Effectiveness Analysis of the Application of the Failure Mode and Effect Analysis Method with Failure Defense Task for Reliability Management Improvement in Sea Water Desalination System of PLTU Paiton Baru (1 X 660 MW)

.Abstract―PT PJB UBJOM Paiton Baru as the O & M Service Manager of PLTU Paiton Baru 1 x 660 MW has approved the concepts and policies of PT PJB on the Reliability Management Program using the FMEA method along with the Failure Defense Task (FDT). However, the FMEA method that has been impelemented not yet effective. First, because first has not been aligned with existing reference books and international journals where there is no process of determining the value of Severity (S), Occurrence (O), and Detection (D), and calculation of Risk Priority Number (RPN), and the process of decreasing the risk value by using the right Failure Defense Task. Second, based on the evaluation of the results of the site visit at UBJOM Paiton Baru for Main Equipment and Sub Equipment for Seawater Desalination Systems, among 21 Sub-Systems in the Seawater Desalination System using Reverse Osmosis Technology, only 7 Sub-Systems have conducted The FMEA and FDT Workshop or 33.3% of the total Sub-Systems, and 14 SubSystems have not conducted FMEA and FDT Workshops or 66.6% of the total Sub-Systems. Third, based on further research on the results of the FMEA and FDT Workshop at UBJOM Paiton Baru in 5 Subsystems namely Mechanical Accelerated Clarifier, Air Scouring Filter, Self Cleaning Filter, Ultra Filtration Device, Energy Recovery Device, that for determining Failure Mode sourced from Manual Book , PM Base, Existing Unit, and Browsing the Internet, so there is no data in identifying Failure Mode. Then FDT for interval 1Y (Annually) is an Overhaul with several types of inspections that have not been implemented / executed for Mechanical, Electrical, Control & Instrumentation Skills which include Assembly and Disassembly, Visual Inspection, repair or replacement if needed according to the results of Visual Inspection, testing, I / O Check , and calibration, so that FDT with Frequency 1Y (Annually) has not been effective. Meanwhile, based on the results of the Workshop on Failure Mode and Effect Analysis (FMEA) and FDT which has been aligned with reference books and international journals, by calculating the Risk Priority Number (RPN) on Failure Mode Failure Mode identified and assessed Severity , Occurrence and Detection Levels for 6 Sub Systems, 14 Failure Modes have been mapped with risk categories of Major Risk, 31 Failure Modes with risk categories of Moderate Risk and 2 Failure Mode with risk categories of Minor Risk according to Ranking based on Risk Priority Number. From 47 Failure Modes that have been mapped risk categories, have been submitted for approval Proposed Maintenance Strategy as an effort in recalculating the value of Risk Priority Number (RPN), based on the results of Review and Evaluation of FMEA and Existing FDT Workshop Data Results and Analysis of Equipment Condition.

Error! Objects cannot be created from editing field codes. There are 2 problems that underlie the writing of this thesis paper, the first has been a problem in the Sea Water Desalination System which caused the unit to experience electricity production disruption due to lack of Make Up Water products in the Sea Water Desalination Plant in Indramayu PLTU and Pacitan PLTU, and potentially occur 1 Ahmad Fajar Ridlo is with Project Management, Department of Technology Management, Faculty of Business and Technology Management, Institut Teknologi Sepuluh Nopember, Surabaya, 60264, Indonesia. E-mail: fajar.ridlo@yahoo.com

The 1 st International Conference on Business and Management of Technology (IConBMT)
August 3rd 2019, Institut Teknologi Sepuluh Nopember, Surabaya, Indonesia in Sea Water The Paiton Baru PLTU Desalination System, and the second is the concept and policy of the Reliability Improvement Program (Reliability Management) using the FMEA method, and RCFA along with the Failure Defense Task. However, the FMEA method that has been compiled has not been aligned with existing reference books and international journals where there is no process of determining Severity (S), Occurrence (O), and Detection (D) and calculation of risk value (RPN), and is not visible the process of reducing the risk value by using the right Failure Defense Task.
The purpose of writing this paper is to assess the effectiveness of the application of the FMEA method along with the Failure Defense Task that has been produced through a workshop mechanism, for Reliability In this paper discussed is the Failure Mode and Effect Analysis Method, an engineering technique used to define, identify, and eliminate known and / or potential failures, problems, errors, etc. from the system, design, process, and / or service before they reached the customer, which was the main topic in writing this paper [1].
Failure Mode and Effect Analysis (FMEA) is a method designed to: 1. Identify and fully understand the possibility of failures mode and their causes, and the effects of failure on the system or end user, for a particular product or process. 2. Assessing risks associated with identified modes, effects, and causes of failure, and prioritizing problems for corrective actions. 3. Identify and carry out corrective actions to address the most serious problems [2]. There are three components that help determine the priority of failure, namely Severity (S), Occurence (O), and Detection (D) [3].
For the next RCM produces a task for a scheduled maintenance program that logically anticipates specific failure modes that can effectively do the following things: 1. Detect failure or damage earlier to take corrective action faster and with the smallest possible interference. 2. Eliminate the causes of some failures or damage before they occur. 3. Eliminate the causes of some failures or damage through design changes. 4. Identify damage that can be safely allowed to occur [4]. RCM has 7 basic stages that meet the criteria that have been issued by the standards of the Society for Automotive Engineers (SAE), the 7 Basic Stages as above can be described in RCM Process Flow and RCM Decision Logic as shown in Figure 2.

III. RESEARCH METHODS
Stages of research are made based on the FMEA method work procedures that are tailored to the actual needs and conditions in the field. The planned research stages are in Figure 3.

A. Data Analysis of Workshop Results of FMEA and FDT Existing Sea Water Desalination System UBJOM Paiton Baru
Based on the analysis of the results of the site visit at UBJOM Paiton Baru

1) Design Severity Rating with Scale 1-10
According to the results of the evaluation of the reference book [3] and by looking at the condition of the Physical Assets being analyzed, the Design of Severity Rating is made with a Scale of 1-10 as shown in Table 1 below:

2) Design Occurrence Rating with Scale 1 -10
According to the results of the evaluation of the reference book [1], [3] and by looking at the condition of the Physical Assets being analyzed, the Occurrence Rating design is made with a Scale of 1 -10. To identify the frequency of each cause with Scale 1 -10, using Cummulative Number of Failure per 1000 existing data (CNF / 1000) or the number of Failure Frequency for each N data, as in Table 2 below:

3) Design Detection Rating with Scale 1 -10
According to the results of the evaluation of the reference book [3] and by looking at the condition of the Physical Assets being analyzed, the Design of Detection Rating is made with a Scale of 1-10 as shown in Table 3 [2] as shown in Figure 4 below:

E. Interview and Brainstorming Results through the Workshop Mechanism
The Interview and Brain Storming process was carried out with a Workshop Mechanism with the format of aligning with the Standard Society of Automotive Engineers SAE J1749.
From the historical data, brainstorming and open questionnaires were then carried out involving several participants from the Engineering Field, Maintenance Fields, and Operations Fields.
The next process is determining the new Maintenance Strategy proposal or recommendation, with Work Flow Process Implementation Workshop with Interview Mechanism and Brain Storming as shown in Figure 5 below: The Interview and Brain Storming process through this Workshop mechanism was carried out in 6 Sub Systems which consisted of: 1. Mechanical Accelerated Clarifier 2. Air Scouring Filter 3. Self Cleaning Filter 4. Ultra Filtration Device 5. 1 st Pass RO Cartridge Filter 6. Energy Recovery Device FMEA analysis is limited to providing maintenance strategy proposals in the sense that it is not until waiting for recommendations to be carried out and re-calculation of RPN as an attempt to reduce risk values, with Major Risk risk categories as shown in the following table:

The 1 st International Conference on Business and Management of Technology (IConBMT)
August 3rd 2019, Institut Teknologi Sepuluh Nopember, Surabaya, Indonesia