BACHELOR THESIS PROPOSAL

(ME184841)

Implementation of Reliability-Centered Maintenance to

Cooling Water Pump (A Study Case of PT. Badak NGL
bontang)

Applicant :
Shaneza Fatma Rahmadhanty
04211541000013

Proposed Supervisor(s) :

1. Dr.Eng. Trika Pitana., ST., M.Sc

2. Ir. Dwi Priyanta, M.SE

DEPARTMENT OF MARINE ENGINEERING

FACULTY OF MARINE TECHNOLOGY
INSTITUT TEKNOLOGI SEPULUH NOPEMBER
SURABAYA
2018
 DEPARTEMENT OF MARINE ENGINEERING
FACULTY OF MARINE TECHNOLOGY
INSTITUT TEKNOLOGI SEPULUH NOPEMBER
SURABAYA
2018

BACHELOR THESIS PROPOSAL

(ME – 184841)

SUMMARY
1. APPLICANT
Name : Shaneza Fatma Rahmadhanty
NRP : 04211541000013

2. PROPOSED SUPERVISOR(S)
2.1. Proposed Supervisor 1:
Nama : Dr.Eng Trika Pitana., ST., M.Sc
NIP : 1976 0129 2001 12 1001
2.2. Proposed Supervisor 2:
Nama : Ir. Dwi Priyanta, M.SE
NIP : 1968 0703 1994 02 1001

3. BACHELOR THESIS PROPOSAL OUTLINE

3.1. Bachelor Thesis Title
Implementation of Reliability-Centered Maintennace to Cooling Water
Pump (A Study Case of PT. Badak NGL Bontang)

3.2. Field of Study

MOM (Marine Operation and Maintenance)

3.3. Bachelor Thesis Overview

Quality control of production is one of the important things to maintain
companies in industries. PT. Badak NGL is a company that manages the liquefaction
of natural gas. This company must be able to produce and fulfill energy needs
independently to support all operations. At this time, the cooling water system which
functions to control temperature and pressure so that the production process runs
optimally, is experiencing problems with the pump, namely the frequent problems
that occur that are shown in the work order of cooling water pump in plant 32. So
that the company will immediately make improvements so that there will be no
excess use of water, waste water, and energy costs which result in higher total
operational costs. With good and correct quality control, products that will be
obtained can reduce operational costs. On this occasion, the bachelor thesis
conducted aims to produce program maintenance based on the implementation of
Reliability-Centered Maintenance (RCM) for cooling water pumps at PT. Badak
NGL Bontang. This technique can identify risks of failure, reduce downtime, and
increase availability of cooling water pumps and supporting components. The final
goal of this bachelor thesis is the maintenance of components with proper
maintenance task selection in accordance with the RCM results criteria obtained.
Also, there should be recommendations for the spare part holding for the proposed
maintenance to run, because the spare parts are very important to support the
maintenance tasks identified to be available at the right time.

Keywords : Reliability, RCM, FMECA, Maintenance, and Cooling Water Pump

3.4. Place of Execution

Places od execution will be taken in :
1. MOM Laboratory (Marine Operation and Maintenance), Departement of
Marine Engineering FTK – ITS
2. Plant. 32 of PT. Badak NGL Bontang
3. Technical Department of PT. Badak NGL Bontang
4. Maintenance Department of PT. Badak NGL Bontang
5. Technical Department Library of PT. Badak NGL Bontang
6. Faculty of Marine Technology Library
7. ITS Library
 CHAPTER I
PRELIMINARY
1.1 BACKGROUND
In recent decades, humans have begun to think about acquiring new energy
sources as a substitute for energy sources that are widely known and used, such as
petroleum and coal because the availability of these energy sources in the natural
world is decreasing, and has been proven to cause pollution to the environment.
This is very undesirable because it will cause greater damage to nature. Various
efforts have been made to obtain substitute energy sources that can meet energy
needs in large and long term, and are environmentally friendly. One of the energy
sources that are currently in demand is natural gas. Natural gas as well as petroleum
is a mixture of hydrocarbon compounds formed from heaps of organic fossils that
have been in the bowels of the earth since millions of years ago. To overcome the
problem of storage and transportation to consumers, liquefaction of natural gas is
considered the best way. In this way natural gas can be stored 1/600 smaller than its
volume in a gas state. In principle, this technology includes liquefaction of natural
gas by using refrigerants. This liquefied natural gas is called Liquified Natural Gas
(LNG).
The Badak LNG Plant is a natural gas refinery that supports the LNG
business in Indonesia, located in Bontang, East Kalimantan. For the efficiency of
the production process, most industries including PT. Badak LNG provides Cooling
Water System to control temperature and pressure by transferring heat (heat) of hot
fluid from the production process into the Cooling Water System. Cooling Water
System is a very important part because in this process the Cooling Water System
will receive heat and needs to be cooled again or replaced with new water from
make-up water. In the world of industry, Cooling Water System is one of the
systems / equipment that must be kept operational with routine maintenance in
order to work optimally. Inadequate cooling water quality control causes excessive
use of water, waste water, and energy costs, resulting in higher total operational
costs. An example is a machine like a Heat Exchange unit, r will experience
corrosion or crust formation. Heat Exchanger that undergoes corrosion causes the
level of efficiency of the low heat transfer system and causes considerable energy
consumption.
One component that influences the Cooling Water System is the pump. This
pump serves to flow the fluid of Cooling Water in the form of sea water to the LNG
plant industry. However at this time, problems with the Cooling Water pump often
occur at plant # 32. This can be evidenced by the WO (Work Order) data recorded
from the problems obtained from the pump. Therefore, to reduce the risk of failures
at the pump, the implementation of Reliability-Centered Maintenance (RCM) is
implemented. But with pump conditions in this period that have been different
compared to the previous conditions, RCM updates are needed. In RCM there is
Failure Mode, Effect, and Criticality Analysis (FMECA), FMECA is designed to
identify potential failure modes of a equipment or process. FMECA requires
identification of the following basic information, namely, Item, Failure, Effect of
Failure, Cause of Failure, and Recommended Action. From the results of this study
we will find suitable maintenance tasks and maintenance strategies that will reduce
the risk to an acceptable level. In addition, analysis of spare part holding will be
carried out so as not to interfere with the LNG production process by not requiring a
long time to find its spare parts in the event of a pump failure. It is expected that this
final project research can increase LNG production at PT. Badak NGL by reducing
or eliminating the risk of failure that occurs in the Cooling Water Pump.

1.2 FORMULATION OF THE PROBLEM

The formulation of the problems that will be discussed in the study are two,
namely:
1. How is the criteria of risk level acceptance on the Cooling Water Pumps
components in PT. Badak NGL Bontang?
2. How is the maintenance task suitable for Cooling Water Pumps components
in PT. Badak NGL Bontang?
3. How is the spare-part holding selection to make maintenance tasks that
have been proposed to run?

I.3 SCOPE OF PROBLEM

Problem boundaries are made so that the scope of this research is more focused,
that are :
1. Instrument Failure, Electrical Failure, and Sodium Hypochlorite Generating
Failure in the Cooling Water Pump are not taken into account.
2. Water Pump Cooling with the status of LTI is not taken into account.
3. Work Order Schedule on 3 January 2003 - 4 June 2018.
4. Components are reviewed from Traveling Screen to Amri Valve.

I.4 RESEARCH PURPOSES

The purposes of this study are as follows:
1. Make RCM with the FMECA method to find out failure and its criticality &
risk level on any equipment of cooling water pumps in Badak LNG
Bontang Plant
2. Choose a maintenance task that is suitable to provide the right
recommended actions for any equipment of cooling water pumps in Badak
LNG Bontang Plant
3. Determining the spare part that is suitable to make proposed maintenance
becomes viable for operational cost efficiency

I.5 BENEFITS OF RESEARCH

The benefits of this study are as follows:
1. Knowing the criteria of risk level acceptance on Cooling Water Pumps
components in PT. Badak NGL Bontang
2. Knowing maintenance tasks that are suitable for Cooling Water Pumps
components in PT. Badak NGL Bontang
3. Knowing the spare-part holding selection to make the proposed
maintenance task running
 CHAPTER II
LITERATURE REVIEW

2.1 COOLING WATER SYSTEM

2.1.1 Introduction of Cooling Water Systems
Water Cooling System is a circuit to overcome the occurrence of over
heating (excessive heat) on the engine so that the machine can work stably.
Water Cooling (cooling water) is waste water derived from the flow of water
used for heat removal and not in direct contact with raw materials, intermediate
products, and end products. The cooling water system is part of the integrated
operation process in the industry. For continuous factory productivity, the
system requires proper chemical processing, preventive measures, and good
maintenance. Most industrial production processes require cooling water for
efficiency and good operation. The cooling water of the system controls
temperature and pressure by transferring heat from the process fluid to the
cooling water which then carries the heat. The total value of the production
process will be meaningful if this cooling system can maintain the process
temperature and pressure well. Monitor & regulate corrosion, deposition,
microbial growth, and operating systems is very important to achieve the
optimal Total Cost of Operation (TCO).
Water Cooling has a considerable influence on the total engine
efficiency and engine life. If the engine's Cooling Water temperature is too
high, the engine's mechanical efficiency will decrease and there will be an over-
heating of the engine. Whereas if the water is too low, the thermal efficiency
will decrease (Handoyo, 1999). The cooling process involves transferring heat
from one substance to another. The substance that loses heat is called cooled,
and the one that receives heat is called coolant.
Water cooling can be defined as a cooling medium that helps the
performance of a production process equipment in order to operate optimally
and last a long time. Water Cooling is used for various industrial purposes, such
as:
1. Production process equipment such as pumps, compressors,
turbines, condensers and heat exchangers.
2. As a cooling medium, cooling water is used to cool the lubricating
oil, air on the inter stage, and water seal gland.

There are 2 types of cooling water systems that are commonly used, namely :
1. Open Cooling System
 Is a cooling system that is directly related to sea water. This system
uses sea water that goes straight in to cool the components that
need to be cooled.
2. Closed Cooling System
Is a cooling system that uses fresh water which is circulated in a
closed circuit to cool the components that need to be cooled by sea
water, then the fresh water is recirculated to cool the components.
This system is divided into two, namely:
 Independent System
That is, where the fresh water used to cool each component
is cooled separately, not together in a heat exchanger.
 Centralized System
That is, where the fresh water used to cool the components
is collected to be cooled together in a heat exchanger. This
cooling system is designed with only one heat exchanger
which is cooled with sea water, while for other coolers
including jacker water, lubricating oil, rinse air is cooled
with low temperature fresh water. This cooling system is
very small equipment that is directly related to sea water so
that corrosion problems can be reduced.

Cooling water or water cooling is a method used to remove heat or

transfer heat contained in industrial components and equipment. So between
cooling water and water cooling it has a clear difference and must be
distinguished. Especially for Badak LNG refineries plant, suitable cooling
media are seawater, because each train requires a very large amount of cooling
media, and this can only be served by sea water. This sea water cooling
medium, generally used for cooling condenser and cooler. But the most widely
used cooling water is on the surface condenser, because there is a phase change
in the cooled media, so it requires a large amount of cooling media.

2.1.2 Equipment of the Water Cooling System

a. Basin
The basin is an artificial pond filled with seawater with the construction
around the pond lined with concrete walls while the front is directly related to
the open sea and on the back is related to the suction side of the pump. The
basin also serves as a place for injection of Sodium Hypochlorite sent from
Chloropac / Daiki Unit which aims to inhibit / limit the growth of various types
of microorganisms that live in cooling water before being pumped and
distributed throughout the refinery. Limitation of Sodium Hypochlorite in
cooling water is 0.2 - 0.5 ppm which is periodically analyzed in the laboratory
section.
b. Travelling Screen
Traveling Screen is a tool that serves to filter seawater impurities that
are installed in front of the pump or the back of the basin. Dirt filtered by
traveling screen is a type of dirt with large size or coarse dirt that will enter the
suction side of the pump.

Figure 2.1. Travelling Screen

(source : PT. Badak NGL Bontang)
c. Cooling Water Pump
Serves to pump seawater into the distribution system, along with pump
components and the lubricating system.

Figure 2.2. Cooling water pump

(source : PT. Badak NGL Bontang)

d. Boving Valve
The boving valve functions as a check valve that is used to prevent the
return flow from the discharge / main pipe to the suction side of the pump. This
is designed because if there is a backflow where water that has a large enough
pressure will return to the basin at the suction side of the pump so that it can stir
up the mud in the basin bottom.
 Figure 2.3. Boving Valve
(sumber : PT. Badak NGL Bontang)

e. Hayward Strainer
Hayward Strainer serves to filter out impurities that may still be in the
pumped sea water.

Figure 2.4. Hayward Stariner

(sumber : PT. Badak NGL Bontang)

f. Amri Valve
Amri Valve is installed on the output side of the Hayward Strainer, a
butterfly type valve made by "AMRI" from France, measuring 48 inch type
"Isoria". Each Amri valve is equipped with an "Acto 401 H" actuator, to move
the disc from the valve when opening and closing the valve. Actuator uses oil
pressure (hydraulic system) as a source of energy.
 Figure 2.5. Amri Valve
(source : PT. Badak NGL Bontang)

2.1.3 Description of Water Cooling System Process

Sea water passes through the basin to get enough clean water from the
impurities contained in it, because each basin is equipped with adequate
filtering facilities. Without screening, of course the quality of sea water that is
pumped will be bad, because there are dirt that can follow the channel system.
In addition to filtering, the disinfectant is added to the basin to weaken the
activity of bacteria and microorganisms, so that algae and lichens do not grow
in the channel system. After that the sea water passes Traveling Screen to be
filtered again from smaller impurities. At Traveling Screen, the level of water
level and pressure to the pump suction is also done so that it does not interfere
with the pumping process. Sea water that has passed Traveling Screen will be
forwarded to the pump, and the boving valve works by preventing the return
flow to the side of the pump suction. Then the cooling water will be filtered
with a smaller filter than the Traveling Screen filter on the Hayward Strainer to
be forwarded to the industrial plant. If the pump needs to stop / standby or is
being repaired, the pump will be isolated by the amri valve.

2.2 PUMP
2.2.1 Pump
The definition and function of a pump is a medium for transferring
liquid or fluid. Liquid only flows when there are certain pressure differences. So
that the pump can be defined as the addition of energy to drive liquid from one
place to another. Because energy is the ability to do work, then the addition of
energy carried out will move / drain the liquid through the pipe or move to a
higher place.
2.2.2 Pump Parts
In general, centrifugal pumps are composed of several important parts,
namely:

Figure 2.6. Bagian-Bagian Pompa

(sumber : https://artikel-teknologi.com)

1. Casing
The first major component of a centrifugal pump is the pump
casing. Centrifugal pump casing is designed in the form of a diffuser that
surrounds the pump impeller. This diffuser is more commonly known as a
volute casing. In accordance with the diffuser function, the volute casing
functions to reduce the flow rate of the fluid entering the pump. Towards
the side of the pump outlet, the volute casing is designed to form a funnel
that functions to convert kinetic energy into pressure by lowering the speed
and increasing the pressure, this also helps balance the hydraulic pressure
on the pump shaft.

Figure 2.7. Volute Casing of Pump

(source : https://artikel-teknologi.com)

2. Impeller
The impeller is a rotating part of a centrifugal pump, which
functions to transfer energy from the motor rotation to the fluid that is
pumped by accelerating it from the center of the impeller to the outside of
the impeller side.
The impeller design depends on the needs of pressure, flow
velocity, and suitability with the system. Impeller is the most important
component affecting pump performance. Modification of the impeller
design will directly affect the shape of the pump's characteristic curve.
There are various kinds of centrifugal pump impeller designs, including
closed and open type, single flow type, mix flow type, radial type, non-
clogging type, single stage type, and multi stage type.

Figure 2.8. Pump Impeller (Suction, Closed, dan Double-Suction Pump)

(source : https://artikel-teknologi.com)

3. Shaft
The pump shaft is the part that transmits the rotation from the
source of motion, such as an electric motor, to the pump. What we need to
pay attention to is, in a centrifugal pump that works at the best efficiency
point, the bending force of the shaft will be perfectly distributed to all parts
of the pump impeller.
4. Bearing
Bearing on the pump serves to hold (constrain) the position of the
rotor relative to the stator in accordance with the type of bearing used. The
bearing used in the pump is in the form of a journal bearing which serves to
withstand the gravity and the forces in the direction of the gravity, and the
thrust bearing which serves to resist the axial force arising on the pump
shaft relative to the pump stator.

Figure 2.9. Bearing of Pump (Journal and Thrust Bearing)

(souce : https://artikel-teknologi.com)
 5. Coupling
Basically the coupling functions to connect two shafts, where one is
the driving shaft and the other is the driven shaft. The coupling used in the
pump depends on the design of the system and the pump itself. The types of
couplings used in the pump can be rigid couplings, flexible couplings, grid
couplings, gear couplings, elastrometic couplings, and disc coupling.
6. Packing & Seal
The packing system at the pump is to control fluid leakage that
might occur on the border side between the rotating pump part (shaft) and
the stator. The sealing system that is widely used in centrifugal pumps is
mechanical seal and gland packing.

Figure 2.10. Sistem Mechanical Seal Figure 2.11. Sistem Gland Packing
(source : https://artikel-teknologi.com) (source : https://artikel-teknologi.com)

7. Lubricating System
The lubrication system at the pump serves to reduce the coefficient
of friction between the two surfaces that meet, thereby reducing the risk of
wear. Lubrication at the pump is mainly used on bearings. The system can
be in the form of lub oil or greas type depending on the pump design itself.

2.2.3 Pump Types

In general, pumps are divided into two major groups, namely dynamic
pump and positive displacement pump. These two big groups are still divided
into several more types.
1. Dynamic Pump
Dynamic pumps are divided into several types, namely centrifugal
pumps, axial pumps, and special-effect pumps (special-effect pump). These
pumps operate by producing high fluid velocities and converting velocity to
pressure through changes in fluid flow section. This type of pump usually
also has a lower efficiency than the positive displacement pump type, but
has a lower cost for maintenance. Dynamic pumps can also operate at high
speeds and high flow rates.
a. Centrifugal Pump
A centrifugal pump is composed of an impeller and an inlet
channel in the middle. With this design, when the impeller rotates, the
fluid flows into the casing around the impeller as a result of centrifugal
force. This casing serves to reduce the speed of fluid flow while the
impeller rotating speed remains high. The velocity of the fluid is
converted to pressure by the casing so that the fluid can reach its outlet
point. Some of the advantages of using centrifugal pumps are smooth
flow inside the pump and uniform pressure on pump discharge, low
cost, and can work at high speeds so that the next application can be
connected directly with steam turbines and electric motors. The use of
centrifugal pumps in the world reaches 80% due to their use which is
suitable for dealing with large amounts of fluids rather than positive-
displacement pumps.

Figure 2.12. Centrifugal Pump

(source : https://artikel-teknologi.com)

b. Axial Pump
Axial pumps are also called propeller pumps. This pump
produces most of the pressure from the propeller and the lifting force
from the blade to the fluid. This pump is widely used in drainage and
irrigation systems. Single-stage vertical axial pumps are more
commonly used, but sometimes two-stage (two-stage) axial pumps are
more economical to implement. Horizontal axial pumps are used for
large fluid flow discharges with small pressures and usually involve the
effect of chiffon in the flow.

Figure 2.13. Axial Pump

(source : https://artikel-teknologi.com)
 c. Special-Effect Pump
This type of pump is used in industries with certain conditions.
Included in this type of pump are jet (educator), gas lift, hydraulic ram,
and electromagnetic. Jet-eductor pump (injector) is a device that uses
the effect of yenturi and convergent-divergent nozzle to convert the
pressure energy from a moving fluid into motion energy, thus creating a
low pressure area and can suck fluid on the suction side.

Figure 2.14. Injector Pump

(source : https://artikel-teknologi.com)

2. Positive Displacement Pump

The types of positive displacement pumps are reciprocating and
rotary pumps. Positive displacement pumps work by giving a certain force
to the fluid volume fixed from the inlet side to the pump outlet point. The
advantage of using this type of pump is that it can produce greater power
density (force per unit weight). And also provides a steady / stable fluid
transfer in each round.
a. Reciprocating Pump
In this type of pump, a certain volume of fluid enters the
cylinder through the inlet valve when it enters and is then pumped out
under positive pressure through the valve outlet at a step forward. The
fluid coming out of the reciprocating pump pulsates and can only
change when the pump speed changes. This is because the volume of
the inlet side is constant. This type of pump is widely used to pump
sediment and mud.

Figure 2.15. Pompa Reciprocating

(sumber : https://artikel-teknologi.com)
 b. Rotary Pump
Is a pump that drives fluid using the principle of rotation. The
vacuum is formed by rotation of the pump and then sucking in the
incoming fluid. The advantage of this type is high efficiency because it
naturally removes air from the flow pipe, and reduces the need for the
user to remove the air manually.
Not that this type of pump is without weakness, because of its
natural nature, the clearence between the rotary blade and the blade of
the follower must be as small as possible, and requires the pump to
rotate at a low and stable speed. If the pump works at too high a speed,
the working fluid can actually cause erosion of the pump blades.
Rotary pumps can be reclassified into several types, namely:
 Gear pumps – a simple rotary pump where the fluid is
pressed using two gears.
 Screw pumps – this pump uses two threads that meet and
rotate to produce fluid flow as desired.
 Vane pumps – has the same principle as a compressor
scroll, which uses a cylindrical rotor that rotates
harmoniously to produce a certain fluid pressure.

Figure 2.16. Gear Pump Figure 2.17. Screw Pump Figure 2.18. Vane Pump
(source : https://artikel-teknologi.com)

2.3 RELIABILITY-CENTERED MAINTENANCE

2.3.1 Realibility-Centered Maintenance (RCM)
Reliability-Centered Maintenance is a process used to determine the
maintenance requirements of any phisical asset in its operating context. In the
light of the definition of maintenance, a fuller definition of RCM could be “a
process used to determine what must be done to ensure that any physical asset
continues to do whatever its users want it to do in its present operating context”.
However, machinery systems have continued to become larger and more
complex, requiring skilled operators with specialized knowledge of the
machinery and systems onboard. RCM was issued as a maintenance philosophy
for the development of a maintenance program using thechniques applied in
other industries for machinery systems.
The RCM strategy can be systematically assess or evaluate various
aspects phases by :
1. Identify fuctional failures with the highest risk, which will then become the
focus for further analyses.
2. Identify equipment items and their failure modes that will cause high-risk
functional failures.
3. Determine maintenance tasks and maintenance strategies that will reduce
risk to acceptable levels.

2.3.2 Functional Failure

In the world of RCM, failed states are known as functional failures because
they occur when an asset is unable to fulfil a function to as standard of
performance which is acceptable to the user. In general, each function must
have at least two functional failures. A functional failure can be a complete loss
of function or partial loss of function. The partial loss of function is usually
represented by deviations in the performance standard. Example functional
failure for the function “to flow cooling water at 65000 GPM capacity and 200
ft head pump” are :
 Total loss of function
o No flow of cooling water
 Partial loss of function
o Flow less than 65000 GPM
o Flow more than 65000 GPM
o Head pump less than 200 ft
o Head pump more than 200 ft
Functional failures can be identified from suction by applying the following
guides to each function:
- No or none of the function
- Less of each performance standard
- More of each performance parameter
- Premature operation of the function
- Failure to cease operation of the function (e.g., function operates too long)
- Intermitten operation of the function
- Other functional failures appropriate for the functional group
Each functional failures should be documented in a functional failure statement
that contains a verb, an object, and the functional deviation.
 2.3.3 Failure Mode, Effect, and Criticality Analysis (FMECA)
Failure Mode and Effect Criticality Analysis (FMECA) is a
methodology designed to identify potential failure modes for a product or
process, to assess the risk associated with those failure modes, to rank the issues
in terms of importance and to identify and carry out corrective actions to
address the most serious concerns.
FMEA menggunakan sebuah format yang umumnya terdiri dari
dokumentasi hal-hal sebagai berikut:
1. Nama komponen.
2. Fungsi komponen
3. Kemungkinan bentuk kesalahan.
4. Penyebab kesalahan.
5. Bagaimana kesalahan dapat dideteksi.
6. Pengaruh kesalahan pada fungsi sistem utama.
7. Pengaruh kesalahan pada komponen lain.
8. Perlunya penanganan atau tindakan memperbaiki.
9. Rata-rata frekuensi dari kesalahan.
10. Rata-rata tingkat dari kesalahan.

The most common method of evaluation of risk is Risk Priority

Number to use the (RPN) Risk Priority Number method to assess risk, the
analysis team must rate severity of each effect of the failure; rate the likelihood
of occurrence for each cause of failure, rate the likelihood of prior detection for
each cause of failure calculate the RPN by obtaining the product of the three
ratings..

𝑹𝑷𝑵 = 𝑺𝒆𝒗𝒆𝒓𝒊𝒕𝒚 × 𝑶𝒄𝒄𝒖𝒓𝒆𝒏𝒄𝒆 × 𝑫𝒆𝒕𝒆𝒄𝒕𝒊𝒐𝒏

The RPN can then be used to compare issues within the analysis and to
priorities problems for corrective action. This risk assessment method is
commonly associated with Failure Mode and Effects Analysis (FMEA).
Table 2.1. The FMEA Form
Component Function Failure Failure Effect Severity Detection Occurence Matrix
of Causes /RPN
component Local End Effect
Effect
What is the What is the Basic The initial The overall Importanc The ability Frequency
component functional equipme change in effect on e of the of the with which
input under group, nt the system the vessel effect on current a given
analysis system, failure operation that is customer control cause
equipment that that would typically requireme scheme to occurs and
items and result in occur if the related to nts detect (then creates
components the postulated the prevent) a failure
are failure failure consequenc given cause modes
designed to mode. mode es of (may be (obtain
do. occurs. interest for difficult to from past
the analysis estimaterly data if
in process possible)
operations)
 In the FMECA method, there are wide variety of scoring, both quantity
or qualitative. Commonly, two types of scales are used, 1-5 or 1-10. The 1-5
scale makes analysis easier to decide on scores. The 1-10 scale may allow for
better precision in estimates and a wide variation in scores, it is the most
common scale used.

Severity
Severity is an assessment of the seriousness of the effects. In the sense
of each failure that arises will be judged how large the level of seriousness.
There is a direct relationship between effect and severity. For example, if the
effect is a critical effect, the severity value will be high. Thus, if the effect does
not constitute a critical effect, the severity value is also low.

Table 2.2. Severity Category

Category Directional Explosion/fire Loss of Safety
Control Containment
Minor Function is not No damage to Little or no Minor impact
(1-3) affected, no affected equipment response on personnel /
significant or compartment, no necessary No impact on
operational delays. significant public
Nuisance. operational delays
Major Function is not Affected Limited response Professional
(4-6) affected, however, equipment is of short duration medical
failure detection / damaged, treatment for
corrective measures operational delays personnel/No
not functional. OR impact on
Function is public
reduced, resulting
in operational
delays
Hazardou Function is An occurrence Serious/significan Serious injury
s reduced, or adversely affecting t commitment of to personnel /
(7-9) damaged the plant resources and Limited
machinery, production personnel impact on
significant public
operational delays
Critical Complete loss of Loss of function or Complete loss of Fatalities to
(10) function result in total containment. Full personnel /
constructive loss scale response of Serious impact
extended duration on public
to mitigate effects
on environment

Occurence
Occurrence is the possibility that the cause will occur and produce a
failure during the operation period. Occurrence is a rating value that is adjusted
to the frequency estimated and / or the cumulative number of failures that can
occur.
 Table 2.3. Occurrence Category
Category Description
Improbable Fewer than 0.001 events/year (Less than 1 event every 1000
(1) years)
Remote 0.001 to 0.01 events/year (1 event every 1000 years to 1 event
(2-3) every 100 year
Occasional 0.01 to 0.1 events/year (1 event every 100 years to 1 event per
(4-6) 10 year)
Probable 0.1 to 1 events/year (1 event every 10 years to 1 event per year)
(7-9)
Frequent 1 or more events/year
(10)

Detection
Detection value is associated with current control. Detection is a
measurement of the ability to control / control failures that can occur.

Table 2. 4. Detection Category

Rangking Level of Detection Criteria of Detection
10 Not detectable Impossible
9 Difficult to detect Veri difficult
8 Difficult to detect Veri difficult
7 Detecting Random Not sure
6 Detecting Random Occasional
5 Possible to detect Low
4 Possible to detect Late
3 Reliable detection Easy
2 Reliable detection Immediate
1 Detection at all times Immediate corective

Table 2.5. Risk Matrix

Critical M H H H H
Consequence

Hazardous M M M H H
Major L M M M H
Minor L L L M M
Improbable Remote Occasional Probable Frequent
Occurence

The following is the risk acceptance criteria when assessing the close outs:
- Red (High Risk)
If the risk is not able to be reduced below RED, the risk must be elevated to
decision board to receive endorsement and to be elevated further to confirm
on how to manage the risks.
- Yellow (Medium Risk)
 Risks may be closed individually with the approval of relevant if the
mitigation has moved the risks to Low (green) area. When the mitigation
plan will not be completed, or will still result in Medium risk, the Project
Management Team should be informed of status and action/path forward
plan.
- Green (Low Risk)
Risk owner may accept a risk in the low (green) area with Discipline Team
Lead approval.

Figure 2.19. Basics of applied Failure Modes Effects and Criticality Analysis
(sumber : https://wildeanalysis.co.uk)

Adavantages of FMECA :
- FMECA is one of the most important and most widely used tools of
reliability analysis.
- The FMECA facilitates identification of potential design reliability
problems.
- It can help removing causes for failures or developing systems that can
mitigate the effects of failures.
- Help engineers prioritize and focus on high-risk components failures.
- It provides detailed insight into the systems interrelationships and potentials
for failure.
- Information and knowledge gained by performing the FMECA can also be
used as a basis for trouble shooting activities, maintenance manual
development and design of effective built-in test techniques.
- Systematically identifies cause and effect relationships
- Indicates critical failure modes.
- Identifies outcomes from causes.
- Framework for identifying mitigating actions.
- Output may be large even for simple systems.
- Prioritizing may become difficult with competing failure modes
- May not easily deal with time sequences, environmental conditions and
maintenance aspects
2.3.4 Maintenance Task Selection
Decide whether the risk associated with the failure mode is the highest or
lowest risk and determine the confidence in the decision.
1. Highest Risk
A failure mode with the highest risk typically cannot achieve an acceptable
level of risk through maintenance alone. In general, to achieve an
acceptable level of a risk, a fundamental change in how the equipment is
designed or operated is needed. Therefore, a one-time change is required to
reduce the risk.
2. Lowest Risk
A failure with the lowest risk is a low-priority failure and, thefore, is
acceptable without any failure management strategy for most organizations.
3. Confidence in the risk characterization
High confidence indicates the team is relatively certain that the risk is
properly characterized and, therefore, can be used in the RCM flow diagram
without any further discussion. Low confidence indicates that the team is
uncertain and that additional data (about the probability or consequence of
the failure) are needed before the risk can be used in the decision-making
process.

Equipments are ranked based on severity, detection and occurrence. The risk
priority number RPN for these equipment’s are found out. The reliability of all
the equipments is calculated.

Table 2.6. Selection Program based on RPN

Ranking Maintenance Technique Criteria
1 Predictive Maintenance RPN>300
2 Preventive Maintenance 200<RPN<300
3 Corrective Maintenance RPN<200

Selection criteria for Maintenance Program is based on risk priority number

RPN value to take a appropriate maintenance plan
1) Predictive Maintenance
Unlike the condition based maintenance policy, in predictive
maintenance the Acquired controlled parameters data are analyzed to find a
possible temporal trend. This makes it possible to predict when the
controlled quantity value will reach or exceed the threshold values. The
maintenance staff will then be able to plan when, depending on the
operating conditions, the component substitution or revision is really
unavoidable.
2) Preventive Maintenance
Preventive maintenance is based on component reliability
ch1aracteristics. This data makes it possible to analyze the behavior of the
element in question and allows the maintenance engineer to define a
periodic maintenance program for the machine. The preventive
maintenance policy tries to determine a series of checks, replacements
 and/or component revisions with a frequency related to the failure rate. In
other words, preventive (periodic) maintenances are effective in
overcoming the problems associated with the wearing of components. It is
evident that, after a check, it is not always necessary to substitute the
component: maintenance is often sufficient
3) Corrective Maintenance
The main feature of corrective maintenance is that actions are only
Performed when a machine breakdown. There is no intervention until a
failure has occurred.

2.3.5 Spare Part Holding

For the proposed maintenance schedules to be viable, it is essential thet the
spares that support the identified maintenance tasks are available at the
appropriate time. The spares holding requirements is to be developed based on
the following considerations:
1. The list of parts necessary to perform tasks to correct each failure mode
identified in the RCM analysis, along with the parts required as a result of
remedial work to correct “condition monitoring”, “planned-maintenance”,
“failure-finding”, “any applicable and effective” and “run-to-failure” tasks.
2. An evaluation of the effects on the functional group or system’s operational
availability if an out of stock condition occurs.
3. Assessment for those parts whose use can be preplanned. For those parts
whose use cannot be preplanned, determine the quantity necessary to
achieve the desired operational availability.

The following decision-making process is to be used to select the most

appropriate strategy for spares when a stock-out or a stock-out and further
failure will result in End Effects:
- For the case when :
1. The parts requirements can be anticipated before failure occurs or there
is sufficient warning time for the parts to be ordered.
2. Lead-time for parts order is consistent over the life cycle of the
equipment item or component.
- Then order parts before demand occurs.

If ordering parts before demand occurs is nor acceptable, then consideration is

to be given to holding parts in warehouse, provided:
- The risk of a stock-out is reduced to an acceptable level.
- The cost and storage basis to hold the parts is feasible.

When neither of the two above strategies is feasible, then the following is to be
considered:
- If the stock-out will result End Effect(s) (either direct or indirect), it is
mandatory to review the RCM analysis with a view to revising the
maintenance task.
- If the stock-out will only have a non-operational effect, it is desirable to
review the RCM analysis with a view to revise the maintenance task.
 CHAPTER III
METHODOLOGY

3.1 FLOW CHART

Start
- Reliability-Centered Maintenance
Book, Journal, Website, Report. Preliminary studies
- Cooling Water & Fire Pump
(Utilities Manual Book) of PT.
Badak NGL Bontang Formulation of the problem
- PT. Badak NGL
- Pump parts and their functions
Bontang Refinery
- And other data needed
Research purposes Plant

Literature Study Field Study

Data Collection
- PFD plant#32 PT. Badak NGL Bontang
- P&ID plant#32 PT. Badak NGL Bontang
- Work Order Cooling Watre Pump Plant#32 PT. Badak NGL Bontang
- PDM (Predictive Maintenance) dan PM (Preventive Maintennace)
- List of Spare-part in warehouse, the quantity & the cost of them

RCM Procedure

Provide recommendations with Maintenance Task Selection

No No
Good results

Yes
Analysis of research results

Conclusion

Finish

Preparation of Reports
Figure 3.1. Flowchart of the Bachelor Thesis Making Report Process
 Flow chart in Figure 3.1. is a stage that is carried out in the process of the
final project. The following is a description of the flow chart.

3.2 IDENTIFICATION AND FORMULATION OF PROBLEMS

At this stage, the problem is identified and formulated from a case that will
be the object of research. Because the condition of the Cooling Water Pump is now
different compared to the previous conditions, it is necessary to update from the
implementation of Reliability-Centered Maintenance to increase the reliability level
of the related object.

3.3 LITERATURE STUDY & FIELD STUDY

Literature study one of the stages in carrying out the final task aims to
increase knowledge, information and basic concepts. Literature study in the final
assignment was obtained from books, journals, websites, and research reports
relating to theories and data to be used in this final project in making RCM with the
FMECA method on the pump plant # 32 at the PT. Badak NGL Bontang. As for the
literature studied, among others :
1. Reliability-Centered Maintenance Methodology and Application
2. Failure Mode and Effect Analysis of Centrifugal Pump
3. Literature study on Water Cooling Systems
4. Literature study of pumps and their failures
5. And other literature studies are needed
In addition, field studies are also conducted that can help add insight into Water
Cooling Water Systems at PT. Badak NGL Bontang. As for the form of field
studies, among others, see first hand the Cooling Water System equipment at the
refinery and interview directly with the Water Cooling System operator.
It is expected that after conducting literature studies and field studies it can
help the RCM manufacturing process by applying it in real life and can help to
select maintenance tasks in the Cooling Water Pump so that problems can be
reduced or eliminated..

3.4 PENGUMPULAN DATA

Data collection is intended to get information related to the object to be
examined. In the Final Task this time the data needed is, among others :
1. PFD (Process Flow Diagram) of Cooling Water Pump Plant # 32 PT. Badak
NGL Bontang
2. P & ID (Piping and Instrument Diagram) of Cooling Water Pump Plant #
32 PT. Badak NGL Bontang
3. WO (Work Order) of Cooling Water Pump Plant # 32 PT. Bontang Rhino
4. Task List of PM (Preventive Maintenance) every 3 months, once a year,
and once every two years of Cooling Water Pump Plant # 32 PT. Badak
NGL Bontang
5. Task List of PDM (Predictive Maintenance) every once a month of Cooling
Water Pump Plant # 32 PT. Badak NGL Bontang
6. List of Spare Parts of Cooling Water Pump Plant # 32 PT. Badak NGL
Bontang
 7. Price list of Spare Parts of Cooling Water Pump Plant # 32 PT. Bontang
Rhino
8. Number of Spare Parts of Cooling Water Pump in Warehouse of PT. Badak
NGL Bontang
From the data written above, it will be used for making RCM at the pump in Plant #
32 using the FMECA method and maintenance tasks that need to be applied so that
the failure of the pumps can be minimized and eliminated.

3.5 FAILURE DATA IDENTIFICATION

After all the data needed is collected, the identification of failure data for
the Water Pump Cooling is obtained from WO (Work Order) based:
- Components of the Cooling Water System
- Failure Mode of the object being observed
- The effect / potential effect caused by potential failure
- The potential cause of failure modes that occur in related objects
- Frequency of failure

3.6 CONDUCT TO FMECA

The next stage was conducting the data failure identified to FMECA which
will then analyzed for failures based on severity, occurrence, and detection level
until the RPN calculation to determine the maintenance selection task that was
suitable for each pump. At this stage, the risk matrix and RPN values will be
obtained. The value obtained is whether the related component is in the high,
medium, or low category.

3.7 MAINTENANCE TASK SELECTION

After getting a ranking from the RPN in the FMEA process, the proposed
improvement needs to be acknowledged against the failure mode that has been
ranked whether it should be chosen PDM (Predictive Maintenace), PM (Preventive
Maintenance), or CM (Corrective Maintenance). In addition, the Task List also
added what should be done to increase the level of reliability of the cooling water
pump.

3.8 DETERMINE SPARE-PART HOLDING

Also carried out analysis of spare part requirements requirements to support
the identified maintenance tasks to be available at the right time. Unavailability of
spare parts that cause delay, due to high delivery time or mistakes in warehouse
stock levels, is the most common cause. New strategies must be implemented to
tackle this problem. Therefore, a prioritization system and a spare parts strategy
have been designed to increase maintenance efficiency.

3.9 ANALYSIS
It is a step that is carried out to observe / examine the results of making
RCM and maintenance task selection and do the spare part holding analysis that is
essential to support the identified maintenance tasks. This analysis is expected to be
 able to reduce the level of risk so that the reliability of the cooling water pump
increases.

3.10 CONCLUSIONS AND RECOMMENDATIONS

The final step is to make a conclusion of the entire process that has been done
before and provide answers to existing problems, suggestions are given based on the
results of the preparation of reports that can be used as a basis for further research,
both directly related to this research or data and methodology will be referenced
later.

3.11 PREPARATION OF REPORTS

Through the acquisition of data analysis and design that was obtained
previously, then the preparation of reports from the formulation to conclusions and
suggestions to make it easier to read this bachelor thesis.

IMPLEMENTATION SCHEDULE
Bulan 1 Bulan 2 Bulan 3 Bulan 4
No Rencanan Kegiatan
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
Formulation of the
1
problem
Literature Study &
2
Field Study
3 Data Collection
Identification of Data
4
Failure
5 Conduct to FMECA
Maintennace Task
6
Selection
Determine Spare-Part
7
Holding
8 Analisys
Conclusions and
9
Recommendations
10 Preparations of Report
 REFERENCES

Islam H, Afefy. 2010.”Reliability Centered Maintenance methodology and

Application: A Case Study”, scientific research, p.g.no. 863-873.

Operation Department Badak LNG. 2014. “Cooling Water & Fire Pump”.
Bontang.

Shankar, Ravi dkk. 2016. “Failure Mode and Effect criticality analysis of
Locomotive Reciprocating Air Compressor”,scientific research: India.

Tarar, Mariam Altaf. 2014. “Study Reliability Centered Maintenance

(RCM) of Rotating Equipment Through Predictive Maintenance”, International
Journal of Industrial Engineering Research and Development (IJIERD): Pakistan.

Vose, david. 2008.”Risk Analysis”, British Library Cataloguiing in

Publication Data: England.

Listiyono, Budi. 2007. “Menentukan Laju Kerusakan/Kegagalan pada

Pompa dengan Menggunakan Metode FMEA&RCM”, Universitas Mercu Buana:
Meruya

Moubray, John. 1997. “Reliability-Centred Maintenance”, Butterworth

Heinemann: Oxford.