Training

PDM for non PDM - 1

PJB ACADEMY
27 – 28 Mei 2021
TUJUAN PEMBELAJARAN

1. Mengetahui filosofi Predictive Maintenance (PdM) dalam

pengelolaan asset.
2. Mengetahui keterkaitan PdM dengan bidang – bidang lain.
3. Mengenal teknologi-teknologi dan aplikasi PdM pada
peralatan di unit pembangkit.
AGENDA

Hari ke 1: Hari ke 2:

✓ Performance and Reliability ✓ Teknologi dan Aplikasi PdM:

Optimization • Vibrasi

✓ Framework Predictive Maintenance • Oil Analysis

✓ Teknologi dan Aplikasi PdM: • Disolve Gas Analysis

• Ultrasound

• Thermography
PERFORMANCE AND
RELIABILITY
OPTIMIZATION
TUJUAN PERFORMANCE AND RELIABILITY OPTIMIZATION

1. Meningkatkan availability.
2. Meningkatkan performance.
3. Menurunkan maintenance cost.
4. Mengelola asset aging.
5. Mengelola potential risk.
6. Optimasi planned outage.
7. Optimasi sumber daya (resource).
ELEMEN PERFORMANCE AND RELIABILITY OPTIMIZATION
FLOW CHART PERFORMANCE AND RELIABILITY OPTIMIZATION
MAINTENANCE HIERARCHY

8
MAINTENANCE MATURITY ROAD MAP

OPTIMASI
RISK BASED
1 MAINTENANCE • Asset Criticality ranking.
• Living Reliability Centered Maintenance Advance Level of Maintenance
• Optimasi maintenance process & resource (fokus pada asset performance)

Basic Level of Maintenance

IF IT AIN’T BROKEN, DON’T FIX IT !!! (fokus pada efisiensi eksekusi)
PREDICTIVE
2
Strategic, Proactive, Optimized

MAINTENANCE • Menggunakan teknologi dan skill spesifik

• APR (Advance Pattern Recognition) and
diagnostic untuk memprediksi kegagalan.

CONDITION MONITORING
CONDITION BASED
3 MAINTENANCE
Download this awesome diagram. Capture your • Pemeliharaan bagi mesin yang membutuhkan
audience’s attention. berdasarkan deviasi data operasional.
• Rule based logic, using sensor data

FIX IT BEFORE IT BREAK

PREVENTIVE MAINTENANCE
4 Download this awesome diagram. Capture your audience’s • Pemeliharaan berbasis waktu atau
statistic untuk mencegah
attention. Your text here
kegagalan..

JUST LET IT BREAK

REACTIVE MAINTENANCE
5 • Mengoperasikan peralatan
sampai terjadi kerusakan
MAINTENANCE MATURITY ROAD MAP
RISK BASED MAINTENANCE

Risk-based maintenance (RBM) merupakan pemeliharaan,

dengan mengoptimalkan maintenence resource yang dimiliki,
pada aset dengan ranking resiko terbesar jika mengalami
kegagalan.

Elemen Risk-based maintenance:

1. Risk criticality assessment
2. Risk-based maintenance program and planning
3. Risk-based spares and repairs
Risk criticality asessment Risk-based maintenance program and planning Risk based spare part
Criticality Maintenance program
Impact on
safety High Generic maintenance concept or
PM/PDM Optimisation and/or
RCM/FMEA
Medium Generic maintenance concept or
PM/PDM Optimisation/Review
Impact on
cost and/or
production RISK Impact on
evironment
Low
existing maintenance
Generic maintenance concept or
Review existing
maintenance/Manufacturers’
recomendation
Impact on Negligible Run to failure
reputation
PREDICTIVE
MAINTENANCE
PREDICTIVE MAINTENANCE (PdM)

• Predictive maintenance adalah bentuk aktivitas dalam mendeteksi perubahan

fisik dari peralatan (gejala kerusakan) untuk menentukan aktifitas pemeliharaan
yang tepat, sehingga dapat memaksimalkan waktu operasi peralatan tanpa
meningkatkan risiko kerusakan.

• Kesuksesan PdM sangat ditentukan kelengkapan dan ketepatan interpretasi

data
PREDICTIVE MAINTENANCE
POTENTIAL FAILURE CURVE

✓ Kerusakan tidak terjadi

secara tiba – tiba.

✓ Kerusakan mesin akan

menyebabkan:
✓ Loss production
✓ Secondary
Damage
✓ Safety effect
PREDICTIVE MAINTENANCE
PDM JOB DISCRIPTION

Mencegah kerusakan secara tiba-tiba

pada peralatan, merubah pemeliharaan
Mendeteksi gejala awal kerusakan emergency menjadi terencana
dan memberikan rekomendasi
pencegahan atau perbaikan

Monitoring, trending, dan Melakukan post test/quality control

reporting kondisi terhadap hasil pekerjaan,
peralatan menggunkan teknologi PdM

PdM
JOB - DESC
PREDICTIVE MAINTENANCE
MANFAAT DAN TANTANGAN

Menurunkan spare part inventory

Meningkatkan MTBF

Meningkatkan uptime dan availability

Menurunkan maintenance cost

Menurunkan unexpected failure

Menurunkan MTTR dan durasi overhaul

PREDICTIVE MAINTENANCE
KEY PERFORMANCE INDICATOR

KEY INDICATOR VARIABLE BEST PRACTICE

• Schadule compliance 𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘 𝑜𝑛 𝑠𝑐ℎ𝑎𝑑𝑢𝑙𝑒 𝑗𝑜𝑏𝑠

%= > 90%
𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑠𝑐ℎ𝑎𝑑𝑢𝑙𝑒

• Emergency maintenance 𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘 𝑜𝑛 𝑒𝑚𝑒𝑟𝑔𝑒𝑛𝑐𝑦 𝑤𝑜𝑟𝑘

%=
percentage 𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘𝑒𝑑 < 10%

• Maintenance overtime 𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑜𝑣𝑒𝑟𝑡𝑖𝑚𝑒 𝑑𝑢𝑟𝑖𝑛𝑔 𝑝𝑒𝑟𝑖𝑜𝑑𝑒

%=
percentage 𝑇𝑜𝑡𝑎𝑙 ℎ𝑜𝑢𝑟𝑠 𝑤𝑜𝑟𝑘𝑒𝑑 < 5%

• Preventive maintenance 𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑒𝑣𝑒𝑛𝑡𝑖𝑣𝑒 𝑚𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑎𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑚𝑝𝑙𝑒𝑡𝑒𝑑

%=
completion percentage 𝑇𝑜𝑡𝑎𝑙 𝑝𝑟𝑒𝑣𝑒𝑛𝑡𝑖𝑣𝑒 𝑚𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑎𝑐𝑡𝑖𝑜𝑛 𝑠𝑐ℎ𝑎𝑑𝑢𝑙𝑒𝑑 > 90%

• Predictive maintenance 𝑃𝑟𝑒𝑑𝑖𝑐𝑡𝑖𝑣𝑒 𝑚𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑐𝑜𝑠𝑡

%=
budget/cost 𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑐𝑜𝑠𝑡 10% - 12%
PREDICTIVE MAINTENANCE
PDM FRAMEWORK

2
PREDICTIVE MAINTENANCE
MATRIX TECHNOLOGY
PREDICTIVE MAINTENANCE
MATRIX TECHNOLOGY
PREDICTIVE MAINTENANCE
INTEGRASI TEKNOLOGI PDM

Menghasilkan informasi untuk menentukan kondisi peralatan secara kemprehensif

dan rekomendasi yang perlu dilakukan
PREDICTIVE MAINTENANCE
OUTPUT PDM

- Rekomendasi dan CBA

- Laporan Bulanan
• Resume kondisi peralatan
• Matrix kondisi peralatan berdasarkan PdM
• Work package

21
PREDICTIVE MAINTENANCE
OUTPUT PDM

Laporan Rekomendasi Teknologi Vibrasi Cost Benefit Analysis

PREDICTIVE MAINTENANCE
OUTPUT PDM

Laporan Rekomendasi Teknologi Oil Analysis Laporan Rekomendasi Teknologi Oil Analysis
PREDICTIVE MAINTENANCE
MONITORING TINDAK LANJUT REKOMENDASI PDM
PREDICTIVE MAINTENANCE
MONITORING HEALTH INDEX

Formulasi berbasis
reliability block
diagram dengan
menggunakan data
predictive
maintenance dan
condition based
sebagai input

Merepresentasikan
kondisi kesehatan
asset (yang termasuk
dalam scope predictive
maintenance)
terhadap resiko
terjadinya trip dan
derating unit.
PREDICTIVE MAINTENANCE
TRENDING HEALTH INDEX
Predictive is Not
Enough…
Output dari program predictive maintenance
adalah informasi, tidak dapat meningkatkan plant
performance secara sendirinya…

Dibutuhkan tindak lanjut untuk merubah

INFORMASI menjadi STRATEGI dan EKSEKUSI
agar dapat meningkatkan plant performance…
PREDICTIVE MAINTENANCE
MISSING LINK PDM

Distribusi Informasi
01
Permasalahan terdeteksi namun tidak
dilaporkan Planning
PdM corrective work is identified, but
02 the work request never gets to
planning.
Schaduling
The corrective work gets planned but
never scheduled.
03

Ditunda/dilupakan 04 Spare part

The work gets planned and scheduled.
The parts are available. But then
emergency work takes precedence and
the PdM corrective work never gets
executed.
The work gets on the schedule, but
05 when it’s time to perform the job,
the parts aren’t available.
PdM Network
RENDAL HAR Daily maintenance,

Rekomendasi

MANAGEMENT Yearly maintenance program R3, R2, P1,P2,P3

OUTAGE
Rekomendasi

PEMELIHARAAN Deteksi awal adanya kelainan,

Test sebelum dan setelah perbaikan
Rekomendasi perbaikan

OPERASI Permit to work

Rekomendasi pengoperasian alat dan change over
Aceptance test

ENGINEERING Root Cause Failure Analysis (RCFA)

Historical dan trending data
FMEA
TEKNOLOGI PREDICTIVE
MAINTENANCE
ULTRASONIC
SOUND
ULTRASOUND

▪ Ultrasound merupakan suara dengan frekuensi di atas 20.000 Hz, dimana tidak dapat didengar
oleh telinga manusia.

▪ Dengan menggunakan teknik heterodyning ultrasound dapat didengar oleh telinga manusia.
(Menggeser/menurunkan frekuensi suara yang ditangkap ke dalam range frekuensi yang dapat
didengar manusia (20 – 20.000 Hz) tanpa merubah karakter dari suara aslinya)
ULTRASOUND TOOLS
SRUCTURE BOND

AIR BOND
PREDICTIVE MAINTENANCE
ULTRASOUND ANALISYS

Leak detection
• Pressure or vacuum
• Heat exchangers
• Tanks and boilers

Valve inspection
Leak detection tubing Leak detection compressed air
• Valve passing detection
• Steam trap inspection

Mechanical inspection
• Condition monitoring of bearings
• Condition based lubrication
• Pump cavitation
Valve inspection Heat Exchanger inspect.
Ultrasound Pada Bearing

Acoustic emission atau teknologi ultrasound

dapat digunakan untuk condition monitoring
pada bearing:
1. Monitoring pelumasan pada bearing.
2. Monitoring kondisi/kerusakan
Monitoring bearing
bearing.
3. Monitoring dalam proses greasing.

Regreasing bearing
Analisa Kualitatif

• Suara rendah, teredam, halus, dan stabil,

menunjukkan bearing berfungsi normal

• Suara bernada tinggi atau suara deras

menunjukkan kurangnya pelumasan,
kelebihan beban, atau kecepatan putar di
luar spesifikasi bantalan.

Bearing lubrication problem

• Bunyi berderak, pembacaan yang tidak
stabil (atau acak), menunjukkan adanya
kerusakan, keausan atau kelonggaran,
partikel logam dalam pelumas.

Kerusakan bearing
Analisa Kuantitatif

• Severity ultrasound menggunakan satuan dB.

• Dalam condition monitoring, perbandingan nilai dB

terhadap base line akan menunjukkan kondisi pelumasan
dan kesehatan bearing

 dB Indikasi
8 dB Pre failure or lack of lubrication
12 dB Beginning of the failure mode
16 dB Advance failure condition
35 – 50 dB Warns of catastrophic failure
PREDICTIVE MAINTENANCE
ULTRASOUND ANALISYS

Electrical inspection
Deteksi corona, tracking, arcing dan
mechanical looseness pada:
• Switchgears
• Power lines & isolators
• Transformers
• Circuit breakers
Loos or vibrating component Corona

Monitoring Breaker Arcing Tracking

PREDICTIVE MAINTENANCE
ULTRASOUND ANALISYS

Kerusakan isolator kabel dalam compartment

THERMOGRAPHY
PREDICTIVE MAINTENANCE
THERMOGRAPHY

Mendeteksi kerusakan equipment

yang bisa ditandai dengan panas

PENGGUNAAN:
• Bearings
• Lubrication issues
• Misalignment
• Worn, mismatched belts
• Steam Trap Surveys
• Electrical /Panels
• Refactory/Boiler
• Valve passing
• dll
Inspection Procedures
• Equipment to be inspected shall be energized and under adequate load; ideally this is
normal operating load. For acceptance testing, higher loads may be warranted.

• Subject equipment shall be externally examined before opening or removing any

protective covers to determine the possible presence of unsafe conditions.

• Electrical and mechanical equipment enclosures shall be opened to provide line-of-

sight access to components contained therein. In some cases, further disassembly
may be required to allow for a complete infrared inspection.

• Whenever possible, similar components under similar load shall be compared to each
other. Components exhibiting unusual thermal patterns or operating temperatures
shall be deemed as exceptions and documented with a thermogram and visible light
image.
 Severity

Delta T Criteria • The infrared thermographer may use the following Delta T (temperature
for Electrical difference) criteria to evaluate the temperature severity of an exception.
Systems
• These Delta T criteria are reported as the temperature rise of the exception
above the temperature of a defined reference, which is typically:
• The ambient air temperature,
• Similar component under the same conditions
• Maximum allowable temperature of the component:
 Severity

NETA Maintenance
Testing Specifications

Military Standard

YK 45
Severity

Experience-Based
for electrical and/or mechanical equipment

YK 46
Severity

Absolute
Temperature
Criteria for
Electrical
Systems
Contoh Tmaxcorr

YK 48
Absolute Temperature Criteria

YK 49
Absolute Temperature Criteria -2

YK 50
Absolute Temperature Criteria -3

YK 51
Absolute Temperature Criteria -4

YK 52
 Severity

Delta T Criteria for • The infrared Thermographer may use Delta T (temperature difference)
criteria to rate the temperature severity of mechanical system
Mechanical exceptions.
Systems • These Delta T criteria are usually reported as the temperature rise of
the exception above the temperature of a defined reference.

• By taking multiple measurements over time of similar components

under similar operating and environmental conditions, statistical
analysis can be used to set operational limits for trending and
predicting the temperature performance of these components.

YK 53
 Severity

Absolute
Temperature
Criteria for
Mechanical
Systems

YK 54
Maximum Allowable Temperature

YK 55
Maximum Allowable Temperature -2

YK 56
Maximum Allowable Temperature -3

YK 57
Maximum Allowable Temperature -4

YK 58
Maximum Allowable Temperature -5

YK 59
PREDICTIVE MAINTENANCE
THERMOGRAPHY

Kebocoran dinding boiler Terminasi buruk pada kabel motor

PREDICTIVE MAINTENANCE
THERMOGRAPHY

Crack pada Fleksibel Joint Trafo PDC SST 2 Crack pada bushing generator chlorine

61
Open or passing valve
THANK YOU