Kajian Dan Modifikasi Disposal Caisson Dengan Metode Root Cause Failure Analysis Dalam Rangka Mengurangi Tingkat Kebocoran (Studi Kasus: PT. Pertamina Hulu Energi – WMO)

Nugraha, Fachri (2019) Kajian Dan Modifikasi Disposal Caisson Dengan Metode Root Cause Failure Analysis Dalam Rangka Mengurangi Tingkat Kebocoran (Studi Kasus: PT. Pertamina Hulu Energi – WMO). Undergraduate thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

PT. Pertamina Hulu Energi – West Madura Offshore (PHE WMO) merupakan perusahaan minyak dan gas bumi nasional dengan lokasi wilayah kerja di sebelah barat lepas pantai Madura. Berdasarkan data laporan kerusakan tahunan 2014-2017, pipa discharge disposal caisson mengalami kebocoran sebanyak 9 kali pada Poleng Process Platform (PPP). Kebocoran yang terjadi dapat menyebabkan terganggunya pemompaan dan dapat mengganggu kinerja operasi dari disposal caisson. Penelitian ini bertujuan untuk mengurangi tingkat kebocoran pipa discharge disposal caisson.
Dalam penelitian tugas akhir ini, penyebab kerusakan dianalisa menggunakan metode Root Cause Failure Analysis (RCFA) untuk menemukan akar permasalahan terjadinya kebocoran pada pipa discharge disposal caisson. RCFA adalah metode untuk menyelesaikan masalah dengan findings, diagnose, analysis, dan recommendation. Data pendukung yang didapatkan dari pihak PT. Pertamina Hulu Energi – WMO berupa gambar kerusakan, histori kerusakan, kondisi aktual operasional, laporan analisis kegagalan, dan tata kerja individu. Dari hasil analisis data yang telah dilakukan, sistem pemompaan disposal caisson yang kurang baik menyebabkan air laut sering terpompa. Air laut yang termasuk elektrolit kuat dan memiliki kandungan bakteri pereduksi sulfat dapat mempercepat laju korosi dari pipa. Dari analisis kegagalan, penyebab kebocoran diakibatkan microbiological induce corrosion yang disebabkan oleh mikroorganisme yaitu bakteri pereduksi sulfat pada area las-lasan. Hal ini diindikasi terdapat molekul surfaktan pada hasil pengamatan menggunakan scanning electron microscopy (SEM) pada titik kebocoran dan kandungan sulfur yang tinggi pada hasil pengamatan energy dispersive x-ray spectroscopy (EDX).
Setelah akar-akar permasalahan ditemukan, kajian menemukan solusi dilakukan untuk menyelasaikan permasalahan tersebut. Beberapa solusi yang ditawarkan adalah penggantian material pipa dengan stainless steel 316, pelapisan phenolic epoxy pada bagian dalam pipa, redesign disposal caisson, dan revisi tata kerja individu. Pipa stainless steel yang memiliki kemampuan tahan korosi, mudah dibentuk, kemampuan untuk dilas yang baik, dan kemampuan self healing dapat mengurangi tingkat kebocoran dibandingkan dengan pipa baja karbon A106. Pelapisan phenolic epoxy pada bagian dalam pipa berfungsi sebagai barrier antara bakteri pereduksi sulfat dengan material pipa yang merupakan baja karbon. Phenolic epoxy merupakan material non metal yang memiliki kemampuan tahan abrasi dan dapat meningkatkan fleksibilitas serta tahan asam pada material yang dilapisi. Redesign yang dilakukan adalah menambahkan instrumen pengukur level interface 2 buah fluida yang dapat membantu operator membaca indikator kapan harus memompa minyak dan kapan harus mematikan pompa. Revisi tata kerja individu yang dilakukan dapat membantu operator melakukan pemompaan minyak pada disposal caisson.
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PT. Pertamina Hulu Energi – West Madura Offshore (PHE WMO) is a national oil and gas company with working area on west coast of Madura. Based on 2014-2017 annual data report, there were 9 times leaks that happened at disposal caisson discharge pipe on Poleng Processing Platform (PPP). Leaks that occur can cause disruption of oil pumping process and performance of operations on disposal caisson system. This study aims to reduce leakage rate of disposal caisson discharge pipe.
On this final project, the causes of damage were analyzed using Root Cause Failure Analysis (RCFA) method to find the root cause of leakage on the disposal caisson discharge pipe. RCFA is a method for solving problems using findings, diagnosis, analysis, and recommendation action. Supporting data obtained from PT. Pertamina Hulu Energi – WMO are damage pipe picture, history data of damage pipe, actual operational conditions, failure analysis report, and individual work procedures. From the results of data analysis that has been done, the weaknesses of disposal caisson pumping system cause seawater pumped. Seawater which is a strong electrolyte and contains sulfate reducing bacteria can accelerate the corrosion rate of the pipe. From failure analysis report, the cause of leakage was happened by microbiological induce corrosion that happened because of sulfate reduce bacteria on the weld area. It was indicated that there were surfactant molecules on the results of observations using Scanning Electron Microscopy (SEM) and high sulfur content on observation of Energy Dispersive X-Ray Spectroscopy (EDX).
After the roots of the problem are found, the study to find the solution was done to solve the problem. Some of the solution offered are replacement of pipe material with stainless steel 316, coating using phenolic epoxy on the inside of the pipe, redesign on disposal caisson, and revision of individual work procedures. Stainlees steel pipe that have the ability to be corrosion resistant, easy to be manufactured, have good weldability, and self healing ability can reduce the leakage rate of the disposal caisson discharge pipe. Phenolic epoxy coating on the inside of the pipe serves as a barrier between sulfate reduce bacteria and pipe material which is carbon steel. Phenolic epoxy is a non ferrous material that have abrasion resistance, high flexibility, and acid resistance on coated material. Redesign on disposal caisson is to add level interface measuring instrument that can help the operators to read the indicator to pump the oil. Revisions to the individual work procedures can help operators to pump the oil on disposal caisson.

Item Type: Thesis (Undergraduate)
Additional Information: RSM 620.72 Nug k-1 2019
Uncontrolled Keywords: Disposal caisson and pump, Root Cause Failure Analysis, Bakteri Pereduksi Sulfat
Subjects: T Technology > TA Engineering (General). Civil engineering (General) > TA347 Finite Element Method
T Technology > TA Engineering (General). Civil engineering (General) > TA418.74 Corrosion and anti-corrosives
T Technology > TA Engineering (General). Civil engineering (General) > TA462 Metal Corrosion and protection against corrosion
T Technology > TA Engineering (General). Civil engineering (General) > TA491 Metal coating.
T Technology > TJ Mechanical engineering and machinery > TJ935 Pipe--Fluid dynamics. Tubes--Fluid dynamics
T Technology > TN Mining engineering. Metallurgy > TN871.3 Offshore well drilling
T Technology > TN Mining engineering. Metallurgy > TN879.5 Petroleum pipelines
Divisions: Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21201-(S1) Undergraduate Thesis
Depositing User: Fachri Nugraha
Date Deposited: 04 Mar 2022 02:55
Last Modified: 04 Mar 2022 02:55
URI: http://repository.its.ac.id/id/eprint/61976

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