Noriyati, Ronny Dwi (2018) Kombinasi Metode Layer Of Protection Analysis Dan Fault Tree Analysis Berbasis Model Dinamika Proses Plant : Studi Kasus Pada Proses Steam Drum Boiler. Doctoral thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Banyak kejadian fatal di dunia industri disebabkan karena “Boiler explosion”.
Potensi kejadian seperti ini masih sering terjadi hingga saat ini. Dampak dari kejadian
tersebut akan sangat merugikan bagi industri itu sendiri, termasuk manusia, aset, dan
lingkungan sekitarnya. Apabila kejadian itu terjadi maka diperlukan waktu cukup lama
untuk bisa beroperasi kembali dan diperlukan biaya yang sangat besar.
Dalam disertasi ini diusulkan metode baru yang merupakan kombinasi dari dua
metode, yaitu Layer of Protection Analysis (LOPA) dan Fault Tree Analysis (FTA)
untuk menganalisis tingkat keandalan pada pengendalian proses Steam Drum Boiler,
agar kriteria keandalan pada produksi saturated steam tetap bisa terjaga kualitasnya
dengan berbasis pada model dinamika proses.
Dengan studi kasus pada Steam Drum Boiler, dimana steam yang dihasilkan
dengan laju aliran 95,2 m3/h, pressure 36,5 kg/cm2, dan temperature 405oC, Steam
yang dihasilkan adalah High Pressure Steam dan Low Pressure Steam. Untuk High
Pressure Steam dengan tekanan 35 kg/cm2 dan temperatur 400oC digunakan sebagai
penggerak turbin TP-6101 (8,5MW-5KV) dan TP-6102 (11,5 MV-5KV).
Sedangkan Low Pressure Steam, dengan pressure 10 kg/cm2 temperature
270oC , steam ini untuk keperluan Sulfuric Acid Plant digunakan pada steam heater
untuk pencairan belerang dan steam jacket. Phosphoric Acid Plant Steam digunakan
untuk steam heater, steam ejector dan evaporator. Kemudian steam juga digunakan
pada Cement Retarder Plant untuk membantu proses filter purified gypsum dan
granulator Cement Retarder, Alluminium Fluoride Plant steam digunakan untuk
crystallizer dan washing cloth centrifuge SiO2, dan unit Ammonium Sulfide Plant Steam
digunakan untuk steam heater, steam ejector, dan evaporator di Pabrik III PT
Petrokimia Gresik. Sehingga, keberadaan Steam Drum Boiler B-6203 sangat vital dan
memerlukan sistem proteksi yang sangat dapat diandalkan, atau highly reliable.
Dengan demikian, untuk menganalisis kegagalan kualitas saturated steam yang
diproduksi oleh Steam Drum Boiler tidak cukup hanya dilakukan melalui analisis layer protection pada input, proses dan output Steam Drum Boiler. Namun, harus dilakukan
juga melalui analisis pada proses dinamika Steam Drum Boiler, dengan kombinasi
metode LOPA dan FTA.
Pada pembahasan ini LOPA digunakan untuk menganalisis pada protection
layer input Steam Drum Boiler, protection layer pada proses Steam Drum Boiler, dan
potection layer pada output Steam Drum Boiler. Dengan menggunakan HAZOP dan
P&ID akan didapatkan protection layer yang harus ditingkatkan.
Selanjutnya dilakukan Root Cause Analysis melalui analisis terhadap variabel
proses Steam Drum Boiler dengan menggunakan metode FTA. Metode FTA yang
digunakan pada disertasi ini adalah berbasis model dinamika proses menggunakan
persamaan kesetimbangan massa dan kesetimbangan energi pada root causenya.
Faktor yang paling berpengaruh terhadap kesetimbangan massa dan kesetimbangan
energi ditinjau dari root cause nya adalah laju aliran masuk Steam Drum Boiler (Mass
Boiler Feed Water flow rate kg/s) dan laju aliran keluar Steam Drum Boiler (Mass
Steam flow rate), pressure dan temperature Steam Drum Boiler. Faktor yang
berpengaruh terhadap kesetimbangan massa dan energy tersebut dibuat pemodelan
dinamik proses Steam Drum Boiler yang hasil simulasinya dapat merepresentasikan
berbagai macam respon dinamik.
Dengan kombinasi metode Layer of Protection Analysis (LOPA) dan metode
Fault Tree Analysis (FTA) diperoleh hasil bahwa variabel proses yang berpotensi
terjadi kegagalan fatality pada Steam Drum Boiler adalah pressure PI 6220. Diperlukan
peningkatan sistem proteksi dari layer 2 ke tingkat yang lebih tinggi dengan voting
system. emergency shutdown, dan meningkatkan dari fungsi indikasi menjadi fungsi
kontrol dengan PIC- 6220 (Pressure Indicator Control) 35 - 45 bar pada proses Steam
Drum Boiler. Dan pada saat terjadi perubahan (gangguan) secara bersamaan proses
operasi Steam Drum Boiler tetap berjalan pada kondisi normal operasi tanpa harus
melakukan Emergency Shut Down . Dengan ketentuan dari hasil simulasi pada kondisi
kritis Steam Drum Boiler diperoleh batasan untuk tekanan pada Steam Drum Boiler 35
- 45 bar, level pada Steam Drum Boiler 0,501 - 0,576 m, Mass Boiler feed water
flowrate 14 - 18 kg/s dan mass steam flowrate 10 - 14 kg/s. Sehingga pada kondisi ini
5 Unit produksi yaitu Sulfuric Acid Plant, Phosphoric Acid Plant, Ammonium Sulfide
Plant, Cement Retarder Plant dan Alluminium Fluoride Plant dapat dipertahankan
tetap beroperasi dengan baik dan tidak perlu harus melakukan Emergency Shut Down
untuk mematikan seluruh Unit Produksi yang ada. Dengan demikian, untuk menjaga
performance perusahaan pada kondisi yang diharapkan masih bisa dicapai.
============================================================Most of the fatal accident in industry are caused by boiler explosion. This kind
of potential accident. The impact of the accident can give disadvantageous impact for
the industry, which includes the human and environment surrounding. If the accident
happens, the recovery time needed to make it able to be operated is quite long and also
costly.
This dissertation proposes combination between two methods, which are Layer
of Protection Analysis (LOPA) and Fault Tree Analysis (FTA) to analyse level of
reliability in process control of Steam Drum Boiler, so that the quality of reliability
criteria in saturated steam production can be maintained with the basis of dynamic
process model.
The case study is taken on steam drum boiler, in which the steam is produced
with the flow rate of 95.2 m3/h, pressure of 36.5 kg/cm2, and temperature of 405oC.
While the high pressure steam with the pressure of 35 kg/cm2 and temperature of
400oC, is used as turbine driver of TP-6101 (8,5MW-5KV) and TP-6102 (11,5 MV-
5KV).
While for low pressure steam, with the pressure of 10 kg/cm2 and temperature
of 270oC, is used in steam heater of Sulfuric Acid Plant for sulfur and steam jacket
melting. Phosphoric Acid Plant Steam is used for steam heater, steam ejector, and
evaporator. Steam is also used in Cement Retarder Plant for helping the process of filter
purified gypsum and granulator cement retarder. Aluminium Fluoride Plant steam is
used for crystallizer and washing cloth centrifuge SiO2. Ammonium Sulfide Plant
Steam unit is used for steam heater, steam ejector, and evaporator in Plant III of PT.
Petrokimia Gresik. Therefore, the existence of Steam Drum Boiler B-6203 is very vital
and needs reliable or highly reliable protection system.
Therefore, analyzing the failure in the quality of saturated steam produced by
Steam Drum Boiler cannot only be done by analyzing the function of protection layer in input, process, and output of Steam Drum Boiler. Meanwhile, the analysis also has
to be done in dynamic process of Steam Drum Boiler with the combination of LOPA
and FTA method.
In this study, LOPA method is used for analyzing the protection analysis in
input, process, and output of Steam Drum Boiler. By using HAZOP and P&ID, later it
will obtain the protection layer that has to be improved
After that, Root Cause Analysis is done by analyzing process variable of Steam
Drum Boiler by using FTA method. FTA method used in this study is based on dynamic
process model using equation of mass and energy balance in the root cause. The most
impactful factor to the mass and energy balance according to the root cause is inflow
rate of Steam Drum Boiler (Mass Boiler Feed Water flow rate kg/s) and outflow rate
of Steam Drum Boiler (Mass Steam flow rate), pressure, and temperature of Steam
Drum Boiler. These impactful factors are made in dynamic process model of Steam
Drum Boiler, in which the result can represent various dynamic responses.
By combining method of Layer of Protection Analysis (LOPA) and Fault Tree
Analysis (FTA), it obtained result that process variable that is potentially has fatality
of failure in Steam Drum Boiler is pressure PI 6220. An increase in protection system
from layer 2 to higher level by voting system and emergency shutdown is needed,
which can increase from indication function becomes control function with PIC-6220
(Pressure Indicator Control) 35 – 45 bar in Steam Drum Boiler process. When a change
(disturbance) occurred at the same time, operation process of Steam Drum Boiler keeps
working in normal operation condition without need to do Emergency Shut Down.
With the condition obtained from simulation result in critical condition of Steam Drum
Boiler, it obtained boundaries in pressure of 35 – 45 bar, level of 0.501 – 0.576 m, Mass
Boiler feed water flow rate of 14 – 18 kg/s, and mass steam flow rate of 10 – 14 kg/s.
Thus, in this condition, 5 production units which are Sulfuric Acid Plant, Phosphoric
Acid Plant, Ammonium Sulfide Plant, Cement Retarder Plant, and Aluminium Fluoride
Plant can be maintained to keep operating in a good condition and does not need
Emergency Shut Down to turn off all the production units. Therefore, it can maintain
the quality of company performance to be in the desired condition.
| Item Type: | Thesis (Doctoral) |
|---|---|
| Uncontrolled Keywords: | LOPA, FTA, HAZOP, Steam Drum Boiler, Dinamika Proses, Protection Layer, Root Cause, LOPA, FTA, HAZOP, Steam Drum Boiler, Dynamic Process, Protection Layer, Root Cause |
| Subjects: | T Technology > T Technology (General) > T55 Industrial Safety |
| Divisions: | Faculty of Electrical Technology > Electrical Engineering > 20001-(S3) PhD Thesis |
| Depositing User: | ansi aflacha |
| Date Deposited: | 27 Nov 2018 08:51 |
| Last Modified: | 27 Nov 2018 08:51 |
| URI: | http://repository.its.ac.id/id/eprint/60026 |
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