Audit Plant Pupuk Indonesia

Brief : In 2025, PT Pupuk Indonesia as a leading petrochemical and fertilizer company, with core products including ammonia, urea, and NPK fertilizers. This company operates an extensivenetwork of plants across Indonesia, such as PT Petrokimia Gresik, PT Pupuk Kujang Cikampek, PT Pupuk Kalimantan Timur, PT Pupuk Sriwidjaja, and PT Pupuk Iskandar Muda

Objective : Conducting consultancy services focused on th identification of bottlenecks and the optimization of plant performance, utilizing effective, measurable, and sustainable solutions, in collaboration with competent and experienced experts in the field.

Solution :

• Conducted plant audits at 4 ammonia & urea plants, as well 3 NPK plants with 7 months duration.
• The audit scope covered process, mechanical static & rotating, instrumentation, and electrical.
• The audit identified that the implementation of the proposed quick win initiatives based on Reliability-Centered Maintenance (RCM) NPK plant is expected to yield potential additional revenue of approximately USD 57 million per year.
• Recurring issues were identified in the dedusting system of the NPK production line. A design modification was proposed, including rerouting the line to a vertical configuration, taking branches directly from the header, and optimizing the placement of the hot air suction point.
• A potential heat loss to the environment from the stack of approximately 220 MMBTU/day was identified, with an estimated annual loss of around USD 8.32 million.