Analisa Resiko dan Perencanaan Inspeksi pada Make up Demineralizer Water Treatment Plant dengan menggunakan Metode Risk Based Inspection (RBI) di PT. IPMOMI Paiton unit 7

Risk Analysis and inspection planning of make up demineralizer water treatment plant using Risk Based Inspection (RBI) methode in PT. IPMOMI Paiton unit 7

Riyandra Bayu Dirgantara (6510040009)


Abstrak

Pembangkit Listrik Tenaga Uap (PLTU) Paiton unit 7 dan 8 merupakan dua unit pembangkit listrik berbahan bakar batu bara dengan kapasitas 2 x 615 MW. Proses produksi listrik sangat bergantung terhadap kebutuhan air sebagai feed water yang nantinya akan diproses menjadi uap untuk menggerakkan turbin. Demineralizer water treatment plant merupakan tahapan terakhir proses pengolahan air laut menjadi feedwater boiler, close cooling, dan hydrogen generator. Kerusakan pada peralatan demineralizer plant akan mengganggu aktivitas dalam pengolahan feedwater. Karena itu diperlukan suatu kajian untuk mengidentifikasi resiko dari kegagalan peralatan sehingga frekuensi dari resiko yang dapat merugikan perusahaan dapat diminimalisir. Penelitian ini menggunakan metode risk management kualitatif dan semi kuantitatif untuk menganalisa resiko. Risk Management ini mengabungkan Likelihood dan Consequences untuk mendapatkan nilai suatu resiko. Resiko kegagalan peralatan secara kualitatif dianalisa dengan metode Failure Mode and Effect Analysis (FMEA) dan mekanisme kegagalan peralatan dianalisa dengan Fault Tree Analysis (FTA). Untuk menilai resiko secara kuantitatif peneliti menggunakan metode semi-kuantitatif Risk Based Inspection (RBI) yang kemudian dilanjutkan dengan penentuan interval serta metode inspeksi pada peralatan demineralizer plant. Berdasarkan hasil analisa kualitatif dengan FMEA, peralatan dengan kategori high risk adalah sulfuric acid feed pump dan Acid pipeline dengan nilai resiko 8. Berdasarkan analisa FTA, top event disebabkan nilai conductivity 0.1 ?s/cm, pH <5/>6.5, volume produk <56 m3/jam, dan kesalahan operator. Berdasarkan perhitungan analisa semi-kuantitatif resiko terbesar adalah sulfuric acid feed pump dengan nilai total resiko 4.89x105 ft2/tahun. Penentuan interval inspeksi peralatan untuk Mixed Bed Polisher 2,5 tahun sekali, untuk Sulfuric Acid storage, Caustic(NaOH) Storage 4 tahun sekali, Sulfuric Acid Feed Pump dan Caustic Feed Pump 6 bulan sekali, Acid Pipeline 2,5 tahun sekali, dan Caustic Pipeline 4 tahun sekali. Metode inspeksi yang direkomendasikan yaitu metode ultrasonic Stright Beam dan visual inspection pada peralatan berbahan logam dan visual internal dan external inspection untuk peralatan berbahan Fabricated Reinforced Plastic (FRP). Kata kunci : Demineralizer plant, Resiko, Risk management, FMEA, Likelihood, Consequence, FTA, RBI, Inpeksi, ultrasonic, Fabricated reinforced plastic (FRP)


Abstract

Paiton Steam Power Plant unit 7 and 8 are two units of power plants with coal-fired capacity of 2 x 615 MW. Electricity production process is very dependent on water as feed water needs that will be processed into steam to drive a turbine. Demineralizer water treatment plant is the last stage of processing sea water into the boiler feedwater, cooling close, and hydrogen generators. Damage due to equipment of demineralizer plant will disrupt the processing activity in the feedwater suply. Therefore we need a study to identify the risk of equipment failures that could harm and then the company's risk can be minimized. This study used qualitative methods of risk management and semi-quantitative risk to analyze. The Risk Management combines Likelihood and Consequences to get the value of a risk. Risk of equipment failure are qualitatively analyzed by Failure Mode and Effect Analysis (FMEA) and equipment failure mechanism analyzed by Fault Tree Analysis (FTA). To assess the risk quantitatively researchers using a semi-quantitative Risk Based Inspection (RBI) followed by determination of inspection intervals and methods demineralizer plant equipment. Based on the results of qualitative analysis with FMEA, equipment with high risk category are sulfuric acid feed pump and acid pipeline with the risk value 8. Based on the analysis of the FTA, the top event caused by the value of conductivity 0.1 ?s /cm, pH <5 /> 6.5, the volume of product <56 m3 / hours, and operator error. Based on the calculation of semi-quantitative analysis, the biggest risks is the sulfuric acid feed pump with a total value 4.89x105 ft2/year. Determination of equipment inspection intervals for mix bed polisher is 2,5 years, for Sulfuric Acid storage, Caustic(NaOH) Storage is 4 years, Sulfuric Acid Feed Pump and Caustic Feed Pump is 6 months, Acid Pipeline is 2,5 years, and Caustic Pipeline 4 years once. Recommended inspection method is the Ultrasonic Stright Beam for equipment made of metal and internal visual inspection for equipment made of Fabricated Reinforced Plastic(FRP). Keywords: Demineralizer plant, Risk, Risk management, FMEA, Likelihood, Consequence, FTA, RBI, inspections, ultrasonic tright beam , Fabricated reinforced plastic (FRP)


Detil Peneliti

Dosen Pembimbing 1 :Agung Nugroho
Dosen Pembimbing 2 : Mohamad Hakam

Program Studi : D4 - TEKNIK KESELAMATAN DAN KESEHATAN KERJA
Angkatan : 2010


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