Penilaian Risiko Pada Sistem Pendingin Ammonia Dengan Integrasi Metode HAZOP, LOPA, Dan Consequence Modelling Di Industri FMCG

Aji, Mareta Danar Purwito (2026) Penilaian Risiko Pada Sistem Pendingin Ammonia Dengan Integrasi Metode HAZOP, LOPA, Dan Consequence Modelling Di Industri FMCG. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Sistem pendingin ammonia banyak digunakan di industri FMCG karena efisien dan ramah lingkungan, namun ammonia merupakan senyawa yang berbahaya bagi manusia dan lingkungan. PT.X merupakan perusahaan FMCG dengan sistem pendingin ammonia berkapasitas 50 m³ dan berlokasi dekat pemukiman. PT.X belum memiliki sistem manajemen keselamatan proses yang komprehensif terbukti dari delapan kejadian kebocoran ammonia dalam lima tahun terakhir. Penelitian ini bertujuan untuk mengevaluasi penerapan sistem manajemen keselamatan proses, mengidentifikasi potensi bahaya, menilai risiko dan memperkirakan dampak kebocoran sistem pendingin ammonia PT.X sebagai dasar penerapan manajemen keselamatan proses yang efisien dan terstruktur. Input dari penelitian ini adalah hasil audit PSM dan HAZOP sebelumnya sebagai dasar untuk mengidentifikasi potensi bahaya dan risiko. LOPA digunakan sebagai analisis lanjutan untuk mengevaluasi efektivitas dan menambahkan lapisan perlindungan terhadap skenario dengan risiko tinggi (intolerable). Consequence modelling digunakan untuk memperkirakan dampak terburuk dari sebuah kebocoran ammonia. Data primer diperoleh melalui observasi dan inspeksi langsung pada sistem pendingin ammonia PT.X, sedangkan data sekunder diperoleh dari referensi code & standard yang berlaku. Hasil dari evaluasi penerapan sistem PSM menyatakan tingkat ketercapaian terhadap internal PSM standard sebesar 79.1%. Dari evaluasi HAZOP menunjukkan bahwa dari total 237 skenario dari 20 node yang dikaji, sebanyak 131 skenario (±55%) dengan tingkat risiko acceptable, 93 skenario (±39%) tolerable dan 13 skenario (±6%) intolerable. Hasil studi LOPA mampu menurunkan 9 dari 13 risiko intolerable menjadi tolerable dengan rekayasa penambahan independent protection layer dengan nilai disproportion factor sebsesar 8.84. Hasil consequence modelling menunjukkan bahwa skenario kebocoran terburuk diperkirakan menghasilkan zona AEGL-3 sebesar 80 meter, AEGL-2 sebesar 212 meter, dan AEGL-1 sebesar 500 meter dengan nilai individual risk sebesar 1,2 x 10⁻6 per tahun dan society risk dalam batas tolerable. Penelitian ini menunjukkan bahwa penerapan integrasi HAZOP, LOPA, dan consequence modelling mampu memberikan evaluasi yang komprehensif dengan memberikan 44 rekomendasi KPI yang berbasis pada pencegahan bahaya dan pengendalian risiko.
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Ammonia refrigeration systems are widely used in the FMCG industry due to their high energy efficiency and environmentally friendly characteristics. However, ammonia is a hazardous chemical that poses significant risks to both humans and the environment. PT.X is an FMCG company operating a 50 m³ ammonia refrigeration system located near a residential area. The company has not yet implemented a comprehensive Process Safety Management (PSM) system, as evidenced by eight ammonia leak incidents recorded over the past five years. This study aims to evaluate the implementation of Process Safety Management, identify potential hazards, assess associated risks, and estimate the consequences of ammonia releases from the refrigeration system at PT.X as a basis for establishing an efficient and structured PSM framework. The study utilized the results of previous PSM audits and HAZOP analyses as inputs for hazard identification and risk assessment. LOPA was employed as a follow-up assessment to evaluate the effectiveness of existing safeguards and to recommend additional protection layers for scenarios classified as having intolerable risk. Consequence modeling was conducted to estimate the worst-case impacts of ammonia releases. Primary data were obtained through direct observation and inspection of the ammonia refrigeration system at PT.X, while secondary data were gathered from applicable codes, standards, and relevant literature. The evaluation of the PSM implementation indicated an overall compliance level of 79.1% with the internal PSM standard. The HAZOP assessment identified 237 scenarios across 20 nodes, consisting of 131 scenarios (±55%) categorized as acceptable, 93 scenarios (±39%) categorized as tolerable, and 13 scenarios (±6%) categorized as intolerable. The LOPA study successfully reduced 9 out of 13 intolerable-risk scenarios to a tolerable level through the addition of Independent Protection Layers (IPLs), with disproportion factor 8.84. The consequence modeling results showed that the worst-case ammonia release scenario could generate an AEGL-3 zone of 80 meters, an AEGL-2 zone of 212 meters, and an AEGL-1 zone of 500 meters. The calculated individual risk was 1.2 × 10⁻⁶ per year, while the societal risk remained within the tolerable region. The findings demonstrate that the integration of HAZOP, LOPA, and consequence modeling provides a comprehensive approach to process safety evaluation and supports the development of 44 KPI-based recommendations focused on hazard prevention and risk control.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Penilain Risiko, Sistem Pendingin Ammonia, HAZOP, LOPA, Consequence Modelling
Subjects:	T Technology > T Technology (General) > T55 Industrial Safety
Divisions:	Interdisciplinary School of Management and Technology (SIMT) > 61101-Master of Technology Management (MMT)
Depositing User:	Mareta Danar Purwito Aji
Date Deposited:	30 Jul 2026 02:50
Last Modified:	30 Jul 2026 02:50
URI:	http://repository.its.ac.id/id/eprint/141047

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