final project reliability ad maintainability group 6th

PROJECT TITLE : DATA MAINTENANCE AND RELIABILITY SYSTEM OF TRANSFER PUMP ON AUXILIARY COOLING WATER SYSTEM PLTP KAMPJANG UNIT-4

RELIABILITY ENGINEER : MUHAMMAD YUDHA YUDHISTIRA 2411100061REZA ARRAFFI BIRAHMATIKA 2411100063SAYYIDATUL ISARAH 'ALLAMAH 2411100067GIGIH EDY SAPUTRA 2411100069RIZA TAUFIQUR ROHMAN 2411100077

DATA MAINTENANCE AND RELIABILITY SYSTEM OF TRANSFER PUMP ON AUXILIARY COOLING WATER SYSTEM PLTP KAMPJANG UNIT-4

THE TASK 1. Select one-linepipe including unit process, instrument, safety device, valve and others2. Redraw point 1 using visio3. Make the I/O list table4. Write the short naration/ process description for point 2

Gambar 2.1 Auxiliary Cooling Water System

CHAPTER 2 PIPING AND INSTRUMENTATION DIAGRAM

Gambar 2.2 Visio Drawing of Auxiliary Cooling Water System

PROCESS DESCRIPTION

INPUT Procees is a warm water from cooling tower KMJ-20-P1-EF-008S

OUTPUT Process will be delivered to Heat Exchanger for decreasing temperature frong warm waterAnd the output of the process is cool water

FUNCTION The Pumps is used for increasing flowrate of delivering warm water because of the lenght of pipelineSo when the flowrate of warm water decreasing in the middle of the way, pumps can increase the flowrateBecause, process control is time scale so that the process can't be late or too fast, and has to run on the line margin.

CONTROL The Pumps is moved by motor, And in the motors system also have redundant system which one motor in running mode and the other in standby modeWhen the running motor is stopped, so the standby motor will be operated.The Pumps also have system control to control running system, on/ off system, and the other system inside the pumps.Which are Indicators as the indicator instrument control for indicates the number of inputMotors are instrument control that a running automatic mode

in the cooling system also have redundant system which one cooling component in running mode and the other in standby mode

Table 2.1. I/O List P&ID figure 2.1No Tag. Number Description1 P-440A and P-440B Transfer Pumps2 PI-440A-2, PI-440B-2, PI-441A, PI-441B Pressure Indicators3 PDT 442 A AND PDT 442B Pressure Differential Transmitter4 TI-441 Temperature Indicator5 PT443 Pressure Transmitter6 M Motor7 PI444 Pressure Indicator 8 E-440 A and E-440B Heat Exchanger9 PSV 446A and PSV 446B Pressure Safety Valve

10 TI 442 Temperature Indicator11 FT 440 Flow Transmitter

1. Select one-linepipe including unit process, instrument, safety device, valve and others

4. Write the short naration/ process description for point 2

Procees is a warm water from cooling tower KMJ-20-P1-EF-008S

Process will be delivered to Heat Exchanger for decreasing temperature frong warm water

The Pumps is used for increasing flowrate of delivering warm water because of the lenght of pipelineSo when the flowrate of warm water decreasing in the middle of the way, pumps can increase the flowrateBecause, process control is time scale so that the process can't be late or too fast, and has to run on the line margin.

And in the motors system also have redundant system which one motor in running mode and the other in standby modeWhen the running motor is stopped, so the standby motor will be operated.The Pumps also have system control to control running system, on/ off system, and the other system inside the pumps.Which are Indicators as the indicator instrument control for indicates the number of input

in the cooling system also have redundant system which one cooling component in running mode and the other in standby mode

FunctionIncrease the flowrate of delivering warm waterAs the Pressure indicator of fluids after pumpingAs The Pressure Sensor and sending Data to DCSAs a Temperature Indicator after water pumpingAs The Pressure Sensor after pumping and sending Data to DCSAs Pump boosterAs a Pressure Indicator after water pumping and sending water toChemical DosingAs a Heat Exchanger to cooling warm Water from KMJ-20-P1--EF-008S with cooling water from KMJ-20-P1-EF-010SAs a safety Instrument for reduction over pressure after process in Heat Exchangeras a Temperature Indicator after Heat ExchangerAs a Pressure Sensor and sending data to DCS

CHAPTER 3 MAINTENANCE AND RELIABILITY

3.1 TAG NUMBERTag Number P-440A

Table 3.1 TTF, MTTF, and λ of Equipment P-440ANumber Equipment ID Order Data_R TTF (day)

1 P-440A 9/8/2013 -2 P-440A 11/10/2013 633 P-440A 12/15/2013 354 P-440A 1/4/2014 205 P-440A 1/20/2014 166 P-440A 1/29/2014 97 P-440A 2/11/2014 138 P-440A 2/24/2014 139 P-440A 3/5/2014 9

10 P-440A 3/19/2014 1411 P-440A 3/27/2014 812 P-440A 4/22/2014 2613 P-440A 4/30/2014 814 P-440A 5/12/2014 1215 P-440A 5/29/2014 1716 P-440A 6/6/2014 817 P-440A 6/17/2014 1118 P-440A 6/30/2014 1319 P-440A 7/18/2014 1820 P-440A 7/29/2014 11

MTTF 17.05263λ 0.058642

From EasyFit graph analysis above, we have :The continuos shape parameter (α) 2.4066The continuos scale parameter (β) 16,482The continuos location parameter (γ) 0

From ReliaSoft Weibull graph analysis above, we have :The continuos shape parameter (β) The continuos scale parameter (θ)The continuos location parameter (ρ)

Tag Number P-440B

Table 3.2 TTF, MTTF, and λ of Equipment P-440BNumber Equipment ID Order Data_R TTF (day)

1 P-440B 9/16/2013 -2 P-440B 11/11/2013 563 P-440B 12/9/2013 284 P-440B 1/7/2014 295 P-440B 1/17/2014 106 P-440B 1/28/2014 117 P-440B 2/4/2014 78 P-440B 2/21/2014 179 P-440B 3/9/2014 16

10 P-440B 3/13/2014 411 P-440B 3/25/2014 1212 P-440B 4/10/2014 1613 P-440B 4/16/2014 614 P-440B 5/12/2014 2615 P-440B 5/25/2014 1316 P-440B 6/9/2014 1517 P-440B 6/17/2014 818 P-440B 6/26/2014 919 P-440B 7/15/2014 1920 P-440B 7/18/2014 3

MTTF 16.05263λ 0.062295

From EasyFit graph analysis above, we have :The continuos shape parameter (α) 1,694The continuos scale parameter (β) 15,871The continuos location parameter (γ) 0

From ReliaSoft Weibull graph analysis above, we have :

The continuos shape parameter (β) The continuos scale parameter (θ)The continuos location parameter (ρ)

FMEAFailure Mode and Effect Analysis

No Tag Number Item Failure Mode

1 P440A and P440B Auxilary Cooling System Pump

Produce no water flow

Cavitation

2 Pressure Indicator

Wrong signal value

Cannot Transmit Signal

3 Pressure Differential Transmitter

Wrong signal value


4 TI-441 Temperature Indicator

Wrong signal value


5 PT443 Pressure Transmitter

Wrong signal value


Transport water below 953.2 m3/hr

PI-440A-2, PI-440B-2, PI-441A,

PI-441B

PDT 442 A and PDT 442B

6 M Motor of Auxilary Pump

7 PI444 Pressure Indicator

Wrong signal value


8 E-440 A and E-440B Heat Exchanger

Process Fluid Leak

9 PSV 446A and PSV 446B Pressure Savety Valve

Open

> Open Winding> Shorted Winding

> Worn bearing> Spalling> Creeping or spin

9 PSV 446A and PSV 446B Pressure Savety Valve

Closed

Leaks

10 TI 442 Temperature Indicator

Wrong signal value


11 FT 440 Flow Transmitter

Wrong signal value



Failure Cause Failure EffectSeverity

S P C

3

2

Broken pump impeller

1

1

Pump Shutdown2

1

Pump Shutdown2

3

1

Pump Shutdown3

Probability

(Occurence)

CriticalRank

Impeller degraded, gasket leak, motor degraded

Lower efficiency of Cooling tower and condenser

Excessive vibration, motor inoperable, broken coupling

Cooling tower and condenser loose ability to chill

Net Positive Suction Head Available (NPSHA) smaller than Net Positive Suction Head Required (NPSHR)

Broken signal cable, high deviation of sensor reading

> Auxilary pumps transport water flow rate unproperly> Cavitation

Power supply doesn't work properly





Incorrect value of temperature will reduce efficiency of Cooling tower and condenser



Auxilary pumps transport water flow rate unproperly, Cavitation


2

2

2

2

Broken Spring

3

> Insulation Breakdown> High ambient temperature> High altitude> Mechanical overload> Frequent stops and starts> Dirt buildup on cooling fins> Excessive Vibration> Mechanical shock

> Motor won't start> Motor failure> Sparking at brushes > Pump inoperable> Cooling tower and condenser loose ability to chill

> Excessive static load> Belt misalignment> Frequent starts and stops under heavy loads> Lubrication problem

> Noisy> Heat build-up> Armature rubbing stator> Motor seized


> Valve VLV 4435 wouldn't work properly> Flow rate to chemical dosing could be both excessive or insufficient


> Loss of wall thickness on entry tube, exit tube, tube OD's, tube ID's> Loss of compression on inlet/outlet flange> Corrosion of Process nozzle on extry/exit

> Reduction of HE efficiency> Rising flow rate from HE to cooling tower

Pressure drop on HE outlet causing reduction of HE efficiency

1

3

3

1

> Corrosion> Faulty manufacture

> Heat exchanger explode> Safety system fail

> Corrosion> Faulty manufacture

Reduction of HE efficiency


Incorrect value of temperature will reduce efficiency of Cooling tower






Repair power supply

Repair power supply

Repair power supply

Repair power supply

Analysis orCorrective action

Replace impeller and gasket, maintain motor

Repair motor, analyze vibration signal to determine possible cause of excessive vibration, repair coupling

Replace current pump with appropriate NPSH

Calibrate Pressure Indicator


Calibrate Temperature Indicator


> Analyze vibration signal to determine possible cause of excessive vibration> Repair Insulation and winding

> Calibrate pressure indicator> Repair power supply

> Cathodic protection on process nozze to prevent corrosion> Maintain auxilary water pump to prevent compression reduction> Replace eroded component

Replace broken spring

Repair power supply

Repair power supply

SE

VE

RE

TY 1

234

1 2 3 4 5OCCURENCE

Severity

Category 1 Catasthrophic Significant system failure occurs that can result in injury, loss of life, of major damageCategory 2 Critical Complete loss of system occurs; performance is unaceptableCategory 3 Marginal System is degraded, with partial loss in performanceCategory 4 Negligible Minor failure occurs, with no effect on acceptable system performance

Occurrence

Category 1 Frequent p ≥ 0.20Category 2 Probable 0.1 ≤ p < 0.20Category 3 Occasional 0.01 ≤ p < 0.1Category 4 Remote 0.001 ≤ p < 0.01Category 5 Extremely Unlikely p < 0.001

> Replace eroded component> Apply cathodic protection on PSV component

> Replace eroded component> Apply cathodic protection on PSV component

Calibrate Temperature Indicator


Significant system failure occurs that can result in injury, loss of life, of major damageComplete loss of system occurs; performance is unaceptable

Minor failure occurs, with no effect on acceptable system performance

final project reliability ad maintainability group 6th

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