance (RCM). Sarjana thesis, Universitas Brawijaya.

Abstract

PT Chandra Asri Petrochemical merupakan salah satu perusahaan manufaktur petrochemical yang terletak di Cilegon, Banten. PT Chandra Asri Petrochemical memproduksi produk seperti ethylene, propylene, dan polypropylene. Permasalahan yang dihadapi PT CAP adalah mesin reactor pada lantai produksi polypropylene yang mengalami downtime/failure paling sering. Perlu adanya analisis lebih lanjut mengenai penyebab matinya mesin reactor dan bagaimana cara memperbaiki serta mencegah failure agar tidak menimbulkan kerugian besar bagi PT CAP. Penelitian ini menggunakan metode Reliability Centered Maintenance (RCM). RCM merupakan landasan untuk perawatan fisik dan pengembangan perawatan pencegahan terjadwal. Analisis kerusakan mesin reactor menggunakan Failure Mode and Effect Analysis (FMEA) guna mengetahui jenis kerusakan dan komponen kritis pada mesin. FMEA akan berguna untuk perhitungan Mean Time To Failure (MTTF) dan Mean Time To Repair (MTTR), yang akan dibutuhkan untuk membuat jadwal perawatan mesin serta tindakan pencegahannya. Hasil penelitian menunjukkan bahwa kegagalan kritis meliputi katup pipa katalis yang menutup karena tersumbat gumpalan chunk (RPN 48), PDS low filling efficiency karena chunk yang menutupi aliran resin dari reactor menuju Product Blow Tank (RPN 30), dan nozzle resin tertutup oleh lembaran chunk (RPN 32). Untuk komponen katup katalis memiliki MTTF selama 115 hari, katup pipa dengan 197 hari, nozzle dengan 223 hari, katup SCA dengan 350 hari dan distributor plate selama 276 hari. Pemeriksaan dilakukan dalam jangka waktu antara 3 bulan sekali sampai dengan 11 bulan sekali. Katup katalis yang tersumbat gumpalan chunk, disarankan adanya pembersihan dan tindakan preventif yaitu memonitor laju aliran katalis, perubahan temperatur dan tekanan proses polimerisasi atau melakukan kill system guna mencegah chunk terbentuk. PDS low filling efficiency dapat diatasi dengan pembersihan kotoran pada katup aliran dan dengan tindakan preventif berupa memonitor perubahan temperatur atau tekanan saat proses reaksi di dalam unggun, pembuatan jadwal pembersihan berkala dan juga dengan penggantian katup. Pembersihan lembaran chunk menjadi tindakan korektif untuk nozzle resin yang tertutup oleh chunk, dan pembuatan jadwal pembersihan reactor serta pengecekan laju aliran resin dan temperaturnya dapat menjadi alternatif untuk tindakan preventif.

English Abstract

PT Chandra Asri Petrochemical is one of the petrochemical manufacturing company located in Cilegon, Banten. They product such as ethylene, propylene and polypropylene. The main problem that occurred for PT CAP is the significant downtime/ failure of the reactor machine at polypropylene production floor. Further analysis upon the cause of the shutdown, the possible ways to repair and prevent the failures are needed to avoid major losses for PT CAP. This research used Reliability Centered Maintenance (RCM) method. It is used for the expansion of physical maintenance and scheduled preventive maintenance. The failure analysis of reactor were using Failure Mode and Effect Analysis (FMEA) to determine the failures and critical components of the machine. FMEA will be useful for the calculation of Mean Time to Failure (MTTF) and Mean Time to Repair (MTTR). It is also needed to proced the maintenance scheduling and determine its preventive actions. This research showed the critical failures such as the blockage of catalyst flow by the chunk (RPN 48), PDS low filling efficiency because of chunk (RPN 30) and the blockage of resin nozzle by the chunk sheets (RPN 32). The examination of catalyst valve component is being done in 115 days, pipe valve in 197 days, nozzle of resin in 223 days, SCA valve in 350 days and distributor plate is being done in 276 days. The examinations are being done by the range of time between once in 3 months to 11 months. For the blockage of catalyst flow by chunk, it is suggested to do a clean up and to do preventive action such as monitoring the catalyst flow rate, its temperature and pressure besides doing kill system procedure to terminate the chunk. PDS low filling efficiency can be solved by cleaning the chunk on the valve and doing the preventive action such as monitoring temperature/ pressure changes during reaction process, making annual schedule for clean up the pipe flow and replacing the valve. Cleaning up the chunk sheets can be a corrective action for the blockage of nozzle by chunk, while scheduling of the reactor clean up and regular check up of the resin flow rate and its temperatures can be the alternative preventive actions.

Item Type: Thesis (Sarjana)
Identification Number: SKR/FT/2017/1122/051712670
Uncontrolled Keywords: Keandalan, Failure Mode and Effect Analysis (FMEA), Reliability Centered Maintenance (RCM)
Subjects: 600 Technology (Applied sciences) > 620 Engineering and allied operations > 620.004 Design, testing, measurement, quality, maintenance, repair > 620.004 6 Maintenance and repair
Divisions: Fakultas Teknik > Teknik Industri
Depositing User: Yusuf Dwi N.
Date Deposited: 08 Jan 2018 06:38
Last Modified: 29 Nov 2020 14:10
URI: http://repository.ub.ac.id/id/eprint/7760
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