Analisis Kegagalan Operasi pada Unit UPS sebagai Catu Daya DCS untuk Meningkatkan Keandalan Sistem Kontrol di PT TPPI Tuban

Sistem daya cadangan merupakan bagian penting dalam menjaga
konitnuitas pasokan listrik bagi beban kritis, khususnya pada lingkungan industri yang beroperasi secara kontinu. Sistem ini dirancang untuk menyediakan suplai listrik yang stabil dan tanpa jeda ketika terjadi gangguan pada sumber utama. Sebagai catu daya tanpa jeda bagi sistem DCS, PT TPPI Tuban menggunakan Uninterruptible Power Supply (UPS) tipe online double conversion. Berdasarkan data operasional di lapangan, ditemukan adanya gangguan operasi UPS berupa perpindahan suplai daya dari sumber utama ke sistem bypass atau baterai, yang menyebabkan penurunan tegangan sesaat dan pemadaman sementara pada sistem DCS. Penelitian ini bertujuan untuk menganalisis penyebab kegagalan operasi UPS serta mengevaluasi tingkat keandalannya sebagai catu daya DCS di PT TPPI Tuban.
Metode penelitian dilakukan melalui motode RCA (Root Cause Analysis) berupa pengumpulan data operasional UPS, observasi kondisi kerja pada mode normal dan saat perpindahan sumber daya. Selain itu, dilakukan analisis keandalan menggunakan parameter Mean Time Between Failure (MTBF), Mean Time To Repair (MTTR), dan perhitungan availability.
Hasil penelitian menunjukkan bahwa gangguan pada modul control board dan ketidaksesuaian sinkronisasi bypass merupakan penyebab utama terjadinya kegagalan sementara suplai daya ke sistem DCS. Berdasarkan analisis laju kegagalan menunjukan estimasi 837 kejadian dalam 10.000 jam operasi. Meskipun nilai availability UPS mencapai 98,54% dan tergolong tinggi, namun usia unit yang telah beroperasi lebih dari 20 tahun meningkatkan potensi kegagalan sistem. Oleh karena itu, diperlukan strategi peremajaan melalui retrofit serta peningkatan metode perawatan preventif guna menjaga kontinuitas dan keandalan sistem kontrol industri di PT TPPI Tuban.

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A backup power system is crucialfor maintaining continuous power supplyfor critical loads, particularly in industrial environments that operate continuously. This system is designed to provide a stable and uninterrupted power supply in the event of a disruption to the primary source. PT TPPI Tuban uses an online double-conversion Uninterruptible Power Supply (UPS) as its uninterrupted power supply for the DCS system. Based on operational data in the field, UPS operational disruptions were observed, including switching powerfrom the primary source to the bypass system or batteries, which caused momentary voltage drops and temporary outages in the DCS system. This study aimed to analyze the causes of UPS operational failures and evaluate their reliability as a DCS power supply at PT TPPI Tuban.
The research method used the Root Cause Analysis (RCA) method, which involved collecting UPS operational data and observing operating conditions in normal mode and during power source transitions. Furthermore, a reliability analysis was conducted using Mean Time Between Failure (MTBF), Mean Time to Repair (MTTR), and availability calculations.
The results indicated that disruptions to the control board module and
mismatched bypass synchronization were the primary causes of temporary power failures to the DCS system. The failure rate analysis indicates an estimated 837 incidents in 10,000 hours of operation. Although the UPS's availability rating is 98.54%, which is considered high, the unit's age, which has been in operation for over 20 years, increases the potential for system failure. Therefore, a rejuvenation strategy through retrofitting and improved preventive maintenance methods is needed to maintain the continuity and reliability ofthe industrial control system at PT TPPI Tuban.