Publications

VICO Indonesia, through its 5 big fields, produced natural gas 307 MMSCFD (YTD average) as of Dec 31st, 2014. Gas production is supported by 127 gas compressors including 32 reciprocating compressors. Based on 2014 Compressor Performance Report, four big capacity reciprocating Compressors contributed to almost 35% of flaring amount. Based on it, Maintenance department created some initiatives to improve the reliability of these Compressors. In the end of 2014, RCM Analysis was conducted to review its maintenance strategy. One of the results is to create Operator-Driven Reliability (ODR) Program to optimize operator’s contribution in monitoring compressor condition. This program is then called Total Productive Maintenance (TPM) Program. TPM Program completed existing operator checklist with some additional activities. The activities are focused in monitoring parameter trending, checking gas, lube oil, and coolant leakage, checking damage at exhaust area, reading & checking local parameter, and doing housekeeping. Training program was designed specifically for leveraging operator’s basic knowledge. Beside basic technical knowledge, the program is also completed with basic motivation subject that is very important to increase operator’s awareness and ownership. Besides, the program is also including on-site field practice to monitor the compressor’s performance. Finally, full support from management team is becoming the most important point that make this program run smoothly. This paper will cover brief process and result of RCM Analysis for ATGL C-5740 unit, which produces TPM Checklist that will be used by the operator. After that, this paper will also describe the socialization and knowledge leverage program in the beginning of implementation phase. Furthermore, there are some living programs to make it sustainable during implementation phase. Monthly evaluation is also conducted to make sure the effectiveness of the program. Lastly, rewards program is also designed to make it more interesting to the operator.