Draft Meeting 14 Maret 2019.pdf
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Draft Materi Meeting Maintenance Program Pembangkit, Distribusi, dan Transmisi PLTU PAMA-1 EPN 14 – 15 Maret 2019
Point of Meeting 1. Persiapan pelaksanaan maintenance planning dan pendukung yang perlu dipersiapkan 2. Persiapan implementasi SERP (RCM untuk PLTU dan distribusi) 3. Penyusunan Maintenance Management System untuk mendukung kedua point di atas 4. Persiapan training & development (OJI distribusi & pembangkit, in class training, dan penyusunan standar kompetensi)
On-Going Process for Maintenance Fullfilment Agenda
Area Pembangkit Distribusi
Identifikasi aset
Pembangkit Distribusi Pembangkit
Asesemen lapangan
Distribusi Pembangkit Distribusi Pembangkit
Praktik maintenance Distribusi dengan panduan dari PJIS dan KE Pembangkit Distribusi Pembangkit Penyusunan SERP (System Equipment Distribusi Reliability Pembangkit Prioritization) Distribusi Pembangkit Pengembangan kompetensi manpower maintenance pembangkit
Distribusi
Penjelasan Klasifikasi peralatan berdasarkan fungsinya
PIC
Status Closed Closed
Perincian peralatan dari tahap island - sistem subsistem - peralatan - komponen
Closed
Pembelajaran cara kerja pembangkit dan distribusi secara keseluruhan, per island, per sistem, dan masing - masing peralatan Pengelompokan manpower berdasarkan island/area, dan bidang kerja (mekanikal, elektrikal, dan instrumentasi)
Closed
Semua aktifitas maintenance di pembangkit dan distribusi berdasarkan arahan dari PJIS dan KE Bertujuan untuk mempelajari cara kerja peralatan, dan filosofi dasar maintenance di pembangkit dan distribusi Program untuk menentukan aktifitas maintenance untuk jangka setahun berdasarkan kehandalan masing - masing peralatan Pengadaan infrastruktur (dokumen dan peralatan) untuk kelengkapan penyusunan SERP Mapping kompetensi manpower maintenance di pembangkit dan distribusi
Pembangkit Distribusi Pembangkit Distribusi
Penyusunan training berdasarkan hasil mapping kompetensi
Pembangkit
Pengembangan kompetensi khusus untuk planner dan engineer agar sesuai dengan SERP
Distribusi
Keterangan tambahan
OJI dan In-class training
Closed Closed Closed Closed OnGoing OnGoing OnGoing OnGoing OnGoing Open OnGoing Open OnGoing OnGoing Open Open Open Open Open Open
On-Going Process for Maintenance Fullfilment
Agenda
Area Pembangkit Distribusi
Pelaksanaan planned Pembangkit maintenance Distribusi program (preventive maintenance) Pembangkit Distribusi
Penjelasan
Keterangan tambahan
PIC
Status
Penyusunan kelengkapan (hourmeter, dokumen teknis, tools, sarana, dll) untuk running planned maintenance program Preventive program dilakukan per interval harian, mingguan, bulanan, 3 bulanan, 6 bulanan, dan tahunan
Open
Preventive program disusun berdasarkan acuan dari equipment serupa yang sudah terdapat di PAMA, dan referensi eksternal untuk equipment yang tidak tersedia di PAMA
OnGoing
Pembangkit
Open Open Open
OnGoing Open
Penyusunan makro proses, SOP, dan INK Distribusi Penyusunan Pembangkit Maintenance Management System Distribusi untuk pembangkit Pembangkit Distribusi Standarisasi struktur Pembangkit organisasi, kompetensi, dan jenjang karir di Distribusi maintenance Pembangkit pembangkit Distribusi Eksekusi SERP
KitDis
Open Penyusunan STD untuk parameter masing - masing aktifitas maintenance Monitoring periodik (harian, mingguan, dan bulanan) untuk KPI aktifitas maintenance dan sistem PI CA/PA (Problem Identification and Corrective/Preventive Action) nya Pemenuhan kebutuhan manpower berdasarkan requirement fungsi kerja di pembangkit dan distribusi Standarisasi kompetensi, fungsi kerja, dan jenjang kerja Pelaksanaan aktifitas maintenance berdasarkan SERP yang telah disusun selama 2019 dengan kompetensi manpower yang telah dikembangkan
Open
Open Open Open OnGoing OnGoing Open Open Open
Identifikasi Aset EPN
Sistem Pembangkit (PLTU 2x 15 MW)
AREA
ISLAND
SYSTEM
BTG Island
Coal Island
Sistem Distribusi (SUTT 36kV)
Water Island
Primary
Sistem Transmisi (SUTT 150 KV)
Secondary
Boiler System
Coal Handling System
Water Intake
Current Carrying
Protection
Turbine System
Ash Handling System
Water Treatment Plant
Insulation
Sarana monitoring & pemeliharaan
Steam Generator System
Limestone Handling System
Waste Water Treatment Plant
Structure
Cooling System
Junction
Fuel Injection System
Fire Fighting System
Sub - System
Equipment Component
Construction progress
System Equipment Reliability Prioritization (SERP)
Metode SERP diperlukan agar proses maintenance pada PLTU dan distribusi bisa lebih tepat guna, dan tidak menimbulkan dampak downtime yang terlalu besar. Pelaksanaannya dilakukan oleh maintenance planner dan maintenance engineer
System Equipment Reliability Prioritization (SERP) Island
System
Sub-System
BTG
Boiler System
BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG
Steam Generator System Steam Turbine System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System
Boiler Unit Steam Turbine Generator Turbine Unit Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries
BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG
Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Steam Turbine System Steam Turbine System
Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Turbine Auxilliaries Turbine Auxilliaries
Equipment
OC
PT
PQ
SF
RC
PE
SCR
OCR
ACR
AFPF
MPI
Circulating fluidized bed boiler
9
8
10
5
6
1020,14944
10201,4944
81611,955
Steam Turbine Generator Steam Turbine Drain tank sampling cooler Superheated steam sampling cooler Saturated steam sampling cooler Boiler water sampling cooler Feed Water sampling cooler Chimney Duplex slag cooler Weighing complete shut-off coal feeder High Pressure Electric Oil Pump AC Lubricating Oil Pump DC Lubricating Oil Pump High Pressure Heater Low Pressure Heater Gland Steam Heater Flash Tank Equalization Box Temperature-decreased pressure reducer for gland steam heater Condense Pump Water Jet Pump Water Jet Ejector Electric Boiler Feed Water Pump Gland Exhaust Fan Jacking Oil Pump Water Jet Tank Primary Air Fan Secondary Air Fan Induced Draft Fan Recycled Fan Continuous Blowdown Flash tank Periodic blowdown flash tank Vertical type flash tank Drain Tank Drainage pump Service water recycled pump Phospate dosing unit Service water recycled pond Service water recycled tank Oil Tank Emergency Containment Sump
9 9 6 6 6 6 6 8 6 6 7 7 7 7 7 7 7 7
8 8 8 8 8 8 8 6 8 8 8 8 8 8 8 8 8 8
10 10 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
4 2 6 6 6 6 6 6 6 6 2 2 2 2 2 2 2 2
1019,64688 1019,33908 1018,02776 1018,02776 1018,02776 1018,02776 1018,02776 1018,02776 1018,02776 1018,02776 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286
10196,4688 10193,3908 10180,2776 10180,2776 10180,2776 10180,2776 10180,2776 10180,2776 10180,2776 10180,2776 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286
81571,751 81547,126 81442,221 81442,221 81442,221 81442,221 81442,221 81442,221 81442,221 81442,221 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428
7 7 7 7 7 7 7 7 6 6 6 6 6 6 6 6 6 6 6 6 6 7 7
8 8 8 8 8 8 8 8 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
2 2 2 2 2 2 2 2 6 6 6 6 6 6 6 6 6 6 6 6 6 2 2
1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1016,67333 1016,67333
10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10166,7333 10166,7333
81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81333,867 81333,867
Contoh SERP yang dicoba implementasinya pada sebagian peralatan di PLTU PAMA-1
System Equipment Reliability Prioritization (SERP) Island
System
BTG Coal BTG Water Water
Fuel Firing System Ash Handling System Fuel Firing System Fire Fighting System Fire Fighting System
BTG
Fuel Firing System
BTG
Fuel Firing System
BTG
Fuel Firing System
BTG
Fuel Firing System
BTG
Fuel Firing System
BTG Coal Water Coal Water Water Water
Fuel Firing System Coal Handling System Fire Fighting System Ash Handling System Water Treatment System Water Treatment System Water Treatment System
Water
Water Treatment System
Water
Water Treatment System
Water
Water Treatment System
Water Water Water Water Water
Water Treatment System Water Treatment System Water Treatment System Water Treatment System Water Treatment System
Water Water Water Water Water
Water Treatment System Water Treatment System Water Treatment System Water Treatment System Water Treatment System
Water
Water Treatment System
Sub-System Diesel Generator Fly Hash Handling Diesel Generator Fire Fighting System Fire Fighting System High Speed Diesel System High Speed Diesel System High Speed Diesel System High Speed Diesel System High Speed Diesel System High Speed Diesel System Coal Feeding Fire Fighting System Fly Hash Handling MMF System MMF System MMF System Ultrafiltration (UF) System Ultrafiltration (UF) System Ultrafiltration (UF) System Ultrafiltration (UF) System 1st RO System 1st RO System 1st RO System 1st RO System 1st RO System 2nd RO System 2nd RO System 2nd RO System 2nd RO System Electrodeionization (EDI) System
Equipment
OC
PT
PQ
SF
RC
PE
SCR
OCR
ACR
AFPF
MPI
Black Start Diesel Generator 2x ESP Emergency Diesel Generator Diesel Engine Fire Pump Fire Pressure Stabilizer
7 7 6 6 5
6 4 4 2 2
10 10 10 2 2
5 2 5 9 9
4 6 4 2 2
415,55635 615,52417 414,45683 813,89244 813,49074
10155,5635 10155,2417 10144,5683 10138,9244 10134,9074
81244,508 81241,934 81156,547 81111,396 81079,259
Gear Oil Drain Pump
6
6
6
5
4
412,84523
10128,4523
81027,619
2x Screw Oil Pump
6
6
6
5
4
412,84523
10128,4523
81027,619
Vertical Type Fuel Oil Filter
6
6
6
5
4
412,84523
10128,4523
81027,619
2x Vertical Type Fuel Oil Filter
6
6
6
5
4
412,84523
10128,4523
81027,619
Fuel Day Tank
7
4
4
5
4
411,74734
10117,4734
8939,7872
Oil Tank 4x Coal & Silica Belt Feeder Motor Driven Fire Pump 2x Pneumatic ash transporter 2xMulti Medium Mechanical Filter (MMF) Backwash Pump Water Tank for MMF Backwash Water Tank for MMF
6 5 5 7 8 8 8
4 4 2 4 4 4 4
4 10 2 6 4 4 4
5 2 9 2 2 2 2
4 2 2 6 2 2 2
411,18034 613,60147 813,49074 613,30413 812,96148 812,96148 812,96148
10111,8034 8108,8118 8107,9259 8106,4331 8103,6919 8103,6919 8103,6919
8894,4272 8870,4941 8863,4072 8851,4646 8829,5348 8829,5348 8829,5348
Ultra Filtration (UF) Device
8
4
4
2
2
812,96148
8103,6919
8829,5348
Reducing Agent & Scale Inhibitor
8
4
4
2
2
812,96148
8103,6919
8829,5348
Backwash UF Water Pump
8
4
4
2
2
812,96148
8103,6919
8829,5348
2x UF Water Pump 1st Reverse Osmosis (RO) Filter System 2x 1RO Filter 2x Pump Motor 1RO 4x Electric Actuator 1RO 2x Supply Water Pump for 2nd RO Filter System 2nd Reverse Osmosis (RO) Filter System 2x 2RO Filter 2x Pump Motor 2RO 4x Electric Actuator 2RO
8 8 8 8 8
4 4 4 4 4
4 4 4 4 4
2 2 2 2 2
2 2 2 2 2
812,96148 812,96148 812,96148 812,96148 812,96148
8103,6919 8103,6919 8103,6919 8103,6919 8103,6919
8829,5348 8829,5348 8829,5348 8829,5348 8829,5348
8 8 8 8 8
4 4 4 4 4
4 4 4 4 4
2 2 2 2 2
2 2 2 2 2
812,96148 812,96148 812,96148 812,96148 812,96148
8103,6919 8103,6919 8103,6919 8103,6919 8103,6919
8829,5348 8829,5348 8829,5348 8829,5348 8829,5348
EDI Device
8
4
4
2
2
812,96148
8103,6919
8829,5348
Contoh SERP yang dicoba implementasinya pada sebagian peralatan di PLTU PAMA-1
System Equipment Reliability Prioritization (SERP) Island
System
Sub-System
Equipment
Water Water Water Water Water Water Coal Water Water Water Water Water Water Water Water Coal Water Water Water Coal Water Coal Coal Water Water
Water Treatment System Water Treatment System Water Treatment System Water Treatment System Water Treatment System Water Treatment System Ash Handling System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Ash Handling System Water Intake System Water Treatment System Water Treatment System Coal Handling System Cooling Water System Ash Handling System Ash Handling System Cooling Water System Cooling Water System
Electrodeionization (EDI) System Cleaning System MMF System MMF System Cleaning System Cleaning System Fly Hash Handling BOP Cooling BOP Cooling BOP Cooling BOP Cooling BOP Cooling BOP Cooling BOP Cooling BOP Cooling Fly Hash Handling Clarifiying Device Raw Water Circulation Deareator Coal Preparation Condensor Cooling Bottom Ash Handling Bottom Ash Handling Condensor Cooling Condensor Cooling
Coal Water Water Coal Coal Coal Coal Coal Coal Water Water Water Coal Coal Coal Water Water Coal Coal Water Water Water Water Water
Ash Handling System Water Intake System Water Intake System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Ash Handling System Water Intake System Water Intake System Water Intake System Coal Handling System Coal Handling System Lime Handling System Cooling Water System Cooling Water System Ash Handling System Coal Handling System Waste Water Treatment Plant Waste Water Treatment Plant Waste Water Treatment Plant Water Treatment System Water Treatment System
Bottom Ash Handling River Intake Clarifiying Device Coal Preparation Coal Preparation Coal Preparation Coal Preparation Coal Preparation Bottom Ash Handling River Intake River Intake Clarifiying Device Coal Preparation Coal Preparation Lime Handling System Cooling Tower Cooling Tower Fly Hash Handling Coal Feeding Sewage treatment Ash Water Treatment Oil Water Treatment MMF System MMF System
Water
Water Treatment System
Ultrafiltration (UF) System UF Water Tank
2x Desalination Water Pump Cleaning System Water Pump Flocculent & Antiseptic Device 2x Security Filter Cleaning System Ammonia Device compressor Feedpump Cooling Water Admitting Pipeline Feedpump Cooling Water Return Pipeline Primary Cooling Water Admitting Pipeline Primary Cooling Water Return Pipeline Secondary Cooling Water Admitting Pipeline Secondary Cooling Water Return Pipeline IDF Cooling Water Admitting Pipeline IDF Cooling Water Return Pipeline Refrigerated compressor air dryer 3x Make Up Water Pump Raw Water Pump 2x Deareator Unit Coal Crusher Condenser No. 1 Scraper Conveyor No. 3 Scraper Conveyor Air Cooler Oil Cooler Slag Silo 2x Intake Sump Clarifier Unit Belt Conveyor 1 Belt Conveyor 2a Belt Conveyor 2b Belt Conveyor 3a Belt Conveyor 3b No.2 Bucket Elevator Water River Intake 2x Primary Supply Water Pump Chlorine Dioxide Generator Grab Crane Vibrating Feeder Limestone Silo (2 Unit) Cooling Tower 5x Circulating Water Pump Gasification device 4x Coal Bunker
Air Tank 1 Air Tank 2
OC
PT
PQ
SF
RC
PE
SCR
OCR
ACR
AFPF
MPI
8 8 8 8 8 8 5 6 6 6 6 6 6 6 6 4 6 6 8 6 7 6 6 6 6
4 4 2 2 2 2 4 2 2 2 2 2 2 2 2 4 4 4 6 4 6 4 4 4 4
4 4 4 4 4 4 6 6 6 6 6 6 6 6 6 6 4 4 8 6 8 6 6 6 6
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
2 2 2 2 2 2 6 2 2 2 2 2 2 2 2 6 2 2 2 2 2 6 6 2 2
8 8 8 8 8 8 6 8 8 8 8 8 8 8 8 6 8 8 8 6 8 6 6 8 8
12,96148 12,96148 12,49 12,49 12,49 12,49 12,36932 12,16553 12,16553 12,16553 12,16553 12,16553 12,16553 12,16553 12,16553 12 11,83216 11,83216 15,36229 11,48913 14,86607 12,80625 12,80625 12,64911 12,64911
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 6 8 6 6 6 6 6
103,6919 103,6919 99,91997 99,91997 99,91997 99,91997 98,95454 97,3242 97,3242 97,3242 97,3242 97,3242 97,3242 97,3242 97,3242 96 94,65728 94,65728 92,17375 91,913 89,19641 76,83749 76,83749 75,89466 75,89466
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
829,5348 829,5348 799,3597 799,3597 799,3597 799,3597 791,6363 778,5936 778,5936 778,5936 778,5936 778,5936 778,5936 778,5936 778,5936 768 757,2582 757,2582 737,39 735,304 713,5713 614,6999 614,6999 607,1573 607,1573
4 6 6 6 6 6 6 6 6 6 6 5 4 4 8 8 7 6 6 6 6 8 8
4 4 4 4 4 4 4 4 4 2 2 2 4 4 4 6 4 4 4 2 2 2 2 2
6 4 4 6 6 6 6 6 6 4 4 4 6 6 6 8 8 6 8 4 4 4 4 4
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
6 2 2 2 2 2 2 2 6 2 2 2 2 2 2 2 2 6 2 6 6 6 2 2
6 8 8 6 6 6 6 6 6 8 8 8 6 6 6 8 8 6 6 8 8 8 8 8
12 11,83216 11,83216 11,48913 11,48913 11,48913 11,48913 11,48913 11,31371 11,31371 11,31371 11,31371 11 10,58301 10,58301 15,36229 14,69694 13,30413 12,64911 12,64911 12,64911 12,64911 12,49 12,49
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 4 4 4 4 4 4 4 4 4
72 70,99296 70,99296 68,93475 68,93475 68,93475 68,93475 68,93475 67,88225 67,88225 67,88225 67,88225 66 63,49803 63,49803 61,44917 58,78775 53,21654 50,59644 50,59644 50,59644 50,59644 49,95998 49,95998
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
576 567,9437 567,9437 551,478 551,478 551,478 551,478 551,478 543,058 543,058 543,058 543,058 528 507,9843 507,9843 491,5933 470,302 425,7323 404,7715 404,7715 404,7715 404,7715 399,6799 399,6799
8
2
4
2
2
8
12,49
4 49,95998
8 399,6799
System Equipment Reliability Prioritization (SERP) Island
System
Water
Water Treatment System
Water Coal Water Water Coal Coal Water Water Coal Coal Coal Coal Coal Coal Coal
Water Treatment System Coal Handling System Water Intake System Water Treatment System Coal Handling System Ash Handling System Water Intake System Cooling Water System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Coal Handling System
Sub-System
Equipment
OC
1st RO System Fresh Water Tank Electrodeionization (EDI) System 2x Demin Water Tank Coal Feeding 4x Silica Sand Bunker Clarifiying Device Chemical dosing pump of Antiscalant Raw Water Circulation Raw Water Tank Coal Preparation 2x5 Dust Collector System Bottom Ash Handling Upper Structure - (C02) Bottom Ash Bin River Intake House Drainage Pump Cooling Tower Electrical Hoist Coal Preparation Electromagnetic Separator Coal Preparation Belt Scale Coal Preparation Underground Coal Hopper Coal Preparation Electric Hoist Coal Preparation Electric Hoist Coal Preparation Chute A Coal Preparation Chute B
PT
PQ
SF
RC
PE
SCR
OCR
ACR
OC
Operating Cost
PT Process Troughput PQ SF RC PE SCR
Product Quality Safety Consideration Regulatory Compliance Plant Efficiency System Criticality Ranking
4
2
2
8
12,49
4 49,95998
8 399,6799
8 5 6 6 5 8 6 6 4 4 5 4 4 4 4
2 4 2 2 4 2 2 2 4 4 2 2 2 2 2
4 8 4 4 6 6 4 2 6 6 2 2 2 2 2
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
2 2 2 2 2 6 2 2 2 2 2 2 2 2 2
8 12,49 6 12,20656 8 11,31371 8 11,31371 6 11 6 13,41641 8 11,31371 8 10,77033 6 10,58301 6 10,58301 6 8,774964 6 8,246211 6 8,246211 6 8,246211 6 8,246211
4 49,95998 4 48,82622 4 45,25483 4 45,25483 4 44 2 26,83282 2 22,62742 2 21,54066 2 21,16601 2 21,16601 2 17,54993 2 16,49242 2 16,49242 2 16,49242 2 16,49242
8 399,6799 8 390,6098 8 362,0387 8 362,0387 8 352 8 214,6625 8 181,0193 8 172,3253 8 169,3281 8 169,3281 8 140,3994 8 131,9394 8 131,9394 8 131,9394 8 131,9394
Source of Data
Keterangan Requirement for Data Source Nilai bisa berubah apabila terdapat penggantian Capital Investment tipe aset Data Investasi / Data procurement FMEA, Data daily breakdown yang Daily Breakdown report / menjelaskan dampak kerusakan KPI Nilai bisa berubah sesuai kondisi operasional terhadap produksi listrik pada PLTU Data operasi PLTU (DCS) / KPI Nilai bisa berubah sesuai kondisi operasional Rekapitulasi data operasional dari DCS Nilai bisa berubah apabila ada risk assesement Data Hazops yang disesuaikan dengan HAZOPS ulang FMEA UU, RKL/RPL, laporan Nilai bisa berubah apabila terdapat peraturan / limbah perizinan baru Data peraturan dan perizinan Data operasi PLTU (DCS) / KPI Nilai bisa berubah sesuai kondisi operasional Rekapitulasi data operasional dari DCS Kalkulasi Nilai bisa berubah sesuai hasil kalkulasi OC, PT, PQ, SF, RC, PE
OCR
ACR AFPF MPI
Operational Criticality Ranking Asset Criticality Ranking Asset Failure Probability Factor Maintenance Priority Index
FMEA, Data operasi PLTU (DCS) Kalkulasi Daily Breakdown report / KPI Kalkulasi
Nilai bisa berubah sesuai kondisi operasional / risk assesement ulang Nilai bisa berubah sesuai hasil kalkulasi Nilai bisa berubah sesuai kondisi operasional Nilai bisa berubah sesuai hasil kalkulasi
MPI
2
Parameter SERP Parameter Description
AFPF
8
FMEA, Daily breakdown yang menjelaskan dampak kerusakan terhadap sistem induk, dan rekapitulasi data operasional dari DCS SCR, OCR Daily breakdown report dan KPI maintenance ACR, AFPF
Formula
System Equipment Reliability Prioritization (SERP) Proses aktualisasi SERP dari konsep menjadi maintenance planning Maintenance Strategy • •
Logic Tree Analysis (untuk menentukan aktifitas maintenance yang sesuai kondisi)
•
Work Planning & Control
Asset Wellness (KPI)
Planning Maintenance Maintenance Preparation Maintenance execution control
Root Cause Analysis (TAR, untuk menentukan penyebab kerusakan)
Continous Improvement
Manpower Development
- Materi di tim PPD HO (Ari Oksendra) -
Eksekusi Preventive Maintenance Planning Maintenance Activities Equipment by Island & System BTG Black Start Diesel Generator BOILER & AUX. CONDENSATE SYSTEM CONDENSOR SYSTEM DEAREATOR SYSTEM ELECTROSTATIC PRECIPITATOR SYSTEM ELECTROSTATIC PRESIPITATOR SYSTEM High Speed Diesel System TURBINE & AUX COAL BOTTOM ASH HANDLING COAL HANDLING PLANT FLY ASH HANDLING SYSTEM WATER COOLING SYSTEM FIRE FIGHTING SYSTEM WTP
Interval of activities Everyday Every week Every month Every 2000 hrs Every 4000 hrs Every 6000 hrs Every 8000 hrs 392 127 157 1210 585 102 448 7 6 2 32 141 15 43 282 62 2 75 10 10 10 47 47 10 36 9 9 9 68 19 9 9 3 3 3 16 22 3 3 4 1 90 8 8 21 3 2 56 2 208 80 84 647 425 78 282 74 22 28 191 41 19 51 37 10 6 74 22 28 118 29 19 43 36 2 2 148 20 18 382 10 8 46 36 1 1 92 1 1 1 52 14 9 128 5 3 35 60 5 8 162 4 4 10
Planning Maintenance Activities Equipment by Level of inspection and System Inspeksi Level 1 Climb Up Inspection Current Cariyying / Pembawa Arus Insulator / Isolasi Junction Monitoring Protection ( Proteksi Petir ) Structure Ground Patrol Current Cariyying / Pembawa Arus Junction Monitoring Pengaman dari Ancaman Akibat Manusia Protection ( Proteksi Petir ) Structure Inspeksi Level 2 ( In Service Measurement ) Pentanahan ( Grounding ) Pentanahan ( Grounding ) Puncture test Puncture test Ranging Meter Ranging Meter Thermovisi Thermovisi TLA TLA Inspeksi Level 3 ( Shutdown Testing Measurement) Current Carrying Current Carrying Insulation / Isolasi Insulation / Isolasi Structure Structure
Interval of Activities Daily Weekly Monthly 3-monthly 6-monthly yearly every 2 year every 5 year Conditional 38 2 3 50 50 50 50 4 4 4 4 14 14 6 6 14 14 8 8 38 2 3 8 3 5 2 2 12 1 8 2 5 2 1 12 2 2 1 1 1 1 4 4 5 5 5 5 2 2 4 1 1 2 2 1 1
Schedule aktifitas maintenance pembangkit berdasarkan interval untuk masing – masing sistem
Schedule aktifitas maintenance distribusi berdasarkan interval untuk masing – masing sistem
Rincian planned maintenance berisi : • masing – masing aktifitas rinci per equipment per interval waktu • Standar parameter nilai normal masing – masing aktifitas (STD)
Eksekusi Preventive Maintenance Koordinasi dengan OPR
Fasilitas
Tools
Spare Parts
Dokumen Pendukung
Pengarahan
Durasi maintenance
Crane
Alat pengukuran
Replaceable equipment
INK
OJI with expert trainer / consultant
Equipment terkait
Welding
Special tools
Lubricants
QA/QC
?
Dampak produksi listrik
A2B
Workshop Tools
Consumable parts
Operational Data reference
?
?
?
?
?
Working Order ?
Bagian Koordinasi
Fasilitas
Tools
Spare Parts
Rincian Durasi maintenance Equipment terkait Dampak produksi listrik Lifting Equipment Welding equipment A2B Alat pengukuran Regular & Special Tools Workshop Tools Replacable Equipment Lubricants Consumable Parts Spare Parts
Document
Instruksi Kerja (INK) QA / QC Guidance Operasional Data Reference Working Order
Pengarahan
OJI with expert trainer
Penjelasan
Action
Notes
Parameter – parameter yang perlu disiapkan dalam eksekusi preventive maintenance
PIC
ELECTRICITY (Generation & Distribution) Maintenance Management System
Agar aktifitas maintenance dapat terencana, terawasi, dan mencapai target yang diinginkan, diperlukan sistem manajemen yang dapat mengakomodir keperluan perencanaan, eksekusi, monitoring target, feedback, dan pengembangan terhadap aktifitas maintenance beserta elemen pendukungnya.
ELECTRICITY (Generation & Distribution) Maintenance Management System
PLANT DIVISION SCOPE Electricity Operation by EPN
• Electricity Generation (PLTU 2 x 15 MW) • Electricity Distribution (Distribusi 36 kV to ASMI, SMMS, TOP) • Electricity Transmission (150 kV integration to PLN future plan)
Electricity Operation Maintenance
• Generation equipment maintenance • Distribution Equipment Maintenance • Transmission Equipment Maintenance
EPN SCOPE
Electricity Operation by EPN
• Electricity Generation (PLTU 2 x 15 MW) • Electricity Distribution (Distribusi 36 kV to ASMI, SMMS, TOP) • Electricity Transmission (150 kV integration to PLN future plan)
ELECTRICITY (Generation & Distribution) Maintenance Management System
ELECTRICITY (Generation & Distribution) Maintenance Management System MAINTENANCE MACRO PROCESS Improvement Management
GENERATION & DISTRIBUTION ENGINEERING
OPERATION
SERP Failure Identification
Operation Parameter
Shutdown Maintenance
Maintenance Planning
Performance Analysis
Operation Engineering Maintenance Engineering
Turn On Maintenance
Operation Lifetime
People Development
Recondition Management
Information Management
Facilities & tools management
HCGS
SUPPLY MANAGEMENT
INFORMATION SYSTEM
Plant ASMI
ELECTRICITY (Generation & Distribution) Maintenance Management System MAIN PROCESS Generation & Distribution Planning & Engineering
SOP & STD REQUIREMENT
Operation Coordination
Maintenance Engineering
Maintenance Planning
Maintenance Execution System of Equipment Reliability Prioritization
Shutdown Maintenance
Performane Analysis
Turn On Maintenance
Key Performance Indicator Failure Analysis
SOP yang diperlukan pada Maintenance Management System
SUPPORT PROCESS
SOP & STD REQUIREMENT
Improvement Management
People Development
Recondition Management Information Management
Facilities & Tools Management
STRUKTUR ORGANISASI & STANDAR KOMPETENSI
- Materi di tim PPD HO (Ari Oksendra) -
Point of Meeting 1. Persiapan pelaksanaan maintenance planning dan pendukung yang perlu dipersiapkan 2. Persiapan implementasi SERP (RCM untuk PLTU dan distribusi) 3. Penyusunan Maintenance Management System untuk mendukung kedua point di atas 4. Persiapan training & development (OJI distribusi & pembangkit, in class training, dan penyusunan standar kompetensi)
On-Going Process for Maintenance Fullfilment Agenda
Area Pembangkit Distribusi
Identifikasi aset
Pembangkit Distribusi Pembangkit
Asesemen lapangan
Distribusi Pembangkit Distribusi Pembangkit
Praktik maintenance Distribusi dengan panduan dari PJIS dan KE Pembangkit Distribusi Pembangkit Penyusunan SERP (System Equipment Distribusi Reliability Pembangkit Prioritization) Distribusi Pembangkit Pengembangan kompetensi manpower maintenance pembangkit
Distribusi
Penjelasan Klasifikasi peralatan berdasarkan fungsinya
PIC
Status Closed Closed
Perincian peralatan dari tahap island - sistem subsistem - peralatan - komponen
Closed
Pembelajaran cara kerja pembangkit dan distribusi secara keseluruhan, per island, per sistem, dan masing - masing peralatan Pengelompokan manpower berdasarkan island/area, dan bidang kerja (mekanikal, elektrikal, dan instrumentasi)
Closed
Semua aktifitas maintenance di pembangkit dan distribusi berdasarkan arahan dari PJIS dan KE Bertujuan untuk mempelajari cara kerja peralatan, dan filosofi dasar maintenance di pembangkit dan distribusi Program untuk menentukan aktifitas maintenance untuk jangka setahun berdasarkan kehandalan masing - masing peralatan Pengadaan infrastruktur (dokumen dan peralatan) untuk kelengkapan penyusunan SERP Mapping kompetensi manpower maintenance di pembangkit dan distribusi
Pembangkit Distribusi Pembangkit Distribusi
Penyusunan training berdasarkan hasil mapping kompetensi
Pembangkit
Pengembangan kompetensi khusus untuk planner dan engineer agar sesuai dengan SERP
Distribusi
Keterangan tambahan
OJI dan In-class training
Closed Closed Closed Closed OnGoing OnGoing OnGoing OnGoing OnGoing Open OnGoing Open OnGoing OnGoing Open Open Open Open Open Open
On-Going Process for Maintenance Fullfilment
Agenda
Area Pembangkit Distribusi
Pelaksanaan planned Pembangkit maintenance Distribusi program (preventive maintenance) Pembangkit Distribusi
Penjelasan
Keterangan tambahan
PIC
Status
Penyusunan kelengkapan (hourmeter, dokumen teknis, tools, sarana, dll) untuk running planned maintenance program Preventive program dilakukan per interval harian, mingguan, bulanan, 3 bulanan, 6 bulanan, dan tahunan
Open
Preventive program disusun berdasarkan acuan dari equipment serupa yang sudah terdapat di PAMA, dan referensi eksternal untuk equipment yang tidak tersedia di PAMA
OnGoing
Pembangkit
Open Open Open
OnGoing Open
Penyusunan makro proses, SOP, dan INK Distribusi Penyusunan Pembangkit Maintenance Management System Distribusi untuk pembangkit Pembangkit Distribusi Standarisasi struktur Pembangkit organisasi, kompetensi, dan jenjang karir di Distribusi maintenance Pembangkit pembangkit Distribusi Eksekusi SERP
KitDis
Open Penyusunan STD untuk parameter masing - masing aktifitas maintenance Monitoring periodik (harian, mingguan, dan bulanan) untuk KPI aktifitas maintenance dan sistem PI CA/PA (Problem Identification and Corrective/Preventive Action) nya Pemenuhan kebutuhan manpower berdasarkan requirement fungsi kerja di pembangkit dan distribusi Standarisasi kompetensi, fungsi kerja, dan jenjang kerja Pelaksanaan aktifitas maintenance berdasarkan SERP yang telah disusun selama 2019 dengan kompetensi manpower yang telah dikembangkan
Open
Open Open Open OnGoing OnGoing Open Open Open
Identifikasi Aset EPN
Sistem Pembangkit (PLTU 2x 15 MW)
AREA
ISLAND
SYSTEM
BTG Island
Coal Island
Sistem Distribusi (SUTT 36kV)
Water Island
Primary
Sistem Transmisi (SUTT 150 KV)
Secondary
Boiler System
Coal Handling System
Water Intake
Current Carrying
Protection
Turbine System
Ash Handling System
Water Treatment Plant
Insulation
Sarana monitoring & pemeliharaan
Steam Generator System
Limestone Handling System
Waste Water Treatment Plant
Structure
Cooling System
Junction
Fuel Injection System
Fire Fighting System
Sub - System
Equipment Component
Construction progress
System Equipment Reliability Prioritization (SERP)
Metode SERP diperlukan agar proses maintenance pada PLTU dan distribusi bisa lebih tepat guna, dan tidak menimbulkan dampak downtime yang terlalu besar. Pelaksanaannya dilakukan oleh maintenance planner dan maintenance engineer
System Equipment Reliability Prioritization (SERP) Island
System
Sub-System
BTG
Boiler System
BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG
Steam Generator System Steam Turbine System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System
Boiler Unit Steam Turbine Generator Turbine Unit Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries
BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG BTG
Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Steam Turbine System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Boiler System Steam Turbine System Steam Turbine System
Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Turbine Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Boiler Auxilliaries Turbine Auxilliaries Turbine Auxilliaries
Equipment
OC
PT
PQ
SF
RC
PE
SCR
OCR
ACR
AFPF
MPI
Circulating fluidized bed boiler
9
8
10
5
6
1020,14944
10201,4944
81611,955
Steam Turbine Generator Steam Turbine Drain tank sampling cooler Superheated steam sampling cooler Saturated steam sampling cooler Boiler water sampling cooler Feed Water sampling cooler Chimney Duplex slag cooler Weighing complete shut-off coal feeder High Pressure Electric Oil Pump AC Lubricating Oil Pump DC Lubricating Oil Pump High Pressure Heater Low Pressure Heater Gland Steam Heater Flash Tank Equalization Box Temperature-decreased pressure reducer for gland steam heater Condense Pump Water Jet Pump Water Jet Ejector Electric Boiler Feed Water Pump Gland Exhaust Fan Jacking Oil Pump Water Jet Tank Primary Air Fan Secondary Air Fan Induced Draft Fan Recycled Fan Continuous Blowdown Flash tank Periodic blowdown flash tank Vertical type flash tank Drain Tank Drainage pump Service water recycled pump Phospate dosing unit Service water recycled pond Service water recycled tank Oil Tank Emergency Containment Sump
9 9 6 6 6 6 6 8 6 6 7 7 7 7 7 7 7 7
8 8 8 8 8 8 8 6 8 8 8 8 8 8 8 8 8 8
10 10 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
4 2 6 6 6 6 6 6 6 6 2 2 2 2 2 2 2 2
1019,64688 1019,33908 1018,02776 1018,02776 1018,02776 1018,02776 1018,02776 1018,02776 1018,02776 1018,02776 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286
10196,4688 10193,3908 10180,2776 10180,2776 10180,2776 10180,2776 10180,2776 10180,2776 10180,2776 10180,2776 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286
81571,751 81547,126 81442,221 81442,221 81442,221 81442,221 81442,221 81442,221 81442,221 81442,221 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428
7 7 7 7 7 7 7 7 6 6 6 6 6 6 6 6 6 6 6 6 6 7 7
8 8 8 8 8 8 8 8 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5
2 2 2 2 2 2 2 2 6 6 6 6 6 6 6 6 6 6 6 6 6 2 2
1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,49286 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1017,23369 1016,67333 1016,67333
10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10174,9286 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10172,3369 10166,7333 10166,7333
81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81399,428 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81378,695 81333,867 81333,867
Contoh SERP yang dicoba implementasinya pada sebagian peralatan di PLTU PAMA-1
System Equipment Reliability Prioritization (SERP) Island
System
BTG Coal BTG Water Water
Fuel Firing System Ash Handling System Fuel Firing System Fire Fighting System Fire Fighting System
BTG
Fuel Firing System
BTG
Fuel Firing System
BTG
Fuel Firing System
BTG
Fuel Firing System
BTG
Fuel Firing System
BTG Coal Water Coal Water Water Water
Fuel Firing System Coal Handling System Fire Fighting System Ash Handling System Water Treatment System Water Treatment System Water Treatment System
Water
Water Treatment System
Water
Water Treatment System
Water
Water Treatment System
Water Water Water Water Water
Water Treatment System Water Treatment System Water Treatment System Water Treatment System Water Treatment System
Water Water Water Water Water
Water Treatment System Water Treatment System Water Treatment System Water Treatment System Water Treatment System
Water
Water Treatment System
Sub-System Diesel Generator Fly Hash Handling Diesel Generator Fire Fighting System Fire Fighting System High Speed Diesel System High Speed Diesel System High Speed Diesel System High Speed Diesel System High Speed Diesel System High Speed Diesel System Coal Feeding Fire Fighting System Fly Hash Handling MMF System MMF System MMF System Ultrafiltration (UF) System Ultrafiltration (UF) System Ultrafiltration (UF) System Ultrafiltration (UF) System 1st RO System 1st RO System 1st RO System 1st RO System 1st RO System 2nd RO System 2nd RO System 2nd RO System 2nd RO System Electrodeionization (EDI) System
Equipment
OC
PT
PQ
SF
RC
PE
SCR
OCR
ACR
AFPF
MPI
Black Start Diesel Generator 2x ESP Emergency Diesel Generator Diesel Engine Fire Pump Fire Pressure Stabilizer
7 7 6 6 5
6 4 4 2 2
10 10 10 2 2
5 2 5 9 9
4 6 4 2 2
415,55635 615,52417 414,45683 813,89244 813,49074
10155,5635 10155,2417 10144,5683 10138,9244 10134,9074
81244,508 81241,934 81156,547 81111,396 81079,259
Gear Oil Drain Pump
6
6
6
5
4
412,84523
10128,4523
81027,619
2x Screw Oil Pump
6
6
6
5
4
412,84523
10128,4523
81027,619
Vertical Type Fuel Oil Filter
6
6
6
5
4
412,84523
10128,4523
81027,619
2x Vertical Type Fuel Oil Filter
6
6
6
5
4
412,84523
10128,4523
81027,619
Fuel Day Tank
7
4
4
5
4
411,74734
10117,4734
8939,7872
Oil Tank 4x Coal & Silica Belt Feeder Motor Driven Fire Pump 2x Pneumatic ash transporter 2xMulti Medium Mechanical Filter (MMF) Backwash Pump Water Tank for MMF Backwash Water Tank for MMF
6 5 5 7 8 8 8
4 4 2 4 4 4 4
4 10 2 6 4 4 4
5 2 9 2 2 2 2
4 2 2 6 2 2 2
411,18034 613,60147 813,49074 613,30413 812,96148 812,96148 812,96148
10111,8034 8108,8118 8107,9259 8106,4331 8103,6919 8103,6919 8103,6919
8894,4272 8870,4941 8863,4072 8851,4646 8829,5348 8829,5348 8829,5348
Ultra Filtration (UF) Device
8
4
4
2
2
812,96148
8103,6919
8829,5348
Reducing Agent & Scale Inhibitor
8
4
4
2
2
812,96148
8103,6919
8829,5348
Backwash UF Water Pump
8
4
4
2
2
812,96148
8103,6919
8829,5348
2x UF Water Pump 1st Reverse Osmosis (RO) Filter System 2x 1RO Filter 2x Pump Motor 1RO 4x Electric Actuator 1RO 2x Supply Water Pump for 2nd RO Filter System 2nd Reverse Osmosis (RO) Filter System 2x 2RO Filter 2x Pump Motor 2RO 4x Electric Actuator 2RO
8 8 8 8 8
4 4 4 4 4
4 4 4 4 4
2 2 2 2 2
2 2 2 2 2
812,96148 812,96148 812,96148 812,96148 812,96148
8103,6919 8103,6919 8103,6919 8103,6919 8103,6919
8829,5348 8829,5348 8829,5348 8829,5348 8829,5348
8 8 8 8 8
4 4 4 4 4
4 4 4 4 4
2 2 2 2 2
2 2 2 2 2
812,96148 812,96148 812,96148 812,96148 812,96148
8103,6919 8103,6919 8103,6919 8103,6919 8103,6919
8829,5348 8829,5348 8829,5348 8829,5348 8829,5348
EDI Device
8
4
4
2
2
812,96148
8103,6919
8829,5348
Contoh SERP yang dicoba implementasinya pada sebagian peralatan di PLTU PAMA-1
System Equipment Reliability Prioritization (SERP) Island
System
Sub-System
Equipment
Water Water Water Water Water Water Coal Water Water Water Water Water Water Water Water Coal Water Water Water Coal Water Coal Coal Water Water
Water Treatment System Water Treatment System Water Treatment System Water Treatment System Water Treatment System Water Treatment System Ash Handling System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Cooling Water System Ash Handling System Water Intake System Water Treatment System Water Treatment System Coal Handling System Cooling Water System Ash Handling System Ash Handling System Cooling Water System Cooling Water System
Electrodeionization (EDI) System Cleaning System MMF System MMF System Cleaning System Cleaning System Fly Hash Handling BOP Cooling BOP Cooling BOP Cooling BOP Cooling BOP Cooling BOP Cooling BOP Cooling BOP Cooling Fly Hash Handling Clarifiying Device Raw Water Circulation Deareator Coal Preparation Condensor Cooling Bottom Ash Handling Bottom Ash Handling Condensor Cooling Condensor Cooling
Coal Water Water Coal Coal Coal Coal Coal Coal Water Water Water Coal Coal Coal Water Water Coal Coal Water Water Water Water Water
Ash Handling System Water Intake System Water Intake System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Ash Handling System Water Intake System Water Intake System Water Intake System Coal Handling System Coal Handling System Lime Handling System Cooling Water System Cooling Water System Ash Handling System Coal Handling System Waste Water Treatment Plant Waste Water Treatment Plant Waste Water Treatment Plant Water Treatment System Water Treatment System
Bottom Ash Handling River Intake Clarifiying Device Coal Preparation Coal Preparation Coal Preparation Coal Preparation Coal Preparation Bottom Ash Handling River Intake River Intake Clarifiying Device Coal Preparation Coal Preparation Lime Handling System Cooling Tower Cooling Tower Fly Hash Handling Coal Feeding Sewage treatment Ash Water Treatment Oil Water Treatment MMF System MMF System
Water
Water Treatment System
Ultrafiltration (UF) System UF Water Tank
2x Desalination Water Pump Cleaning System Water Pump Flocculent & Antiseptic Device 2x Security Filter Cleaning System Ammonia Device compressor Feedpump Cooling Water Admitting Pipeline Feedpump Cooling Water Return Pipeline Primary Cooling Water Admitting Pipeline Primary Cooling Water Return Pipeline Secondary Cooling Water Admitting Pipeline Secondary Cooling Water Return Pipeline IDF Cooling Water Admitting Pipeline IDF Cooling Water Return Pipeline Refrigerated compressor air dryer 3x Make Up Water Pump Raw Water Pump 2x Deareator Unit Coal Crusher Condenser No. 1 Scraper Conveyor No. 3 Scraper Conveyor Air Cooler Oil Cooler Slag Silo 2x Intake Sump Clarifier Unit Belt Conveyor 1 Belt Conveyor 2a Belt Conveyor 2b Belt Conveyor 3a Belt Conveyor 3b No.2 Bucket Elevator Water River Intake 2x Primary Supply Water Pump Chlorine Dioxide Generator Grab Crane Vibrating Feeder Limestone Silo (2 Unit) Cooling Tower 5x Circulating Water Pump Gasification device 4x Coal Bunker
Air Tank 1 Air Tank 2
OC
PT
PQ
SF
RC
PE
SCR
OCR
ACR
AFPF
MPI
8 8 8 8 8 8 5 6 6 6 6 6 6 6 6 4 6 6 8 6 7 6 6 6 6
4 4 2 2 2 2 4 2 2 2 2 2 2 2 2 4 4 4 6 4 6 4 4 4 4
4 4 4 4 4 4 6 6 6 6 6 6 6 6 6 6 4 4 8 6 8 6 6 6 6
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
2 2 2 2 2 2 6 2 2 2 2 2 2 2 2 6 2 2 2 2 2 6 6 2 2
8 8 8 8 8 8 6 8 8 8 8 8 8 8 8 6 8 8 8 6 8 6 6 8 8
12,96148 12,96148 12,49 12,49 12,49 12,49 12,36932 12,16553 12,16553 12,16553 12,16553 12,16553 12,16553 12,16553 12,16553 12 11,83216 11,83216 15,36229 11,48913 14,86607 12,80625 12,80625 12,64911 12,64911
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 6 8 6 6 6 6 6
103,6919 103,6919 99,91997 99,91997 99,91997 99,91997 98,95454 97,3242 97,3242 97,3242 97,3242 97,3242 97,3242 97,3242 97,3242 96 94,65728 94,65728 92,17375 91,913 89,19641 76,83749 76,83749 75,89466 75,89466
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
829,5348 829,5348 799,3597 799,3597 799,3597 799,3597 791,6363 778,5936 778,5936 778,5936 778,5936 778,5936 778,5936 778,5936 778,5936 768 757,2582 757,2582 737,39 735,304 713,5713 614,6999 614,6999 607,1573 607,1573
4 6 6 6 6 6 6 6 6 6 6 5 4 4 8 8 7 6 6 6 6 8 8
4 4 4 4 4 4 4 4 4 2 2 2 4 4 4 6 4 4 4 2 2 2 2 2
6 4 4 6 6 6 6 6 6 4 4 4 6 6 6 8 8 6 8 4 4 4 4 4
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
6 2 2 2 2 2 2 2 6 2 2 2 2 2 2 2 2 6 2 6 6 6 2 2
6 8 8 6 6 6 6 6 6 8 8 8 6 6 6 8 8 6 6 8 8 8 8 8
12 11,83216 11,83216 11,48913 11,48913 11,48913 11,48913 11,48913 11,31371 11,31371 11,31371 11,31371 11 10,58301 10,58301 15,36229 14,69694 13,30413 12,64911 12,64911 12,64911 12,64911 12,49 12,49
6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 4 4 4 4 4 4 4 4 4
72 70,99296 70,99296 68,93475 68,93475 68,93475 68,93475 68,93475 67,88225 67,88225 67,88225 67,88225 66 63,49803 63,49803 61,44917 58,78775 53,21654 50,59644 50,59644 50,59644 50,59644 49,95998 49,95998
8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8
576 567,9437 567,9437 551,478 551,478 551,478 551,478 551,478 543,058 543,058 543,058 543,058 528 507,9843 507,9843 491,5933 470,302 425,7323 404,7715 404,7715 404,7715 404,7715 399,6799 399,6799
8
2
4
2
2
8
12,49
4 49,95998
8 399,6799
System Equipment Reliability Prioritization (SERP) Island
System
Water
Water Treatment System
Water Coal Water Water Coal Coal Water Water Coal Coal Coal Coal Coal Coal Coal
Water Treatment System Coal Handling System Water Intake System Water Treatment System Coal Handling System Ash Handling System Water Intake System Cooling Water System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Coal Handling System Coal Handling System
Sub-System
Equipment
OC
1st RO System Fresh Water Tank Electrodeionization (EDI) System 2x Demin Water Tank Coal Feeding 4x Silica Sand Bunker Clarifiying Device Chemical dosing pump of Antiscalant Raw Water Circulation Raw Water Tank Coal Preparation 2x5 Dust Collector System Bottom Ash Handling Upper Structure - (C02) Bottom Ash Bin River Intake House Drainage Pump Cooling Tower Electrical Hoist Coal Preparation Electromagnetic Separator Coal Preparation Belt Scale Coal Preparation Underground Coal Hopper Coal Preparation Electric Hoist Coal Preparation Electric Hoist Coal Preparation Chute A Coal Preparation Chute B
PT
PQ
SF
RC
PE
SCR
OCR
ACR
OC
Operating Cost
PT Process Troughput PQ SF RC PE SCR
Product Quality Safety Consideration Regulatory Compliance Plant Efficiency System Criticality Ranking
4
2
2
8
12,49
4 49,95998
8 399,6799
8 5 6 6 5 8 6 6 4 4 5 4 4 4 4
2 4 2 2 4 2 2 2 4 4 2 2 2 2 2
4 8 4 4 6 6 4 2 6 6 2 2 2 2 2
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
2 2 2 2 2 6 2 2 2 2 2 2 2 2 2
8 12,49 6 12,20656 8 11,31371 8 11,31371 6 11 6 13,41641 8 11,31371 8 10,77033 6 10,58301 6 10,58301 6 8,774964 6 8,246211 6 8,246211 6 8,246211 6 8,246211
4 49,95998 4 48,82622 4 45,25483 4 45,25483 4 44 2 26,83282 2 22,62742 2 21,54066 2 21,16601 2 21,16601 2 17,54993 2 16,49242 2 16,49242 2 16,49242 2 16,49242
8 399,6799 8 390,6098 8 362,0387 8 362,0387 8 352 8 214,6625 8 181,0193 8 172,3253 8 169,3281 8 169,3281 8 140,3994 8 131,9394 8 131,9394 8 131,9394 8 131,9394
Source of Data
Keterangan Requirement for Data Source Nilai bisa berubah apabila terdapat penggantian Capital Investment tipe aset Data Investasi / Data procurement FMEA, Data daily breakdown yang Daily Breakdown report / menjelaskan dampak kerusakan KPI Nilai bisa berubah sesuai kondisi operasional terhadap produksi listrik pada PLTU Data operasi PLTU (DCS) / KPI Nilai bisa berubah sesuai kondisi operasional Rekapitulasi data operasional dari DCS Nilai bisa berubah apabila ada risk assesement Data Hazops yang disesuaikan dengan HAZOPS ulang FMEA UU, RKL/RPL, laporan Nilai bisa berubah apabila terdapat peraturan / limbah perizinan baru Data peraturan dan perizinan Data operasi PLTU (DCS) / KPI Nilai bisa berubah sesuai kondisi operasional Rekapitulasi data operasional dari DCS Kalkulasi Nilai bisa berubah sesuai hasil kalkulasi OC, PT, PQ, SF, RC, PE
OCR
ACR AFPF MPI
Operational Criticality Ranking Asset Criticality Ranking Asset Failure Probability Factor Maintenance Priority Index
FMEA, Data operasi PLTU (DCS) Kalkulasi Daily Breakdown report / KPI Kalkulasi
Nilai bisa berubah sesuai kondisi operasional / risk assesement ulang Nilai bisa berubah sesuai hasil kalkulasi Nilai bisa berubah sesuai kondisi operasional Nilai bisa berubah sesuai hasil kalkulasi
MPI
2
Parameter SERP Parameter Description
AFPF
8
FMEA, Daily breakdown yang menjelaskan dampak kerusakan terhadap sistem induk, dan rekapitulasi data operasional dari DCS SCR, OCR Daily breakdown report dan KPI maintenance ACR, AFPF
Formula
System Equipment Reliability Prioritization (SERP) Proses aktualisasi SERP dari konsep menjadi maintenance planning Maintenance Strategy • •
Logic Tree Analysis (untuk menentukan aktifitas maintenance yang sesuai kondisi)
•
Work Planning & Control
Asset Wellness (KPI)
Planning Maintenance Maintenance Preparation Maintenance execution control
Root Cause Analysis (TAR, untuk menentukan penyebab kerusakan)
Continous Improvement
Manpower Development
- Materi di tim PPD HO (Ari Oksendra) -
Eksekusi Preventive Maintenance Planning Maintenance Activities Equipment by Island & System BTG Black Start Diesel Generator BOILER & AUX. CONDENSATE SYSTEM CONDENSOR SYSTEM DEAREATOR SYSTEM ELECTROSTATIC PRECIPITATOR SYSTEM ELECTROSTATIC PRESIPITATOR SYSTEM High Speed Diesel System TURBINE & AUX COAL BOTTOM ASH HANDLING COAL HANDLING PLANT FLY ASH HANDLING SYSTEM WATER COOLING SYSTEM FIRE FIGHTING SYSTEM WTP
Interval of activities Everyday Every week Every month Every 2000 hrs Every 4000 hrs Every 6000 hrs Every 8000 hrs 392 127 157 1210 585 102 448 7 6 2 32 141 15 43 282 62 2 75 10 10 10 47 47 10 36 9 9 9 68 19 9 9 3 3 3 16 22 3 3 4 1 90 8 8 21 3 2 56 2 208 80 84 647 425 78 282 74 22 28 191 41 19 51 37 10 6 74 22 28 118 29 19 43 36 2 2 148 20 18 382 10 8 46 36 1 1 92 1 1 1 52 14 9 128 5 3 35 60 5 8 162 4 4 10
Planning Maintenance Activities Equipment by Level of inspection and System Inspeksi Level 1 Climb Up Inspection Current Cariyying / Pembawa Arus Insulator / Isolasi Junction Monitoring Protection ( Proteksi Petir ) Structure Ground Patrol Current Cariyying / Pembawa Arus Junction Monitoring Pengaman dari Ancaman Akibat Manusia Protection ( Proteksi Petir ) Structure Inspeksi Level 2 ( In Service Measurement ) Pentanahan ( Grounding ) Pentanahan ( Grounding ) Puncture test Puncture test Ranging Meter Ranging Meter Thermovisi Thermovisi TLA TLA Inspeksi Level 3 ( Shutdown Testing Measurement) Current Carrying Current Carrying Insulation / Isolasi Insulation / Isolasi Structure Structure
Interval of Activities Daily Weekly Monthly 3-monthly 6-monthly yearly every 2 year every 5 year Conditional 38 2 3 50 50 50 50 4 4 4 4 14 14 6 6 14 14 8 8 38 2 3 8 3 5 2 2 12 1 8 2 5 2 1 12 2 2 1 1 1 1 4 4 5 5 5 5 2 2 4 1 1 2 2 1 1
Schedule aktifitas maintenance pembangkit berdasarkan interval untuk masing – masing sistem
Schedule aktifitas maintenance distribusi berdasarkan interval untuk masing – masing sistem
Rincian planned maintenance berisi : • masing – masing aktifitas rinci per equipment per interval waktu • Standar parameter nilai normal masing – masing aktifitas (STD)
Eksekusi Preventive Maintenance Koordinasi dengan OPR
Fasilitas
Tools
Spare Parts
Dokumen Pendukung
Pengarahan
Durasi maintenance
Crane
Alat pengukuran
Replaceable equipment
INK
OJI with expert trainer / consultant
Equipment terkait
Welding
Special tools
Lubricants
QA/QC
?
Dampak produksi listrik
A2B
Workshop Tools
Consumable parts
Operational Data reference
?
?
?
?
?
Working Order ?
Bagian Koordinasi
Fasilitas
Tools
Spare Parts
Rincian Durasi maintenance Equipment terkait Dampak produksi listrik Lifting Equipment Welding equipment A2B Alat pengukuran Regular & Special Tools Workshop Tools Replacable Equipment Lubricants Consumable Parts Spare Parts
Document
Instruksi Kerja (INK) QA / QC Guidance Operasional Data Reference Working Order
Pengarahan
OJI with expert trainer
Penjelasan
Action
Notes
Parameter – parameter yang perlu disiapkan dalam eksekusi preventive maintenance
PIC
ELECTRICITY (Generation & Distribution) Maintenance Management System
Agar aktifitas maintenance dapat terencana, terawasi, dan mencapai target yang diinginkan, diperlukan sistem manajemen yang dapat mengakomodir keperluan perencanaan, eksekusi, monitoring target, feedback, dan pengembangan terhadap aktifitas maintenance beserta elemen pendukungnya.
ELECTRICITY (Generation & Distribution) Maintenance Management System
PLANT DIVISION SCOPE Electricity Operation by EPN
• Electricity Generation (PLTU 2 x 15 MW) • Electricity Distribution (Distribusi 36 kV to ASMI, SMMS, TOP) • Electricity Transmission (150 kV integration to PLN future plan)
Electricity Operation Maintenance
• Generation equipment maintenance • Distribution Equipment Maintenance • Transmission Equipment Maintenance
EPN SCOPE
Electricity Operation by EPN
• Electricity Generation (PLTU 2 x 15 MW) • Electricity Distribution (Distribusi 36 kV to ASMI, SMMS, TOP) • Electricity Transmission (150 kV integration to PLN future plan)
ELECTRICITY (Generation & Distribution) Maintenance Management System
ELECTRICITY (Generation & Distribution) Maintenance Management System MAINTENANCE MACRO PROCESS Improvement Management
GENERATION & DISTRIBUTION ENGINEERING
OPERATION
SERP Failure Identification
Operation Parameter
Shutdown Maintenance
Maintenance Planning
Performance Analysis
Operation Engineering Maintenance Engineering
Turn On Maintenance
Operation Lifetime
People Development
Recondition Management
Information Management
Facilities & tools management
HCGS
SUPPLY MANAGEMENT
INFORMATION SYSTEM
Plant ASMI
ELECTRICITY (Generation & Distribution) Maintenance Management System MAIN PROCESS Generation & Distribution Planning & Engineering
SOP & STD REQUIREMENT
Operation Coordination
Maintenance Engineering
Maintenance Planning
Maintenance Execution System of Equipment Reliability Prioritization
Shutdown Maintenance
Performane Analysis
Turn On Maintenance
Key Performance Indicator Failure Analysis
SOP yang diperlukan pada Maintenance Management System
SUPPORT PROCESS
SOP & STD REQUIREMENT
Improvement Management
People Development
Recondition Management Information Management
Facilities & Tools Management
STRUKTUR ORGANISASI & STANDAR KOMPETENSI
- Materi di tim PPD HO (Ari Oksendra) -
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