DAFTAR ISI

LEMBARAN PENGESAHAN PERUSAHAAN..................................................i

LEMBARAN PENGESAHAN JURUSAN..........................................................ii
KATA PENGANTAR............................................................................................iv
DAFTAR ISI..........................................................................................................vi
DAFTAR TABEL................................................................................................viii
DAFTAR GAMBAR.............................................................................................ix

BAB I PENDAHULUAN
1.1 Latar Belakang Kerja Praktek.............................................................1
1.2 Perumusan Masalah............................................................................2
1.3 Batasan Masalah..................................................................................2
1.4 Tujuan..................................................................................................2
1.4.1 Tujuan Kerja Praktek.................................................................2
1.4.2 Tujuan Tugas Khusus................................................................3
1.5 Waktu Pelaksanaan Kerja Praktek.......................................................3
1.6 Jam Kerja Praktek...............................................................................3
BAB II PROFIL PERUSAHAAN
2.1 Sejarah Ringkas PT Pupuk Iskandar Muda.........................................4
2.2 Lokasi dan Area Pabrik PT Pupuk Iskandar Muda.............................4
2.3 Pabrik dan Sarana Pendukung.............................................................5
2.3.1 Pabrik Utilitas..........................................................................5
2.3.2 Pabrik Ammonia......................................................................6
2.3.3 Pabrik Urea..............................................................................7
2.3.4 Pabrik PIMIT..........................................................................7
2.4 Unit Penunjang Produksi.....................................................................8
2.5 Pencegahan Pencemaran.....................................................................8
2.6 Struktur Organisasi PT Pupuk Iskandar Muda....................................9
BAB III URAIAN PROSES PRODUKSI
3.1 Utilitas...............................................................................................11
3.1.1 Unit Water Intake..................................................................12
3.1.2 Unit Pembangkit Uap............................................................17
3.1.3 Unit Pembangkit Listrik........................................................18
3.1.4 Unit Udara Instrumen dan Udara Pabrik...............................19
3.1.5 Unit Pemisahan Udara..........................................................20
3.1.6 Unit Pengukuran Gas............................................................20
3.1.7 Unit Pengolahan Air Buangan...............................................20
3.2 Ammonia...........................................................................................21
3.2.1 Unit Persiapan Gas Umpan Baku..........................................22
3.2.2 Sistem Pembuatan Gas Sintesa.............................................24
3.2.3 Unit Pemurnian Gas Sintesis.................................................26
3.2.4 Unit Sintesa Ammonia...........................................................28
3.2.5 Sistem Pendinginan Ammonia..............................................29
3.2.6 Unit Daur Ulang Ammonia...................................................30
3.2.7 Unit Daur Ulang Hidrogen....................................................31

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 3.2.8 Unit Pembangkit Steam.........................................................32
3.3 Urea...................................................................................................33
3.3.1 Sifat Urea..............................................................................34
3.3.2 Bahan Baku Pembuatan Urea................................................35
3.3.3 Proses Pembuatan Urea.........................................................35
3.3.4 Unit Sintesa...........................................................................40
3.3.5 Unit Purifikasi.......................................................................43
3.3.6 Unit Recovery........................................................................44
3.3.7 Unit Kristalisasi Dan Pembutiran.........................................45
3.4 Unit PIMIT........................................................................................46
3.4.1 Proses Pembuatan Adsorben PIMIT.....................................47
3.4.2 Instrumen Pada Unit PIMIT..................................................48
BAB IV PENGUMPULAN & PENGOLAHAN DATA
4.1 Landasan Teori..................................................................................51
4.1.1 Pengertian Maintenance........................................................51
4.1.2 Pengertian Six Big Losses......................................................52
4.2 Total Productive Maintenance (TPM)...............................................53
4.3 Overall Equipment Effectiveness (OEE)...........................................54
4.3.1 Pengertian Overall Equipment Effectiveness (OEE).............54
4.3.2 Pengertian Availability..........................................................56
4.3.3 Pengertian Performance........................................................57
4.3.4 Pengertian Quality.................................................................57
4.4 Pengumpulan Data............................................................................59
4.4.1 Data Berakdown Pada Urea-1...............................................59
4.4.2 Data Reject, Total Product, Good Product............................60
4.5 Pengolahan Data................................................................................61
4.5.1 Menghitung Availability Rate...............................................61
4.5.2 Menghitung Performance Rate.............................................62
4.5.3 Menghitung Rate of Quality Product....................................66
4.5.4 Menghitung Nilai Overall Equipment Effectiveness (OEE). 67
BAB V ANALISIS
5.1 Analisis Nilai OEE Pada Tahun 2013...............................................69
5.2 Analisis Nilai OEE Pada Tahun 2014...............................................70
5.3 Analisis Nilai OEE Pada Tahun 2015...............................................72
BAB VI PENUTUP
6.1 Kesimpulan.......................................................................................74
6.2 Saran..................................................................................................74
DAFTAR PUSTAKA............................................................................................75

LAMPIRAN

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 DAFTAR TABEL

1.1 Jam Kerja Praktek di PT Pupuk Iskandar Muda................................................3

2.1Karakteristik Air Demin....................................................................................17
2.2 Karakteristik Udara Pabrik..............................................................................19
2.3 Sifat Fisika Urea..............................................................................................34
2.4 Perbandingan Beberapa Proses Pembuatan Urea Skala Komersial................35
2.5 Rekap Data Downtime, Total Time, Excluded Time, Loading Time, dan
Operating Time......................................................................................59
2.6 Rekap Data Total Produk dan Data Reject......................................................60
2.7 Perhitungan Availability Rate..........................................................................61
2.8 Perhitungan % Jam Kerja................................................................................62
2.9 Perhitungan Cycle Time dan Waktu Siklus Ideal.............................................63
4.1 Perhitungan Performance Rate.......................................................................65
4.2 Perhitungan Quality Rate................................................................................66
4.3 Perhitungan Nilai OEE....................................................................................67

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 DAFTAR GAMBAR

2.1Gambar Keterkaitan Unit Utilitas dengan Pabrik Ammonia dan Urea.............12

3.1 Gambar BlogDiagram Water Treatment.........................................................13
3.2 Gambar DCS Ammonia Converter..................................................................29
3.3 Gambar DCS Ammonia Refrigerant system Unit............................................30
4.1 Gambar DCS Ammonia Pured Gas dan Condensate Recovery Unit..............31
4.2 Diagram Proses Pembuatan Urea....................................................................35
4.3 Snamprogetti Thermal Stripping Process.......................................................37
4.4 Diagram Alir Stamicarbon CO2 Stripping Process.........................................38
4.5 Seksi Sintesa Stamicarbon Setelah Penambahan Pool Condenser.................39
4.6 Diagram Alir Proses ACES.............................................................................40
4.6 Diagram Alir Seksi Sintesa Urea....................................................................43
4.7 Diagram Alir Seksi Purifikasi.........................................................................45
4.8 Diagram Alir Seksi Recovery, Kristalisasi dan Pembutiran............................47
4.9 Diagram Batang Nilai OEE Tahun 2013.........................................................69
4.10Diagram Batang Nilai OEE Tahun 2014.........................................................70
4.11Diagram Batang Nilai OEE Tahun 2015.........................................................72