| dc.description.abstract | PT Kaltim Methanol Industri (PT KMI) is a company in the petrochemical industry that produces AA grade methanol with a high purity level of > 99.85% with a capacity of 660,000 metric tons/year. PT KMI produces methanol from natural gas feedstock using a low-pressure methanol synthesis process licensed by Lurgi Germany. One of the main units in PT KMI's methanol production process is Unit 300 (Methanol Distillation). There are 11 pumps that function to support the methanol purification process in Unit 300. The process water 030-G04A pump is one of the pumps in Unit 300. This pump has the highest frequency of damage and the highest repair cost compared to other pumps, which experienced 8 breakdowns and the repair cost reached 86,289.72 USD. This problem shows the failure of the machine to operate as expected by the company, where the company must incur considerable costs for repairs compared to other pumps. The failure of the engine in this company indicates a gradual decrease in engine reliability. For this reason, research was conducted with the aim of improving pump reliability using FMEA and Reliability Centered Maintenance (RCM) methods. Through FMEA analysis, it was found that the critical components of the pump are the shaft and impeller with RPN of 288 and the sealing system with RPN of 270 with the highest damage and downtime of 8 times damage and downtime of 5455.46 hours. The calculation results show the MTTF value of the shaft and impeller component of 10642.1367 hours with an MTTR of 534.1685 hours and MTTF of the sealing system component of 3771.1716 hours and MTTR of 762.8510 hours. The percentage of reliability obtained for the shaft and impeller is only 20.49% and the sealing system component is 23.39%. This indicates maintainability or the ability to maintain machines and components is low. Through the reliability standard, the pump reliability is set at 70%. So, the preventive maintenance interval for the shaft and impeller components is set every 12 days and the sealing system components every 9 days. Maintenance costs have been saved, namely the average corrective maintenance cost for production for one year is 27,985.80 USD to 25,314.96 USD with the latest proposed preventive maintenance interval. Savings occurred in the amount of 2,670.84 USD or 9.5%. Furthermore, with the RCM Decision Worksheet analysis, a proposed maintenance task for each failure mode is obtained, namely scheduled on-condition, scheduled restoration task in the form of periodic inspection and maintenance actions and scheduled discard task in the form of regular replacement of components and parts | en_US |
