Analisa Kekritisan Peralatan Utama Pabrik Semen Menggunakan Metode Risk Based Inspection (RBI) di PT XYZ

Wardoyo, Qunto Tri (2023) Analisa Kekritisan Peralatan Utama Pabrik Semen Menggunakan Metode Risk Based Inspection (RBI) di PT XYZ. Masters thesis, Institut Teknologi Sepuluh November.

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Abstract

Penjualan semen nasional saat ini mengalami tren terus menurun terutama saat covid19 serta tidak seimbang antara supply, demand, utilisasi semen. Untuk memenangkan persaingan maka dibutuhkan performance plant yang baik dengan biaya produksi optimal dimana indikator performance plant diwakili oleh sistem kiln, termasuk kiln inlet. Dalam pengelolaan pemeliharaan kiln inlet, belum ada matrik tingkat risiko. Matrik tingkat risiko diperlukan mengingat peralatan bekerja dengan kondisi operasi yang berpotensi menimbulkan bahaya. Pencegahan bahaya dapat dilakukan dengan pemeliharaan preventive berupa inspeksi. Inspeksi yang terukur dan terstruktur terdapat di metode Risk Based Inspection (RBI). Penelitian ini diperlukan untuk menyusun matrik tingkat risiko dari peralatan kiln inlet tersebut. Dengan metode Risk Based Inspection (RBI) mengacu pada API 581. Metode RBI memperhitungkan dan menganalisa kemungkinan kerusakan /Probability of Failure (PoF), dan konsekuensi kerusakan /Consequence of Failure (CoF), menentukan tingkat risiko dari peralatan kiln inlet berdasarkan nilai PoF dan CoF yang dituangkan ke dalam matrik risiko, merencanakan program inspeksi dan interval inspeksi berdasarkan tingkat risiko. Hasil dari analisis dan perhitungan nilai frekuensi kegagalan umum, faktor kerusakan, faktor sistim manajemen didapatkan probabilitas kegagalan 0,00002842 kegagalan/tahun maka sesuai matrik tingkat risiko API 581 berada pada kategori 1. Kategori 1 menjelaskan bahwa peralatan mempunyai nilai faktor kerusakan kurang dari 2. Hasil dari perhitungan area akibat konsekuensi kegagalan sebesar 19.568,14 ft2 serta potensi kerugian produksi sebesar Rp.127 miliar dimana API 581 memberikan kategori E. Kategori E yaitu jika area kegagalan lebih dari 10.000 ft2 dan atau kerugian secara keuangan lebih dari $.10.000.000. Pengelompokan kategori ini diperlukan untuk menentukan tingkat risiko. Berdasarkan kategori tersebut maka tingkat risiko alat ini berada pada tingkat medium-high. Hasil dari pengukuruan corrosion rate 0,11335 inch/tahun dan berdasarkan efektifitas inspeksi dan jumlah inspeksi yang telah dilakukan didapatkan bahwa kategori efektifitas inspeksinya adalah usually effective sehingga metode pemeriksaan peralatan kiln inlet yang optimal sesuai API 581 adalah pemeriksaan berupa visual examination dan ultrasonic thickness measurement yang dapat dilakukan saat overhaul dengan interval pemeriksaan setiap 1 tahun. Metode ini dipilih karena paling efisien, cepat mendapatkan hasil serta biaya yang relative murah.
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Cement sales in Indonesia are currently experiencing a continuing downward trend, especially during the COVID-19 pandemic, and there is an imbalance between supply, demand, and cement utilization. To win the competition, a plant with good performance and optimal production costs is needed, where the performance indicator is represented by the kiln system, including the kiln inlet. In maintenance management of kiln inlet, currently no risk level matrix. A risk level matrix is necessary considering that the equipment operates under potentially hazardous operating conditions. Hazard prevention can be done through preventive maintenance, including inspections. Measurable and structured inspections are found in the Risk Based Inspection (RBI) method. This research is needed to develop a risk level matrix for the kiln inlet equipment. Using the Risk Based Inspection (RBI) method, referring to API 581, the RBI method analyzes the probability of failure (PoF) and the consequence of failure (CoF), determining the risk level of the kiln inlet equipment based on the values of PoF and CoF, which are then incorporated into the risk matrix. Inspection programs and intervals can be planned based on the risk level. The results of the analysis and calculations a general failure frequency, damage factor, and a management system factor obtained a failure probability of 0.00002842 failures/year. According to the API 581 risk level matrix, this falls into category 1. Category 1 indicates that the equipment has a damage factor less than 2. The result of the calculation of the area due to failure consequences is 19,568.14 ft2 and the potential loss of production is Rp.127 billion where API 581 gives category E. Category E indicates that the failure area is greater than 10,000 ft2 and/or the financial loss exceeds $10,000,000. This categorization is necessary to determine the level of risk. Based on these categories, the risk level of this equipment is classified as medium-high. The measured corrosion rate is 0.11335 inches/year, and based on the effectiveness of inspections and the number of inspections conducted, the effectiveness category of the inspections is usually effective. Therefore, the optimal inspection method for the kiln inlet equipment, according to API 581, is visual examination and ultrasonic thickness measurement, which can be performed during overhauls with an inspection interval of every 1 year. This method is chosen because it is the most efficient, provides quick results, and is relatively inexpensive.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Kiln inlet, Risk Based Inspection (RBI), Probability of Failure (PoF), Consequence of Failure (CoF), API 581, Risk Matrix.
Subjects:	T Technology > T Technology (General) > T174.5 Technology--Risk assessment.
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Qunto Tri Wardoyo
Date Deposited:	18 Jul 2023 08:03
Last Modified:	18 Jul 2023 08:03
URI:	http://repository.its.ac.id/id/eprint/98580

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