Analisis Preventive Maintenance Pada Sistem Perawatan Boiler Water Tube Dengan Metode Failure Mode And Effect Analysis (Fmea) Pt.Pacific Indopalm Industries Dumai

Water Tube Boilers are one of the main pieces of equipment at PT. Pacific Indopalm Industries Dumai, functioning to generate steam as a source of thermal energy and turbine power. Boiler failures can disrupt the production process and increase downtime. This study aims to identify failure modes, determine the level of failure risk, and develop preventive maintenance recommendations for Water Tube Boiler 1 and Water Tube Boiler 2. The methods used in this study were Failure Mode and Effect Analysis (FMEA) to assess risk levels based on Severity, Occurrence, and Detection values, and the Fishbone Diagram to identify the root causes of failures. The data analyzed consisted of boiler failure records from January to December 2024. The results showed that the critical RPN threshold for Boiler 1 was 233.48, with the most critical component being the economizer, which experienced tube leakage failure with an RPN value of 360. For Boiler 2, the critical RPN threshold was 242.63, with the most critical component being the ID Fan, which experienced ID fan blower ducting failure with an RPN value of 450. The main causes of failure included poor feedwater quality, corrosion, scale and ash accumulation, excessive vibration, bearing damage, and material fatigue. Preventive maintenance recommendations focus on periodic inspections, feedwater quality control, component cleaning, vibration monitoring, lubrication, and replacement of worn components. The implementation of these actions is expected to reduce downtime and improve boiler system reliability.