Scheduling Program Analysis of Pressure Relief Device (PRD) According to RBI API 581 on Production Gas Separator System

Pressure relief device serves to control and limit the pressure by directing the flow into an additional path. In the process of purification of oil and gas, application of PRD are found in production gas separator system. However, based on API 581, the PRD also has a risk of failure that every oil and gas company needs to conduct regular inspections to ensure the reliability of PRD. One approach to evaluating critically the PRDs for arranging and scheduling programs is to use the risk-based inspection (RBI) method. The RBI is a systematic approach to the method of inspection management of equipment or works unit based on the level of risk that the equipment or work units. Risk assessment for production gas separator system’s PRD has based on API RP 581 third edition.  After knowing the level of risk for PRD, the risk needs to be evaluated. For acceptable risk, it can be used as a reference to determine the next inspection until risk target. Meanwhile, unacceptable risk should be inspected immediately after RBI analysis

Implementation of Risk-Based Inspection (RBI) in Condensate Separator and Storage Vessel: A Case Study

In the processing of oil and gas, a pressure vessel is an important piece of equipment. It needs a method to prevent the failure of the pressure vessel. The Risk-Based Inspection (RBI) is a systematic approach to the inspection management method for equipment based on the level of risk. RBI is expected to provide sufficiently accurate recommendations to prevent equipment failures. In this research, the objects to be carried out are the 10V2102 condensate separator and the 10V2103 condensate storage vessel. According to RBI analysis, the risk category of the current RBI date is low risk for the condensate separator 10V2102 and condensate storage vessel 10V2103. Meanwhile, the inspection date of Condensate Separator 10V2102 is 2 April 2026 and 11 February 2027 for Condensate Storage Vessel 10V2103 and selected inspection methods are Visual Testing, Ultrasonic Testing (UT), Radiography Test (RT), Eddy Current Test, and Magnetic Particle Inspection

Reviewing the RCM on Cooling Water Pump of LNG Production Company

Maintenance is one of the important things to maintain a company in the industry. A company, such as LNG production company, must be able to produce and meet energy needs independently to support all operations, such as cooling water system that functions to control the temperature and pressure so that the production process runs optimally. If this system is disrupted, there will be excess use of water, waste water, and energy costs needed which result in higher total operational costs. With good and right care, it can reduce all risks posed. One component that plays a role in the cooling water system is a pump. This pump serves to flow the cooling water which is seawater to the LNG industry plant. At present, the amount of Work Order data recorded from the problems obtained from the pump requires maintenance updates. In this study, the method in the maintenance programs are used based on the Reliability-Centered Maintenance (RCM) implementation. RCM will increase cost efficiency, reliability, pump uptime, and propose maintenance tasks. Beside pump, the reviewing also involve supports components that affect pump optimization. In this paper, the functions, causes, and effects are identified and the new scheduled maintenance tasks are show

Determination of Maintenance Task on Rotary Equipment Using Reliability Centered Maintenance II Method

The process of natural gas into LNG (Liquefied Natural Gas) requires many steps and various types of chemical products. The process also produces waste. The Liquid Incinerator treats waste from LNG process. This unit often experiences damages which causes the plant do not work properly and even a down/trip problems due to the continuous operation and the absence of maintenance program, especially for rotary equipments. This causes environmental pollution because the waste is unprocessed and could have an impact on the increased cost to treat the waste elsewhere. One of approaches to analyze the causes of the damage, the impact and effective treatment for equipment is using Reliability Centered Maintenance (RCM). The RCM method is expected to be able to identify the primary and secondary functions of the system, possible failure function, Failure Mode and Effect Analysis (FMEA), and the maintenance actions on the plant. The FMEA result will be used to determine the proposed maintenance task. Based on the proposed maintenance task, the maintenance interval for each equipment is obtained. After RCM analysis is done on 4 equipments, liquid waste feeding pump (34-G-2), quencher pump (34-G-3), scrubber pump (34-G-4) and air compressor (34-K-4). For 34-G-2 failure mode, requires 78% preventive maintenance and 22% corrective maintenance, 34-G-3 requires 87% preventive maintenance and 13% corrective maintenance, 34-G-4 requires 87% preventive maintenance and 13% corrective maintenance and 34-K-4 requires 70% preventive maintenance and 30% corrective maintenance. Workpackage for each interval is created from every failure mode for each interval for maintenance / inspection.

Dynamic Information System for Failure Analysis with It’s Application on Ship Main Engine

Ships are often used to move cargo, and their main engines are crucial. Accidents and financial losses might result from the main engine being in poor condition. Before completing maintenance, conducting a failure analysis is necessary. The existing method is static and involves using a list of failure modes from the engine's manufacturing phase. This study proposes a preliminary design of dynamic system prototype that seeks to improve ship engine monitoring of status. It includes features such as a list of failure modes and codes based on ISO 14224:2016, data collection unit worksheet, and dynamic charts for visualizing the results. Two testing iterations were performed on the prototype. First, literature data obtained from the internet was used to generate annual and monthly report charts, confirming the functionality of the prototype. Second, real data from engine failures on the tanker ship were used to ensure logical correlations among failure causative factors. The result from real data testing included Structural Deficiency (STD), External Leakage Fuel (ELF), and Breakdown (BRD) were shown. Based on these results through the prototype simulation, can be taken into consideration for the ship's crew and shipping company management to plan oil monitoring, heating the oil properly, and conduct routine maintenance check as a preventive action to reduce the impact of engine damage in the future due to Engine Breakdown and Structural Defiency

Modification of Sea Water Scrubber System into Fresh Water of Inert Gas System on the Crude Oil Tanker 85,000 DWT

Each ship carrying a hydrocarbon must be equipped with an inert gas system. On tankers, the function of inert gas is to prevent fires or explosions caused by oxygen levels contained in cargo tanks. Inert gas is produced by cleaning the exhaust gas boiler using a sea water scrubber system. However, seawater has corrosive properties that cause the use of material in scrubber system components to be resistant to corrosion. Therefore, through this research a modification of the sea water scrubber system was made into a freshwater scrubber system. The advantages of a freshwater scrubber system include a low corrosive level that causes the use of inexpensive materials. Modification of seawater scrubber systems into fresh water causes additional components to be made, including adding NaOH tank, expansion tank of freshwater, seawater pumps, freshwater pumps, NaOH pumps, heat exchanger, and wash water treatment unit. Economic calculations are carried out to determine the installation costs and operational costs needed from this modification. Based on the technical and economical analysis, modification of the sea water scrubber system into fresh water inert gas system of Crude Oil Tanker 85,000 DWT can be done with an estimated installation cost of 1.5 Bill. Rupiahs