Perpustakaan Digital ITB

The oil and gas industry demands high standards of reliability and safety, especially in aging upstream facilities where equipment degradation and operational risk pose growing challenges. This study presents the development of risk-based maintenance strategies for upstream oil and gas assets using the Risk Based Reliability-Centered Maintenance (RCM 3) methodology, guided by the principles of the Asset Integrity Management System (AIMS). The research was conducted on 33 critical rotating equipment units distributed across five key facilities in ABC Field. The study began by identifying critical equipment using an Equipment Criticality Assessment (ECA) followed by Pareto analysis based on real historical failure data. The RCM 3 methodology was then applied to each critical unit, including functional decomposition, failure mode identification (using OREDA 2015), failure effect analysis at four levels, and quantitative risk assessment through a hybrid matrix adapted from API 581 and the RCM 3 framework. Maintenance task selection and justification followed the RCM 3 Decision Diagram, ensuring that each proposed strategy effectively addressed risk and performance goals. The results showed that significant inherent risks, particularly in high-impact systems such as the 1st Stage Gas Compressor (K-01), could be reduced to tolerable levels by implementing a combination of scheduled discard, restoration, on-condition, and failure finding maintenance tasks. For the K-01 system, the estimated average annual maintenance cost across the 10-year projection was USD 7,930. For the entire set of 33 critical equipment across the ABC Field, the total annual maintenance cost was estimated to range from USD 595,955 to USD 801,288 over the 10 years projection. These findings confirm that the RCM 3 approach in this study offers a structured and scalable model for optimizing maintenance in aging upstream facilities.