STOPBAR BFP

Special Tool Pull Out Barrel BFP untuk Mencegah

Kerusakan Inner Part & Efisiensi Durasi Kerja

Gresik, 1 Maret 2023

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 INNOVATION TEAM

GALLIH BAGUS WICAKSONO BAGUS SURYA PREMONO MUHAMMAD LARDIANSYAH

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 LATAR BELAKANG
SIKLUS PEMBANGKIT LISTRIK TENAGA UAP

1 UNIT MOTOR DRIVEN BOILER FEED PUMP

BOILER FEED PUMP BERFUNGSI UNTUK MENGALIRKAN

FEED WATER DARI DEAERATOR MENUJU STEAM DRUM 2 UNIT TURBINE DRIVEN BOILER FEED PUMP

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 PERMASALAHAN
OVERHAUL SIMPLE INSPECTION

UMRO
ON TIME, ON COST, ON QUALITY

DISASSEMBLY

PELEPASAN ATAU PULL OUT

INSPEKSI BARREL DENGAN SPECIAL TOOL
EXISTING DARI SISI NDE

REPAIR
TERDAPAT KENDALA YAITU
PUTUSNYA BAUT STAGE CASING
SEHINGGA BARREL TETAP
GANTI PART TERTINGGAL DI DALAM CASING

MENGAKIBATKAN DURASI
REASSEMBLY PEKERJAAN MENJADI SEMAKIN
LAMA, PULL OUT DARI SISI NDE
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 METODOLOGI INOVASI

FISH BONE DIAGRAM

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 PRODUK INOVASI

DESAIN DIMENSI SPECIAL TOOL

PROPERTIES SUPPORTING TOOL

MATERIAL : ASTM A36 HYDRAULIC JACK PUMP 1 EA
SPESIFIKASI KETEBALAN : 20 MM CYLINDER 50 TON 2 EA
YIELD STRENGTH : 250 MPA BOLT 2EA
UTS : 500 MPA NUT 4 EA

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 KETERBARUAN INOVASI
Via AMIO Via Google Patent

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 RIWAYAT IMPLEMENTASI
TELAH DIIMPLEMENTASIKAN SPECIAL TOOL PULL OUT BARREL BFP DI PLTU TANJUNG AWAR-AWAR
OH SI UNIT 2 TAHUN 2021 DAN OH SE UNIT 1 TAHUN 2023

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 PERBANDINGAN

No Parameter Perbandingan Special Tool Existing Special Tool STOPBAR

1 Durasi 16 jam 4 jam

2 Potensi macet saat pull out Ada Tidak ada

3 Potensi kerusakan part (baut last stage Ada Tidak ada

casing)

4 Potensi kerusakan tool saat dioperasikan Ada, kebocoran seal silinder karena Tidak ada
overload saat barrel macet

5 Gaya yang digunakan Gaya tarik Gaya dorong

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 ANALISA DAN MITIGASI RISIKO

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 MANFAAT INOVASI

ON TIME MEMPERCEPAT DURASI DISASSEMBLY BARREL BFP

MENCEGAH BIAYA YANG TIMBUL KARENA

ON COST KERUSAKAN INNER PART

MENJAGA KUALITAS PART POMPA TETAP PADA

ON QUALITY KONDISI TERBAIK TANPA KERUSAKAN

MENDAPATKAN POTENSI KEUNTUNGAN KARENA

FINANCIAL PERCEPATAN DURASI KERJA
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 PELUANG DISEMINASI

SPECIAL TOOL SESUAI UNTUK SEMUA POMPA DENGAN STUFFING BOX MENYATU DENGAN BARREL

PLTU TANJUNG AWAR-AWAR PLTU BANJARSARI PLTU PAITON PLTU INDRAMAYU

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 1
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PA IL AN
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or distribute this document without permission of PLN NUSANTARA POWER, PT

AT
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2 SP
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AR IAL IL D TA
-A T AK SI

The information contained in this document is strictly confidential. It is strictly forbidden to use, disclose, copy, modify,
W OO UK
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1 PL LE
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13
 THANK YOU
TERIMA KASIH

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or distribute this document without permission of PLN NUSANTARA POWER, PT
 LAMPIRAN

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or distribute this document without permission of PLN NUSANTARA POWER, PT
 BARREL SEBELUM DI PULL OUT BARREL SETELAH DI PULL OUT

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 TOOL EXISTING SPECIAL TOOL INOVASI

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or distribute this document without permission of PLN NUSANTARA POWER, PT 17
The information contained in this document is strictly confidential. It is strictly forbidden to use, disclose, copy, modify,
or distribute this document without permission of PLN NUSANTARA POWER, PT 18
The information contained in this document is strictly confidential. It is strictly forbidden to use, disclose, copy, modify,
or distribute this document without permission of PLN NUSANTARA POWER, PT 19
 Potensi Keuntungan = Daya Mampu Netto x konversi ke MW x jumlah jam per
hari x biaya pokok produksi

= 323 x 1000 x 12 x 669

= Rp 2.593.044.000,-

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or distribute this document without permission of PLN NUSANTARA POWER, PT 20
 WBS SEBELUM IMPLEMENTASI SPECIAL TOOL

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or distribute this document without permission of PLN NUSANTARA POWER, PT 21
 WBS SETELAH IMPLEMENTASI SPECIAL TOOL

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or distribute this document without permission of PLN NUSANTARA POWER, PT 22
 No Bahan Jumlah Keterangan Harga satuan Harga

1. Plat besi tebal 20mm, ukuran 1200 x 1 lembar Material Carbon Steel Rp.4.999.000,- Rp.4.999.000,-
2400 mm

2. Baut dan Nut M30 panjang 80mm 2 ea Material Carbon Steel Rp.183.200,- Rp.366.400,-

3. Cat warna kuning 1 ea Pylox Rp.48.000,- Rp.48.000,-

4. Tenaga kerja (freelance welder) 2 personil, 2 hari - Rp.260.000,- Rp.1.040.000,-

Total Rp.6.453.400,-

BIAYA PEMBUATAN SPECIAL TOOL

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 Harga baut last stage casing = 6 x 88.281

= Rp.529.686,-

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or distribute this document without permission of PLN NUSANTARA POWER, PT 24