Zahra, Siti Nafira (2025) Analisis Risk Based Inspection (RBI) Pada Waste Heat Boiler (WHB) Menggunakan Standar API 581 Dan Standar ASME PCC-3 Sebagai Data Support Penentuan Damage Mechanism. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Amonia merupakan bahan dasar yang digunakan pada berbagai kalangan industri khususnya pada pabrik pupuk, amonia dibutuhkan dengan skala besar untuk memenuhi kebutuhan pupuk nitrogen yang terus meningkat setiap tahunnya. Pabrik amonia memiliki komponen untuk mendukung keberjalannya produksi, salah satunya yaitu waste heat boiler. Waste heat boiler (WHB) merupakan boiler dengan jenis fire tube boiler, WHB merupakan ketel uap panas yang digunakan untuk menurunkan temperatur gas buang hasil pembakaran dari komponen sebelumnya yakni secondary reformer yang masuk kedalam tube pada WHB.Untuk memastikan bahwa equipment beroperasi sesuai dengan standar, maka diperlukan suatu inspeksi dengan metode Risk based inspection (RBI). Inspeksi dengan metode RBI ini diperlukan untuk mengetahui probabilitas dan konsekuensi kegagalan pada waste heat boiler. Standar yang digunakan dalam melakukan perhitungan RBI adalah API 581, Sedangkan untuk penentuan damage mechanism sebelum dilakukannya RBI akan ditentukan dengan metode screening menggunakan standar ASME PCC-3 yang dikorelasikan kembali dengan API 571 tentang damage mechanism. Untuk menentukan probability of failure, perhitungan akan dilakukan pada bagian shell dan tube secara terpisah dikarenakan sifatnya yang berbeda. Perhitungan pada shell akan dilakukan dengan perhitungan damage factor thinning. Sedangkan pada tube, akan dilakukan perhitungan spesifik dengan metode weibull untuk tubebundle, perhitungan damage factor Thinning dan High temperature hydrogen attack (HTHA). Untuk hasil perhitungan PoF shell terhadap thinning yakni sebesar 0,00000306. Sedangkan hasil perhitungan tube menggunakan metode weibull yakni sebesar 0,853399009. Selanjutnya, untuk perhitungan damage HTHA pada sisi tube didapat nilai sebesar 0,0612. Dengan hasil perhitungan PoF, Sisi shell dikategorikan 1 dan sisi tube 5. Selanjutnya untuk perhitungan consequence of failure, perhitungan akan ditentukan dari fluida representatif yakni water pada sisi shell, hidrogen dan karbonmonoksida pada sisi tube. Didapatkan nilai akhir pada CoF Shell yakni 6.100 m2 pada area konsekuensi cedera personal dan dikategorikan sebagai medium risk, Sedangkan nilai akhir pada CoF Tube yakni 59.500 m2 terhadap area konsekuensi cedera dan dikategorikan sebagai high risk.
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Ammonia is a basic raw material used across various industrial sectors, particularly in fertilizer plants. It is required on a large scale to meet the increasing annual demand for nitrogen-based fertilizers. An ammonia plant consists of several components to support the production process, one of which is the waste heat boiler (WHB). The Waste heat boiler (WHB) is a type of fire tube boiler. It functions as a heat recovery steam generator used to reduce the temperature of exhaust gas resulting from the combustion process in the previous component, namely the secondary reformer, which flows into the tubes of the WHB. To ensure that the equipment operates in accordance with standards, an inspection using the Risk-Based Inspection (RBI) method is necessary. RBI inspection is conducted to determine the probability and consequence of failure in the waste heat boiler. The standard used for RBI calculation is API 581, while the identification of damage mechanisms prior to conducting RBI is determined through a screening method using the ASME PCC-3 standard, which is further correlated with API 571 regarding damage mechanisms. To determine the probability of failure, calculations are performed separately on the shell and tube sections due to their differing characteristics. The shell is evaluated using a damage factor calculation for thinning. For the tube, specific calculations are carried out using the Weibull method for the tube bundle, including damage factor calculations for thinning and High temperature hydrogen attack (HTHA). The result of the PoF (Probability of failure) calculation on the shell due to thinning is 0.00000306. Meanwhile, the result of the Weibull method calculation on the tube is 0.853399009. For the HTHA damage calculation on the tube side, the resulting value is 0.0612. Based on these PoF results, the shell is categorized as level 1, while the tube is categorized as level 5. Next, for the calculation of the consequence of failure (CoF), the assessment is based on representative fluids, namely water on the shell side, and hydrogen and carbon monoxide on the tube side. The final CoF value for the shell is 6,100 m² in the area of personal injury consequence and is categorized as medium risk, while the final CoF value for the tube is 59,500 m² in the personal injury consequence area and is categorized as high risk.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | Damage Mechanism, Damage Factor, Risk based inspection ,Waste heat boiler, API 581, ASME PCC-3 |
| Subjects: | T Technology > TJ Mechanical engineering and machinery T Technology > TJ Mechanical engineering and machinery > TJ263 Heat exchangers T Technology > TJ Mechanical engineering and machinery > TJ263.5 Boilers (general) |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis |
| Depositing User: | Siti Nafira Zahra |
| Date Deposited: | 28 Jul 2025 10:02 |
| Last Modified: | 28 Jul 2025 10:02 |
| URI: | http://repository.its.ac.id/id/eprint/122310 |
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