DAFTAR ISI

Halaman
LEMBAR PENGESAHAN JURUSAN
LEMBAR PENGESAHAN PERUSAHAAN
LEMBAR PENILAIAN PERUSAHAAN
LEMBAR PERNYATAAN ORISINALITAS
KATA PENGANTAR ......................................................................................i
DAFTAR ISI...................................................................................................iii
DAFTAR TABEL...........................................................................................vi
DAFTAR GAMBAR .....................................................................................vii
DAFTAR RUMUS..........................................................................................ix
BAB I PENDAHULAN
1.1 Latar Belakang Kerja Praktik ..................................................1
1.2 Tujuan Kerja Praktik ...............................................................1
1.3 Manfaat Kerja Praktik .............................................................2
1.3.1 Bagi Mahasiswa/i ...........................................................2
1.3.2 Bagi Fakultas..................................................................2
1.3.3 Bagi Perusahaan .............................................................2
1.4 Ruang Lingkup Kerja Praktik .................................................2
1.4.1 Tempat Kerja Praktik .....................................................3
1.4.2 Lokasi Kerja Praktik ......................................................3
1.4.3 Waktu Pelaksanaan Kerja Praktik..................................3
1.4.4 Jam Kerja Praktik...........................................................3
1.5 Sistematika Penulisan Laporan Kerja Praktik .........................3

BAB II GAMBARAN UMUM PERUSAHAAN

2.1 Sejarah Singkat Perusahaan ....................................................5
2.2 Lokasi dan Area Pabrik Perusahaan ........................................7
2.3 Logo Perusahaan .....................................................................8
2.4 Visi dan Misi Perusahaan ......................................................10
2.4.1 Visi ...............................................................................10
2.4.2 Misi...............................................................................10
2.5 Tata Nilai, Makna, Tri Tekad Perusahaan.............................10
2.5.1 Tata Nilai ......................................................................10
2.5.2 Makna ...........................................................................11
2.5.3 Tri Tekad ......................................................................11
2.6 Struktur Organisasi Perusahaan ............................................12
2.7 Sumber Daya Manusia di PT Pupuk Iskandar Muda ............14
2.8 Produk dan Pemasaran di PT Pupuk Iskandar Muda ............14
2.8.1 Produk Utama...............................................................14
2.8.2 Produk Samping ...........................................................15
2.8.3 Pemasaran Produk ........................................................15
2.9 Prestasi dan Penghargaan ......................................................16
2.10 Proses Pengolahan Produk ..................................................17

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 2.11 Unit Utilitas ..........................................................................17
2.11.1 Unit Water Intake ......................................................18
2.11.2 Unit Pengolahan Air..................................................19
2.11.3 Unit Pembangkit Uap ................................................22
2.11.4 Unit Pembangkit Listrik ............................................23
2.11.5 Unit Udara Instrumen dan Udara Pabrik...................25
2.11.6 Unit Pemisah Udara ..................................................25
2.11.7 Unit Pengukuran Gas ................................................26
2.11.8 Unit Pengolahan Air Buangan...................................26
2.12 Unit Ammonia ......................................................................29
2.12.1 Unit Persiapan Gas Bahan Baku ..............................31
2.12.2 Sistem Pembuatan Gas Sintesa .................................33
2.12.3 Unit Pemurnian Gas Sintesa......................................36
2.12.4 Unit Sintesa Ammonia...............................................37
2.12.5 Sistem Pendingin Ammonia ......................................38
2.12.6 Unit Daur Ulang Ammonia........................................38
2.12.7 Unit Daur Ulang Hidrogen........................................39
2.12.8 Unit Pembangkit Steam .............................................40
2.13 Unit Urea ..............................................................................40
2.13.1 Seksi Sintesa..............................................................42
2.13.2 Seksi Purifikasi..........................................................44
2.13.3 Seksi Granulasi..........................................................45
2.13.4 Seksi Recovery ..........................................................47
2.13.5 Seksi Proses Pengolahan Kondesat ...........................48
2.14 Unit Penunjang Produksi......................................................48
2.15 Kepedulian Lingkungan .......................................................49
2.16 Pembinaan Wilayah..............................................................50

BAB III TUGAS KHUSUS

3.1 Pendahuluan ..........................................................................51
3.1.1 Latar Belakang ...........................................................51
3.1.2 Rumusan Masalah ......................................................52
3.1.3 Tujuan Masalah ..........................................................52
3.1.4 Manfaat Penelitian......................................................53
3.1.5 Batasan Masalah Dan Asumsi....................................53
3.1.5.1 Batasan Masalah.............................................53
3.1.5.2 Asumsi............................................................54
3.2 Landasan Teori ......................................................................54
3.2.1 Pengertian Perawatan (Maintenance).........................54
3.2.2 Sistem Pemeliharaan ..................................................55
3.2.3 Tujuan Sistem Pemeliharaan ......................................57
3.2.4 Tindakan Pencegahan dan Perbaikan. ........................58
3.2.5 Klasifikasi Perawatan .................................................58
3.2.5.1 Breakdown Maintenance................................59
3.2.5.2 Corrective Maintenance .................................59

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 3.2.5.3 Preventive Maintenance .................................59
3.2.5.4 Predictive Maintenance..................................59
3.2.6 Pompa Sentrifugal ......................................................60
3.2.7 Komponen Pompa Sentrifugal ...................................60
3.2.8 Reliability ...................................................................61
3.2.9 Diagram Pareto...........................................................63
3.2.10 Jenis-jenis Fungsi Distribusi Kegagalan. ...................64
3.2.11 Mean Time To Failure (MTTF)
dan Mean Time To Repair (MTTR) ..........................66
3.2.12 Model Age Replacement.............................................68
3.3 Pompa Cooling Water System ...............................................70
3.4 Metode Penelitian..................................................................71
3.4.1 Tempat dan Waktu Penelitian. ....................................71
3.4.2 Teknik Pengumpulan Data ..........................................72
3.4.3 Langkah-langkah Penelitian ........................................72
3.5 Pengumpulan Data ................................................................74
3.5.1 Downtime Kerusakan Komponen Pompa
E63-GA2001 ...............................................................75
3.6 Pengolahan Data....................................................................77
3.6.1 Penentuan Komponen Kritis Pompa
E63-GA2001A ............................................................77
3.6.2 Penentuan Waktu Antar Kerusakan (TTF)
dan Waktu Perbaikan (TTR) Komponen Kritis
Pompa E63-GA2001A ................................................79
3.6.3 Uji Distribusi ...............................................................80
3.6.4 Pengujian Pola Distribusi Pada TTF
(Time To Failure) ........................................................82
3.6.5 Pengujian Pola Distribusi Pada TTR
(Time To Repair) .........................................................88
3.6.6 Penentuan Parameter ...................................................94
3.6.7 Perhitungan MTTF (Mean Time To Failure)
dan MTTR (Mean Time To Repair) ............................95
3.6.8 Perhitungan Penentuan Interval Waktu Penggantian
Pencegahan Komponen Pompa E63-GA2001A .........97

BAB IV KESIMPULAN DAN SARAN

4.1 Kesimpulan............................................................................99
4.2 Saran ......................................................................................99

DAFTAR PUSTAKA
LAMPIRAN

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 DAFTAR TABEL

Tabel Halaman
1.1 Jam Kerja Praktik .................................................................................... 3
2.1 Jumlah Karyawan Berdasarkan Gender ................................................ 14
2.2 Jumlah Karyawan Berdasarkan Kompartemen ..................................... 14
2.3 Spesifikasi Produk Urea Prill PT Pupuk Iskandar Muda...................... 15
2.4 Spesifikasi Produk Samping PT Pupuk Iskandar Muda........................ 15
2.5 Prestasi dan Penghargaan ...................................................................... 16
2.6 Unit-Unit di Pabrik Utilitas ................................................................... 18
2.7 Unit-Unit di Pabrik Ammonia................................................................ 30
3.1 Data Kerusakan Pompa E63-GA2001A Periode September 2021
Sampai Agustus 2022 ............................................................................ 74
3.2 Downtime Kerusakan Komponen Bearing
Pompa E63-GA2001A........................................................................... 75
3.3 Downtime Kerusakan Komponen Wearing Ring
Pompa E63-GA2001A ........................................................................... 75
3.4 Downtime Kerusakan Komponen Gear Pompa E63-2001A ................ 76
3.5 Downtime Kerusakan Komponen Shaft Pompa E63-2001A ................ 76
3.6 Downtime Kerusakan Komponen Mechanical Seal
Pompa E63-2001A ................................................................................ 76
3.7 Downtime Kerusakan Komponen Gasket Flange
Pompa E63-2001A ................................................................................ 77
3.8 Downtime Kerusakan Komponen Valve Pompa E63-2001A ................ 77
3.9 Downtime Kerusakan Komponen Lube Oil Pompa E63-2001A ........... 77
3.10 Downtime Kerusakan Komponen Rotor Pompa E63-2001A ................ 77
3.11 Persentase Downtime Kerusakan Komponen Pompa E63-2001A ........ 78
3.12 Perhitungan TTR dan TTF Bearing ...................................................... 80
3.13 Perhitungan TTR dan TTF Wearing Ring ............................................. 80
3.14 Perhitungan TTR dan TTF Gear ........................................................... 80
3.15 Output Uji Distribusi TTF Komponen Bearing .................................... 84
3.16 Output Uji Distribusi TTF Komponen Wearing Ring ........................... 86
3.17 Output Uji Distribusi TTF Komponen Gear ......................................... 88
3.18 Output Uji Distribusi TTR Komponen Bearing .................................... 90
3.19 Output Uji Distribusi TTR Komponen Wearing Ring .......................... 92
3.20 Output Uji Distribusi TTR Komponen Gear......................................... 94
3.21 Rekapitulasi Uji Distribusi dan Parameter TTF .................................... 94
3.22 Rekapitulasi Uji Distribusi dan Parameter TTR .................................... 95
3.23 Rekapitulasi Perhitungan MTTF dan MTTR ........................................ 97
3.24 Perhitungan Penentuan Interval Waktu Penggantian
Pompa E63-GA2001A .......................................................................... 98

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 DAFTAR GAMBAR

Gambar Halaman
2.1 Lokasi PT Pupuk Iskandar Muda.............................................................. 8
2.2 Logo PT Pupuk Iskandar Muda ................................................................ 8
2.3 Clarifier .................................................................................................. 22
2.4 Turbin Uap .............................................................................................. 23
2.5 Generator................................................................................................. 25
2.6 Cooling Water......................................................................................... 27
2.7 Ammonia Storage .................................................................................... 31
2.8 Primary Reformer ................................................................................... 34
2.9 Secondary Reformer................................................................................ 35
2.10 CO2 Removal.......................................................................................... 36
2.11 Kompresor............................................................................................... 37
2.12 Prilling Tower ......................................................................................... 41
2.13 Bulk Storage ............................................................................................ 42
2.14 Granule Tower ........................................................................................ 47
2.15 Pelabuhan PT Pupuk Iskandar Muda ...................................................... 49
3.1 Kurva Bathub .......................................................................................... 55
3.2 Pompa Sentrifugal .................................................................................. 60
3.3 Contoh Diagram Pareto........................................................................... 63
3.4 Kurva Distribusi Normal ........................................................................ 65
3.5 Kurva Distribusi Lognormal ................................................................... 65
3.6 Kurva Distribusi Weibull ........................................................................ 66
3.7 Kurva Distribusi Eksponensial ............................................................... 66
3.8 Model Age Replacement ......................................................................... 68
3.9 Kebijakan Penggantian Pencegahan Model Age Replacement ............... 69
3.10 Pompa E63-GA2001A ............................................................................ 71
3.11 Flowchart Metodologi Penelitian ........................................................... 72
3.12 Diagram Pareto Komponen Kritis Pompa E63-GA2001A ..................... 78
3.13 Input Nilai TTF Bearing ......................................................................... 81
3.14 Klik Analyze dan Fit Distribution ........................................................... 81
3.15 Available Data Tabels ............................................................................. 82
3.16 Pemilihan Pola Distribusi Sesuai Kebutuhan ......................................... 82
3.17 Diagram PDF TTF Komponen Bearing Pola Distribusi Normal ........... 83
3.18 Diagram PDF TTF Komponen Bearing Pola Distribusi
Exponential ............................................................................................. 83
3.19 Diagram PDF TTF Komponen Bearing Pola Distribusi
Lognormal ............................................................................................... 83
3.20 Diagram PDF TTF Komponen Bearing Pola Distribusi
Weibull .................................................................................................... 84
3.21 Diagram PDF TTF Komponen Wearing Ring Pola Distribusi
Normal .................................................................................................... 85
3.22 Diagram PDF TTF Komponen Wearing Ring Pola Distribusi
Exponential ............................................................................................. 85
3.23 Diagram PDF TTF Komponen Wearing Ring Pola Distribusi
Lognormal ............................................................................................... 85

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3.24 Diagram PDF TTF Komponen Wearing Ring Pola Distribusi
Weibull .................................................................................................... 86
3.25 Diagram PDF TTF Komponen Gear Pola Distribusi Normal ................ 87
3.26 Diagram PDF TTF Komponen Gear Pola Distribusi Exponential ......... 87
3.27 Diagram PDF TTF Komponen Gear Pola Distribusi Lognormal .......... 87
3.28 Diagram PDF TTF Komponen Gear Pola Distribusi Weibull ................ 88
3.29 Diagram PDF TTR Komponen Bearing Pola Distribusi Normal ........... 89
3.30 Diagram PDF TTR Komponen Bearing Pola Distribusi
Exponential ............................................................................................. 89
3.31 Diagram PDF TTR Komponen Bearing Pola Distribusi
Lognormal ............................................................................................... 89
3.32 Diagram PDF TTR Komponen Bearing Pola Distribusi
Weibull .................................................................................................... 90
3.33 Diagram PDF TTR Komponen Wearing Ring Pola Distribusi
Normal .................................................................................................... 91
3.34 Diagram PDF TTR Komponen Wearing Ring Pola Distribusi
Exponential ............................................................................................. 91
3.35 Diagram PDF TTR Komponen Wearing Ring Pola Distribusi
Lognormal ............................................................................................... 91
3.36 Diagram PDF TTR Komponen Wearing Ring Pola Distribusi
Weibull .................................................................................................... 92
3.37 Diagram PDF TTR Komponen Gear Pola Distribusi Normal................ 93
3.38 Diagram PDF TTR Komponen Gear Pola Distribusi Exponential ........ 93
3.39 Diagram PDF TTR Komponen Gear Pola Distribusi Lognormal .......... 93
3.40 Diagram PDF TTR Komponen Gear Pola Distribusi Weibull ............... 94
3.41 Menu Tools Easyfit 5.6 Professional ...................................................... 96
3.42 Menu Calculations Easyfit 5.6 Professional .......................................... 96
3.43 Input Nilai Parameter .............................................................................. 96
3.44 Hasil Output Perhitungan........................................................................ 97

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 DAFTAR RUMUS

Rumus Halaman
3.1 MTTF Distribusi Weibul ....................................................................... 67
3.2 MTTF Distribusi Exponensial ............................................................... 67
3.3 MTTF Distribusi Normal ...................................................................... 67
3.4 MTTF Distribusi Lognormal ................................................................. 67
3.5 MTTR ................................................................................................... 67
3.6 MTTR Distribusi Weibul ..................................................................... 67
3.7 MTTR Distribusi Exponensial .............................................................. 67
3.8 MTTR Distribusi Normal ...................................................................... 67
3.9 MTTR Distribusi Lognormal ................................................................ 67
3.10 Pembentukan Model Biaya Penggantian Pencegahan........................... 69
3.11 Ekspektasi Biaya Penggantian Per Siklus ............................................. 69
3.12 Ekspektasi Panjang Siklus ..................................................................... 69
3.13 Nilai Interval Rata-rata Terjadinya Kerusakan...................................... 69
3.14 Interval Penggantian Pencegahan Kriteria Meminimalisi Biaya ........... 69
3.15 Fungsi Kepadatan Probabilitas .............................................................. 70
3.16 Fungsi Distribusi Kumulatif .................................................................. 70
3.17 Fungsi Keandalan .................................................................................. 70

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