Studi Mekanisme Kerusakan Risk-Based Inspection (RBI) API 581 yang Dikustomisasi Failure Mode Effect Analysis (FMEA) Pada Urea Synthesis Unit

Darmawan, Muhammad Rifqi (2024) Studi Mekanisme Kerusakan Risk-Based Inspection (RBI) API 581 yang Dikustomisasi Failure Mode Effect Analysis (FMEA) Pada Urea Synthesis Unit. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

RBI (Risk-Based Inspection) adalah suatu metode yang dapat membantu dalam merancang program inspeksi untuk menentukan kapan dan bagaimana suatu peralatan diinspeksi berdasarkan tingkat resikonya. Metode Risk-Based Inspection pada penelitian ini diaplikasikan pada peralatan statis yang terdapat pada unit synthesis urea. Peralatan yang terdapat pada unit synthesis urea terdiri dari Reactor (DC101), Stripper (DA101), Carbamate Condenser (EA101). Pada penelitian ini dilakukan analisa Probability of Failure (POF), Consequence of Failure (COF) berdasarkan API 581 dan Risk Priority Number (RPN) sehingga nantinya didapatkan level resiko pada peralatan yang ada di unit synthesis urea dan Risk Priority Number (RPN) yang mengacu pada lembar kerja FMEA. Adapun langkah-langkah dalam analisis ini yaitu mengumpulkan data dan informasi yang diperlukan untuk analisis RBI, selanjutinya dilakukan perhitungan kemungkinan kegagalan dan konsekuensi kegagalan untuk mendapatkan nilai resiko. Melalui nilai ini, dapat diketahui level resiko dari komponen akan berada pada level resiko low, medium, medium-high, atau high. Selanjutnya adapun langkah-langkah juga untuk melakukan analisa FMEA yaitu dengan cara mengumpulkan data berdasarkan data historis dan melakukan wawancara dengan engineer secara langsung. Kemudian melakukan penilaian pada nilai severity dan occurrence dalam skala 1-5. Kemudian dilakukan perkalian antara nilai severity dan occurrence untuk mendapatkan Risk Priority Number (RPN). Berdasarkan penentuan tingkat resiko tahun 2024, tingkat resiko medium terdapat pada semua peralatan yaitu shellside stripper, shellside, top head, bottom head reactor, dan shellside carbamate condenser. Pada tahun 2024 berdasarkan penelitian yang telah dilakukan, tingkat level resiko yang didapat pada semua peralatan memiliki tingkat resiko medium yang merupakan tidak melebihi tingkat risk target yang telah ditentukan oleh perusahaan. Namun disarankan tetap dilakukan inspeksi pada saat plan date yaitu 31 Mei 2034 dengan metode inspeksi visual testing, ultrasonic testing, radiography testing, pit gauged. Berdasarkan data historis dan wawancara secara langsung oleh engineer, nilai risk priority number (RPN) yang didapat pada stripper sebesar 3, sedangkan pada reactor nilai RPN yang didapat sebesar 4, dan pada carbamate condenser nilai RPN yang didapat sebesar 6 yang merupakan nilai RPN terbesar. Berdasarkan perhitungan remaining life (RL) terdapat 4 peralatan yang memiliki sisa usia peralatan lebih dari 100 tahun dan 1 peralatan memiliki sisa usia perlatan 99 tahun.

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RBI (Risk-Based Inspection) is a method that can help in designing an inspection program to determine when and how a device is inspected based on the level of risk. The Risk-Based Inspection method in this study was applied to the static equipment found in the urea synthesis unit. The equipment in the urea synthesis unit consists of a reactor (DC101), a stripper (DA101), and a carbamate condenser. (EA101). The study conducted Probability of Failure (POF), Consequence of failure (COF) analysis based on API 581 and Risk Priority Number (RPN) in order to obtain the risk level on the equipment present in the urea synthesis unit and risk priority number (R PN) referring to the FMEA work sheet. As for the steps in this analysis, which is to gather the data and information necessary for the RBI analysis, then calculate the possible failure and the consequences of failure to obtain a risk value. Through these values, it is known that the risk level of the component will be at a low, medium, medium-high, or high risk level. The next step is to conduct FMEA analysis by collecting data based on historical data and conducting interviews with engineers in person. Then make an assessment on the severity and occurrence values on a scale of 1-5. Then multiply between severity and occurrence to get a Risk Priority Number (RPN). Based on the risk level determination by 2024, the medium risk level exists for all equipment: shellside stripers, shellsides, top head, bottom head reactors, and shellsid carbamate condensers. By 2024, based on research that has been carried out, the risk level attained on all equipment has a medium risk level that does not exceed the target risk level set by the company. However, it is recommended that inspections be carried out at the planned date of 31 May 2034 using visual inspection testing, ultrasonic testing, radiography testing, pit gauged. Based on historical data and direct interviews by engineers, the risk priority number (RPN) of the stripper was 3, while the RPN of the reactor was 4, and of the carbamate condenser RPN was 6 which was the highest RPN value. Based on the remaining life (RL) calculation, there are four devices that have a remaining lifespan of more than 100 years and one device has a resting life of 99 years.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Consequence of Failure, Probability of Failure, Risk, RBI, FMEA, Consequence of Failure, Probability of Failure, Risiko, RBI, FMEA
Subjects:	T Technology > T Technology (General) > T174.5 Technology--Risk assessment.
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis
Depositing User:	Muhammad Rifqi Darmawan
Date Deposited:	07 Aug 2024 08:13
Last Modified:	07 Aug 2024 08:13
URI:	http://repository.its.ac.id/id/eprint/112623

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