Baihaqie, Muhammad Zulizar (2026) HAZOP Studi Dan Penentuan Safety Integrity Level (SIL) - Layer Of Protection Analysis (LOPA) Pada Pabrik Urea Unit 1A di PT Petrokimia Gresik. Masters thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Keselamatan proses pada pabrik urea memerlukan evaluasi berkala karena penggunaan amonia, karbon dioksida, serta kondisi operasi bertekanan dan bertemperatur tinggi dapat menimbulkan konsekuensi serius apabila sistem proteksi gagal. Penelitian ini bertujuan mengidentifikasi dan mengevaluasi bahaya proses, menentukan kebutuhan Safety Integrity Level (SIL), serta memverifikasi kinerja Safety Instrumented Function (SIF) pada Pabrik Urea 1A PT Petrokimia Gresik. Penelitian dilakukan melalui studi Hazard and Operability Study (HAZOP) pada 18 node proses, kemudian dilanjutkan dengan Layer of Protection Analysis (LOPA) terhadap lima skenario kritis. Nilai initiating event likelihood ditentukan berdasarkan data reliabilitas dan maintenance history peralatan melalui Mean Time Between Failures (MTBF), failure rate, serta time at risk. Untuk skenario dengan severity level 4 digunakan Target Mitigated Event Likelihood (TMEL) sebesar 1×10⁻⁵ per tahun. Hasil LOPA menunjukkan bahwa sebelum rekomendasi terdapat tiga skenario yang membutuhkan SIL 3, satu skenario SIL 2, dan satu skenario tidak memerlukan SIL tambahan. Setelah penambahan alarm independen dan SIF minimum SIL 2, seluruh skenario memenuhi target risiko. Empat SIF hasil rekomendasi menghasilkan PFDavg sebesar 4,39×10⁻³ dan RRF sebesar 227,64, sehingga memenuhi target SIL 2 berdasarkan PFDavg. Analisis menunjukkan bahwa final element menjadi kontributor terbesar terhadap PFDavg total. Integrasi HAZOP, LOPA, dan verifikasi SIL memberikan dasar yang lebih terukur untuk mengevaluasi kecukupan lapisan proteksi dan menentukan kebutuhan sistem keselamatan.
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Process safety in urea plants requires periodic evaluation because the use of ammonia, carbon dioxide, and operating conditions involving high pressure and high temperature may lead to serious consequences if the protection system fails. This study aims to identify and evaluate process hazards, determine the required Safety Integrity Level (SIL), and verify the performance of Safety Instrumented Functions (SIFs) at Urea Plant 1A of PT Petrokimia Gresik. The study was conducted through a revalidation of Hazard and Operability Study (HAZOP) on 18 process nodes, followed by Layer of Protection Analysis (LOPA) for five critical scenarios. The initiating event likelihood was determined based on reliability data and equipment maintenance history using Mean Time Between Failures (MTBF), failure rate, and time at risk. For scenarios with severity level 4, the Target Mitigated Event Likelihood (TMEL) used was 1×10⁻⁵ per year. The LOPA results show that, before recommendations, three scenarios required SIL 3, one scenario required SIL 2, and one scenario required no additional SIL. After the addition of independent alarms and minimum SIL 2 SIFs, all scenarios met the risk target. The four recommended SIFs produced a PFDavg of 4.39×10⁻³ and an RRF of 227.64, thereby meeting the SIL 2 target based on PFDavg. The analysis shows that the final element was the largest contributor to the total PFDavg. The integration of HAZOP, LOPA, and SIL verification provides a more measurable basis for evaluating the adequacy of protection layers and determining the required safety system.
| Item Type: | Thesis (Masters) |
|---|---|
| Uncontrolled Keywords: | HAZOP, LOPA, SIL, SIF, PFDavg, MTBF |
| Subjects: | T Technology > T Technology (General) > T174.5 Technology--Risk assessment. T Technology > T Technology (General) > T55 Industrial Safety |
| Divisions: | Faculty of Industrial Technology and Systems Engineering (INDSYS) > Physics Engineering > 30101-(S2) Master Thesis |
| Depositing User: | Muhammad Zulizar Baihaqie |
| Date Deposited: | 06 Aug 2026 05:11 |
| Last Modified: | 06 Aug 2026 05:11 |
| URI: | http://repository.its.ac.id/id/eprint/143277 |
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