Ali Musyafa : RISK MANAGEMENT OF ILC SLC IN PT. SEMEN INDONESIA (Persero), Tbk. TUBAN PLANT III

Dr.Ir. Ali Musyafa M.Sc.

Year

-

Published in

9 th IASTEM International Conference, Bali, Indonesia, 9th January 2016,

Authors

External link

Type

Seminar Internasional

Keywords

ILC;SLC;Risk Management;HAZOP;hazards identification;ADISTY D. NURDIANAADISTY D. NURDIANA


Abstract

In-Line-Calciner (ILC) and Separate-Line-Calciner (SLC) are the equipments of pre-calcinations process in mostly modern industrial cement kilns that have importance due to its impacts for fuel consumption, pollutant emission and final cement quality. Any failures in this system will lead to stop the clinker production process and increase losses of the company since 60% calcinations process has done outside the rotary kiln. Therefore risk management needs to be done in this system. In this paper, HAZOP method has been used to determine hazard identification and analysis with two nodes that are ILC and SLC with each has five parameters to measured and controlled that are Preheater Exit %O2, Preheater Exit %CO, Preheater Exit Gas Temperature, Stage IV Calciner Exit Material Temperature, and Preheater Exit Pressure Difference. Guide word and deviation determination based on control chart constructed from operational data of each components of measurement points. Likelihood estimation based on data operational failure that taken along 180 days while consequence estimated based criteria as well as the data posed by control chart. Risk criterion of measurement points in each node produced by multiplying likelihood and consequence. Based on the analysis known that any hazards or failures occur in the component of measurement points in each nodes have potential causing main risks as operational clinker production process has to stop and inappropriate product quality standard mainly because of incomplete preheating and combustion process. To reduce the risk in the system, routine preventive maintenance and calibration should be done especially in Preheater Exit Pressure Difference measurement point components that have an extreme level of risk and indicates any potential hazards that causing operation process to stop.