1 / 33

ANNUAL SHUTDOWN MAINTENANCE OF FIELD INSTRUMENT IN PT ASAHIMAS CHEMICAL

ANNUAL SHUTDOWN MAINTENANCE OF FIELD INSTRUMENT IN PT ASAHIMAS CHEMICAL. End of Probation Presentation 29 September 2014 Yuniawan Erwin Seloaji Instrument Department. Background. Proses di plant berlangsung secara kontinu (beberapa proses berlangsung secara batch)

lucian-vaughn
Download Presentation

ANNUAL SHUTDOWN MAINTENANCE OF FIELD INSTRUMENT IN PT ASAHIMAS CHEMICAL

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript

  1. ANNUAL SHUTDOWN MAINTENANCE OFFIELD INSTRUMENTIN PT ASAHIMAS CHEMICAL End of Probation Presentation 29 September 2014 Yuniawan Erwin Seloaji Instrument Department

  2. Background • Proses di plant berlangsung secara kontinu (beberapa proses berlangsung secara batch) • Peralatan beroperasi terus-menerus • Lama-kelamaan peralatan akan “lelah” • Jika dibiarkan saja dapat menjadi potensi bahaya • Peralatan perlu di-maintenance secara berkala

  3. 5W 2HAnnual Shutdown Maintenance of Field Instrument • What? • Who? • Why? • Where? • When? • How many? • How?

  4. What? Apasajafield instrument yang di-maintenance? • Transmitters • Thermoelements • Gauges • Switches • Control Valves

  5. Who? Siapasaja yang terlibatdalam ASDM field instrument? • INS • MCA • MVM • MPU • Production (CA-2, VCM-2, UTL) • Business Partner

  6. Why? Mengapafield instrumentperlu di-maintenance? • Field instrument tetapawet • Performa field instrumenttetapbaik • Proses berjalandenganaman

  7. Where? Plant yang Shutdown: • CA-2 • VCM-2 • UTL TempatMaintenance Field Instrument: • W/S II INS

  8. When? Kapan ASDM field instrumentinidilaksanakan? • Rencana : 19 Agustus 2014 – 18 September 2014 • Realisasi : 19 Agustus 2014 – 10 September 2014

  9. How Many? Berapa banyak field instrument yang di-maintenance? Transmitter Control Valve

  10. How? H/O to workshop Take out from plant WORKSHOP MAINTENANCE ACTIVITIES: Disassembly Cleaning Overhaul Assembly Leak test Calibration Reinstall H/O from workshop

  11. Scheduling • Menyusun jumlah rata-rata field instrument yang harus dikerjakan dalam satu hari • Berdasarkan jadwal take out – maintenance - install • Berdasarkan request

  12. Handover • Formhandover kurang praktis, memuat daftar instrument secara berurut • Sulit diinput ke komputer • Kapan suatu field instrument datang dan keluar sulit dilacak secara kronologis • Seharusnya hanya form kosong berisi tanggal, waktu, field instrument yang masuk/keluar, PIC yang menyerahkan, PIC yang menerima • Letak tag number field instrument tidak seragam sehingga mesti dibolak-balik terlebih dahulu

  13. Tahapan Maintenance di Workshop

  14. Disassembly • Transmitter • Hanya untuk transmitter dengan model D/P biasa • Transmitter dipisahkan dari manifold dan process flange • Dibuat gambar orientasi • Control Valve • Aktuator dipisahkan dari body • Body, bonnet, stem, packing flange, packing follower, gland packing dipisahkan • Dibuat gambar orientasi

  15. Tahapan Maintenance di Workshop

  16. Overhaul • Lapping • Modification • Painting

  17. Tahapan Maintenance di Workshop

  18. Leak TestTransmitter Bagian yang berpotensiterjadikebocoran: • Process flange • Manifold

  19. Leak TestControl Valve Leak test untuk Control Valve: • Body leak test • Seat leak test

  20. Tahapan Maintenance di Workshop

  21. KalibrasiTransmitter

  22. Menginput Data Kalibrasi ke CACS

  23. KalibrasiKendala & Solusi • Transmitter menumpuk di ruang kalibrasi • Portable calibrator • Alat bantu setup untuk remote seal • Temperature calibrator • Teknisi kesulitan menentukan item yang harus dikalibrasi lebih dulu • Membuat label tag number di kertas ukuran A4 • Menuliskan item yang harus segera dikalibrasi & pencapaian kalibrasi hari ini di whiteboard • Memisahkan transmitter yang mesti segera dikalibrasi

  24. ASDM Reporting • Aktivitas selama ASDM field instrument dilaporkan dalam bentuk: • Progress Report • Today-Tomorrow Report • Highlighted Item Report • Semuanya disimpan di direktori S:asdm • Laporan dapat langsung dilihat oleh jajaran manajemen

  25. End of Part I

  26. MENGUKUR FLOWRATE DENGAN CONTROL VALVE End of Probation Presentation 29 September 2014 Yuniawan Erwin Seloaji Instrument Department

  27. Verifikasi Flowrate • (SS dari PI Processbook)

  28. Langkah-Langkah Pengerjaan

  29. Data Awal yang Diketahui FV-51011 • Rated Cv = 600 • P1 = 1.673 kg/cm2.G = 2.673 kg/cm2.A • P2 = 0.289 kg/cm2.G = 1.289 kg/cm2.A • t = 37.5°C • % travel = 76.7%

  30. Persamaan untuk Menghitung Cv (Fluida Gas) • P1 = 1.673 kg/cm2.G = 2.673 kg/cm2.A ½ P1 = 1.337 kg/cm2.A • P2 = 0.289 kg/cm2.G = 1.289 kg/cm2.A • ΔP = 1.384 kg/cm2.D

  31. Data-Data Lain Berdasarkan specification sheet FV-51011 diketahui • Model : • Flow Characteristic : Equal Percentage • Fluida : ethylene • Fasa : gas • G : 0.9683

  32. Mencari Nilai Rated Cv MencarinilaiCv • Grafik %travel vs %Cv

  33. Menghitung Nilai Flowrate DenganmembalikpersamaanuntukmenghitungCv: • Q = (225)(249)(2.673) / sqrt {(0.9683)(273+37.5)} = 8637 m3/h Q [m3/h] = 1.0569 x Q [Nm3/h] • Q [Nm3/h] = (8637 m3/h) / 1.0569 = 8172 Nm3/h

More Related