Optimization of Boiler Feed Pump Maintenance Planning using Reliability-Centered Maintenance:  A Case Study at a Thermal Power Plant in Banten

Arif Budi Sulistyo; Erhan Joemaytanti; Afni Khadijah; Hartadi Wijaya

doi:10.36722/sst.v11i3.6125

Authors

Arif Budi Sulistyo Universitas Banten Jaya
Erhan Joemaytanti Universitas Banten Jaya
Afni Khadijah Universitas Banten Jaya
Hartadi Wijaya Universitas Banten Jaya

DOI:

https://doi.org/10.36722/sst.v11i3.6125

Keywords:

Boiler Feed Pump, Failure Mode and Effect Analysis (FMEA), Preventive Maintenance, Reliability Centered Maintenance, Risk Priority Number

Abstract

The Boiler Feed Pump (BFP) is essential to power generation systems because it supplies high-pressure water to the boiler. BFP failures can cause operational disruptions, efficiency losses, unplanned downtime and substantial financial impacts. This study aims to optimize the maintenance plan for BFP Unit 4B using Reliability-Centered Maintenance (RCM). Historical failure data from July 2024 to June 2025 were evaluated using Failure Mode and Effect Analysis (FMEA). Three maintenance experts assessed the failure modes to identify critical components and calculate Risk Priority Numbers (RPN). Time-to-failure and time-to-repair data were fitted to exponential, Weibull, normal and lognormal distributions. Maintenance parameters were then calculated using the best-fitting distributions. The Motor, Mechanical Seal, Filter Inlet and Coupling recorded the highest average RPN values of 121, 118, 91, and 89, respectively and were prioritized for maintenance. At a reliability threshold of 0.90, the recommended preventive maintenance intervals are 2,138 hours for the Mechanical Seal, 2,137 for the Motor, 2,177 for the Shaft, 1,761 for the Bearing, 2,514 for the Impeller, 2,515 for the Coupling and 2,513 for the Filter Inlet. The proposed RCM-based schedule is recommended to reduce recurring failures, improve reliability, minimize downtime and lower long-term maintenance costs.

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