Analisis Fitness-for-Service dan Remaining Life Assessment pada Pressure Vessel Unit Sintesis Urea Berdasarkan API 579-1/ASME FFS-1

Kinanti, Sang Tembang (2025) Analisis Fitness-for-Service dan Remaining Life Assessment pada Pressure Vessel Unit Sintesis Urea Berdasarkan API 579-1/ASME FFS-1. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Terdapat tiga pressure vessel utama dalam unit sintesis urea, yaitu Reactor, Stripper, dan Vertical Submerged Carbamate Condenser (VSCC). Berdasarkan hasil inspeksi ketebalan dengan menggunakan ultrasonic thickness testing, diketahui terjadi penurunan ketebalan dari ketebalan awalnya. Oleh karena itu, diperlukan evaluasi terhadap kondisi peralatan untuk memastikan keandalan dan keamanannya. Salah satu metode evaluasi yang dapat digunakan adalah Fitness for Service (FFS) sesuai dengan standar API 579-1/ASME FFS-1. Penelitian ini berfokus pada penilaian bagian shell dari tiga pressure vessel dalam unit sintesis urea menggunakan Part 4 – General Metal Loss dari dokumen API 579-1/ASME FFS-1 yang bertujuan untuk menganalisis kelayakan operasi dan menentukan estimasi sisa umur pakai peralatan. Hasil analisis menunjukkan bahwa ketiga peralatan dinyatakan masih layak untuk dioperasikan dalam kondisi saat ini tanpa memerlukan adanya remediasi tertentu. Hasil evaluasi menunjukkan sisa umur peralatan pada bagian lining plate yaitu: Reactor sekitar 20 tahun, Stripper 29 tahun, dan VSCC 84 tahun. Berdasarkan sisa umur peralatan, interval inspeksi internal dan on-stream untuk ketiga peralatan adalah setiap 10 tahun. Sedangkan, interval inspeksi eksternal untuk ketiga peralatan adalah setiap 5 tahun. Ditemukan adanya indikasi korosi pasif yaitu terbentuknya lapisan pasif pada permukaan lining plate yang ditandai dengan penurunan ketebalan merata serta perubahan warna permukaan menjadi warna coklat. Disarankan untuk melakukan pengukuran ketebalan secara berkala pada base metal untuk memastikan tidak terjadi penurunan ketebalan di bawah lapisan lining yang dapat membahayakan integritas peralatan selama masa operasi.
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There are three main pressure vessels in the urea synthesis unit, which are the Reactor, Stripper, and Vertical Submerged Carbamate Condenser (VSCC). Based on thickness inspection results using ultrasonic thickness testing, a reduction in wall thickness was identified. Therefore, it is necessary to evaluate the equipment condition to ensure reliability and safety. One method that can be used for this purpose is the Fitness for Service (FFS) approach based on API 579-1/ASME FFS-1 standards. This study focuses on evaluating the shell sections of the three pressure vessels in the urea synthesis unit using Part 4 – General Metal Loss from API 579-1/ASME FFS-1, which is intended to assess operational fitness and estimate remaining service life. The analysis results showed that all three vessels are still fit for service under current conditions without requiring immediate remediation. The estimated remaining life for the lining plate of the Reactor is approximately 20 years, the Stripper is 29 years, and the VSCC is 84 years. Based on these results, the recommended interval for internal and on-stream inspections is every 10 years, while external inspections should be performed every 5 years. An indication of passive corrosion was observed, characterized by the formation of a passive layer on the surface of the lining plate, uniform wall thinning, and a change in surface color to brown.
It is recommended to regularly measure the thickness of the base metal to ensure that the wall loss beneath the lining does not compromise the structural integrity of the equipment during operation.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Fitness for Service, API 579-1/ASME FFS-1, Remaining Life, Pressure Vessel, Unit Sintesis Urea, Fitness for Service, API 579-1/ASME FFS-1, Remaining Life, Pressure Vessel Urea Synthesis Unit
Subjects:	T Technology > T Technology (General) T Technology > TA Engineering (General). Civil engineering (General) > TA169 Reliability (Engineering) T Technology > TA Engineering (General). Civil engineering (General) > TA660.T34 Tanks. Pressure vessels
Divisions:	Faculty of Industrial Technology > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis
Depositing User:	Sang Tembang Kinanti
Date Deposited:	28 Jul 2025 09:51
Last Modified:	28 Jul 2025 09:51
URI:	http://repository.its.ac.id/id/eprint/122297

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