Studi Kasus Audit Maintenance Rotating Equipmen,Pada PT. Toba Pulp Lestari, Tbk “Porsea” Medan

STUDI KASUS AUDIT MAINTENANCE ROTATING EQUIPMENT PADA PT. TOBA PULP LESTARI, Tbk, “Porsea”, Medan SKRIPSI

  Skripsi Yang Diajukan Untuk Melengkapi Syarat Untuk Memperoleh Gelar Sarjana Teknik

  HARJONO T MANALU NIM. 080401150

  KATA PENGANTAR Puji dan syukur penulis ucapkan ke Hadirat Tuhan Yang Maha Esa atas segala karunia dan rahmat-Nya yang senantiasa diberikan kepada penulis, sehingga penulis dapat menyelesaikan skripsi ini.

  Skripsi ini adalah salah satu syarat untuk dapat lulus menjadi Sarjana Teknik di Departemen Teknik Mesin Fakultas Teknik Universitas Sumatera Utara. Adapun judul skripsi ini adalah “Studi Kasus Audit Maintenance Rotating Equipmen,Pada

PT. Toba Pulp Lestari, Tbk “Porsea” Medan ”.

  Selama penulisan skripsi ini,sangat banyak yang membantu dalam penyelesaian skripsi ini, sehingga penulis merasa perlu untuk berterima kasih kepada:

  1. Kedua orang tua tersayang, B. Manalu dan R. Lumbangaol yang telah memberikan segala dukungan moril dan materil dalam kehidupan saya.

  2. Bapak Ir. Alfian Hamsi M.Sc selaku dosen pembimbing yang telah banyak meluangkan waktunya membimbing penulis hingga skripsi ini dapat terselesaikan.

  3. Bapak Dr. Ing. Ir. Ikhwansyah Isranuri dan Ir. Syahril Gultom, MT selaku Ketua dan Sekretaris Departemen Teknik Mesin, Fakultas Teknik USU.

  4. Bapak/Ibu staf pengajar dan pegawai Departemen Teknik Mesin, Fakultas Teknik USU.

  5. Kepada Saudara-saudara saya yang saya sayangi, Marlis A.E Manalu, Toni T Manalu, Sudarmo J.M Manalu, Rosa M manalu, Sondang M Manalu, Junita B Manalu

  6. Kakanda Paulus Purba, ST yang telah banyak memberikan masukan selama melakukan penelitian di PT.Toba Pulp Lestari, tbk

  7. Tiodora Sinaga dan Teman-teman mahasiswa Teknik Mesin USU yang telah banyak membantu dalam penyusunan laporan ini.

  Disadari bahwa skripsi ini belum sempurna, baik dari segi teknik maupun dari segi materi. Oleh sebab itu, demi penyempurnaan skripsi ini kritik dan saran sangat diharapkan guna membangun skripsi ini menjadi lebih baik.

  Akhir kata, penulis berharap agar laporan ini bermanfaat bagi pembaca pada umumnya dan penulis sendiri pada khususnya.

  Medan, september 2012 Penulis, Harjono T Manalu NIM : 080401150 ABSTRAK Semakin meningkat kebutuhan akan kertas, secara langsung kebutuhan akan pulp sebagai bahan baku kertas semakin meningkat pula. Dengan meningkatnya kebutuhan akan kertas maka kinerja proses rotating equipment juga akan bertambah. Ini tentu juga akan memaksa untuk melakukan Preventive Maintenance secara rutin terhadap

  

rotating equipment , yang bertujuan untuk mencari masalah-masalah dan cara

  mengatasi masalah tersebut demi berjalannya proses produksi pulp. Setelah itu, mengamati proses pembuatan pulp dan membuat daftar proses permesinan pada pulp tersebut kemudian membuat daftar rotating equipment yang merupakan Salah satu bagian dari mesin produksi yang sangat berpengaruh pada kinerja mesin tersebut seperti , fan boiler, debarking drum, chipper, poros, blade turbin, bearing, gearbox. Adapun masalah yang sering terjadi pada rotating equipment (peralatan yang berputar) ini meliputi, getaran yang tinggi, bearing aus, kerusakan pada blade, pemasangan yang tidak sesuai, unbalance, pelumasan yang tidak memadai, dan

  

misalignment . Penanganan masalah tersebut dilakukan dengan dua cara rekayasa

enngineering dan rekayasa material. Seiring dengan perkembangan zaman dan

  teknologi, maka cara untuk melakukan perhitungan terhadap poros turbin juga berkembang salah satunya dengan menggunakan software Ansys 5.4 dan perhitungan manual. Dengan penggunaan software ini maka perhitungan dapat dilakukan dengan mudah, cepat dan akurat. Dari hasil perhitungan yang diperoleh dengan menggunakan

  9

  2

software ansys 5.4 maka didapat tegangan geser 4,03.10 N/m , dan dengan

  τ =

  9

  perhitungan manual tegangan geser yang diperoleh 4,06 . 10 , torsi T = 174,85

  τ =

  5

  2

  2

  2 .10 N m, Tegangan Geser Ijin Bahan a = 840 kg/mm = 8,40.10 N/m .

  τ Kata kunci: Rotating equipment, Preventive Maintenance, Poros.

  

ABSTRACT

The increasing demand for paper, directly the needs of pulp as the raw material of

paper has increased as well. With the increasing demand for paper and the

performance process of rotating equipment will also increase. This of course would

also be forced to perform Preventive Maintenance on a regular basis to the rotating

equipment, which aims to find the problems and how to resolve the issue in favor of

passage of the pulp production process. After that, watching the process of making

pulp process engineering products and make a list on the pulp and then make a list of

rotating equipment which is one part of the production machine that is very

influential on the performance of the machine such as boiler, fan, debarking drum,

chipper, shafts, bearings, turbine blade, gearbox. As for the problems that often

occur in rotating equipment (rotating equipment) This includes, high vibration,

bearing wear, damage to the blade, inappropriate installation, unbalance,

inadequate lubrication, and misalignment. The handling of the issue is done with two

ways of enngineering engineer and engineering materials. Along with the changing

times and technologies, then how to do calculations on the turbine shaft is also

developed by using software Ansys 6.1 and the calculation manually. With the use of

this software then the calculations can be done easily, quickly and accurately. From

the results of the calculations are obtained by using software ansys 5.4 then come by

the shear stress τ = 4, 03.109 N/m2, and with the manual calculation of shear stress τ

a

  

= 4.06 earned. 109, the torque T = 174,85 105 N m, the shear stress = 840

τ

  2

  2

  2 _.

  kg/mm = 8,40.10 N/m .

  Keywords: Rotating equipment, Preventive Maintenance, Shaft _.

  DAFTAR ISI

HALAMAN JUDUL .................................................................................................... i

LEMBAR PENGESAHAN ....................................................................................... ii

SPESIFIKASI TUGAS .............................................................................................. iii

KATA PENGANTAR ................................................................................................ iv

ABSTRAK .................................................................................................................. vi

DAFTAR ISI ............................................................................................................... ix

DAFTAR TABEL ..................................................................................................... xi

DAFTAR GAMBAR ................................................................................................ xii

BAB I PENDAHULUAN ...................................................................................................

  1.1 Latar Belakang 1 ................................................................................................

  1.2 Batasan Masalah 2 ...............................................................................................

  1.3 Tujuan Penulisan 3 ..........................................................................................

  1.4 Metode Pembahasan 3 .......................................................................................

  1.5 Sistematika Penulisan

  4 BAB II TINJAUAN PUSTAKA

  2.1 Sejarah Perkembangan Maintenance (perawatan) ..................................... 5 2.1.1 strategi maintenance (perawatan) ................................................ 6

  2.2 Audit Maintenance (perawatan) ................................................................. 8

  2.2.2 Tujuan Audit Maintenance (perawatan) ..................................... 8

  2.3 Klasifikasi Maintenance (perawatan) ...................................................... 10

  2.4 Tugas- Tugas Bagian Maintenance .......................................................... 15

  3.2 Waktu dan Tempat ................................................................................... 27

  3.5.2 Fungsi Rotating Equipment ....................................................... 33

  3.5.1 Defenisi Rotating Equipment .................................................... 32

  3.5 Rotating Equipment .................................................................................. 32

  3.4 Langkah-Langkah Penelitian ................................................................... 30

  3.3 Flowchart Metodologi Penelitian ............................................................. 28

  3.2.2 Tempat ....................................................................................... 28

  3.2.1 Waktu ........................................................................................ 27

  3.1 Surat Izin Pengambilan Data ke Perusahaan ........................................... 27

  2.5 Instruksi-Instruksi Umum Dalam Maintenance (perawatan) ................... 19

  BAB III METODOLOGI PENELITIAN

  2.6 Failure Defenition .................................................................................... 24

  2.5.6 Equipment, Tool, Material, dan Consumable ............................ 24

  2.5.5 Man hour ................................................................................... 23

  2.5.4 Man Power ................................................................................ 22

  2.5.3 Perawatan Langsung dan Tidak Langsung ............................... 21

  2.5.2 Perawatan Mesin Yang Beroperasi Terus Menerus .................. 21

  2.5.1 Pentingnya Pekerjaan Maintenance (perawatan) ...................... 19

  3.6 Proses Pengolahan Pulp ........................................................................... 35

  BAB IV TEMUAN MASALAH PADA ROTATING EQUIPMENT

  4.1 Data Kerusakan Rotating Equipment ....................................................... 40

  4.2 Metode Pemecahan Masalah Rotating Equipment .................................. 50

  4.3 Analisa Data Rotaing Equipment ............................................................. 50

  4.4 Analisa Poros Turbin ............................................................................... 58

  4.4.1 Macam-Macam Poros ............................................................... 58

  4.4.2 Hal-Hal Penting Dalam Perencanaan Poros .............................. 59

  4.5 Rumus Perhitungan Poros ........................................................................ 62

  4.6 Data-Data Poros Turbin ........................................................................... 66

  4.6.1 Torsi .......................................................................................... 68

  4.6.2 Momen Kutub Inersia ............................................................... 68

  4.6.3 Torsi Tegangan Geser ............................................................... 69

  4.6.4 Regangan Geser ........................................................................ 69

  4.6.5 Modulus Elastisitas Geser ......................................................... 70

  4.6.6 Sudut Puntir ............................................................................... 70

  4.6.7 Torsi Plastis ............................................................................... 71

  4.7 Perhitungan Dengan Menggunakan Ansis 5.4 .......................................... 73

  4.7.1 _{Pemodelan Pada Ansys ............................................................. 73}

  4.7.2 Mendefinisikan Element Type .................................................... 74

  4.7.3 Menentukan Material Bahan ...................................................... 75 .............................................................

  4.7.4 Pembagian element (Mesh)

  76 ..............................................................

  4.7.5 Proses Membuat Tumpuan

  78

  4.7.6 Mendefenisikan Beban ............................................................... 80

  4.8 Perbandingan Perhitungan Manual Dengan Perhitungan Simulasi Ansys

  84 BAB V KESIMPULAN DAN SARAN

  5.1 Kesimpulan .............................................................................................. 85

  5.2 Saran ......................................................................................................... 87

  

DAFTAR PUSTAKA ............................................................................................... 88

LAMPIRAN

  Lampiran I .................................................................................................................. 89 Lampiran II ................................................................................................................. 90 Lampiran III ............................................................................................................... 91

  

DAFTAR TABEL

Tabel 4.1 debarking drum .......................................................................................... 52Tabel 4.2 chipper ........................................................................................................ 53Tabel 4.3 fan boiler .................................................................................................... 54Tabel 4.4 poros turbin ................................................................................................ 55Tabel 4.5 sudu turbin.................................................................................................. 55Table 4.6 roller belt conveyor ..................................................................................... 56Table 4.7 gear box ...................................................................................................... 57Table 4.8 coupling fan................................................................................................. 57Table 4.9 bearing pompa ........................................................................................... 58Table 4.10 baja paduan untuk bahan porositas .......................................................... 65Table 4.11 faktor koreksi porositas ............................................................................ 67Table 4.12 data poros turbin ...................................................................................... 68

  DAFTAR GAMBAR

Gambar 2.1 diagram alir Maintenance......................................................................... 8Gambar 2.2 Spider Chart Overview of the Maintenance Management System .......... 11Gambar 2.3 Failure Defenition ................................................................................... 26Gambar 3.1 Diagram Alir Pengerjaan Tugas Akhir.................................................... 30Gambar 3.2 Diagram alir pembuatan pulp ................................................................. 32Gambar 3.3 Proses pengolahan pulp ........................................................................... 33Gambar 4.1 Debarking Drum ...................................................................................... 41Gambar 4.2 Chipper ................................................................................................... 42Gambar 4.3 Fan Boiler .............................................................................................. 43Gambar 4.4 Poros Turbin ........................................................................................... 44Gambar 4.5 Sudu Turbin ............................................................................................ 46Gambar 4.6 Belt Conveyor ......................................................................................... 47Gambar 4.7 Gear Box ................................................................................................ 48Gambar 4.8 Coupling Fan .......................................................................................... 49Gambar 4.9 Bearing Pompa ....................................................................................... 50Gambar 4.10 Porositas Dengan Sistem 2 Penumpu ................................................... 58Gambar 4.11 Turbin uap ............................................................................................ 66Gambar 4.12 Momen Torsi ........................................................................................ 68Gambar 4.13 Pergerakan Titik Tegangan .................................................................. 69

  Gambar 4.14Pergeseran Akibat Torsi Pada Poros ..................................................... 70

Gambar 4.15 Sudut Puntir .......................................................................................... 71Gambar 4.16 Tampilan pembuatan gambar spesimen melalui ansys. ........................ 74

  Gambar 4.17Tampilan element type .......................................................................... 75

Gambar 4.18 pemilihan material bahan ...................................................................... 76Gambar 4.19 Proses meshing material (a)................................................................... 77Gambar 4.20 Proses meshing material (b) .................................................................. 78

  Gambar 4.21Tampilan untuk membuat tumpuan (a) .................................................. 79

Gambar 4.22 Tampilan untuk membuat tumpuan (b) ................................................. 79Gambar 4.23 Tampilan untuk mendefenisikan beban (a) .......................................... 80Gambar 4.24 Tampilan untuk mendefenisikan beban (b) .......................................... 81Gambar 4.25 Proses analisa Ansys ............................................................................. 82Gambar 4.26 Hasil analisa ansys ............................................................................... 82Gambar 4.27 Tegangan pada poros ............................................................................ 83Gambar 4.28 Pergeseran pada poros .......................................................................... 84

  

DAFTAR NOTASI

Simbol Arti Satuan

  D Diameter mm σ

  Tegangan N/m

  2

  ε Regangan _

  R Gaya Reaksi N

  V Gaya Geser N M Momen Nm

  I Moment Inertia ( m )

  4 J Moment Inertia Polar ( m )

  4

  τ Tegangan Geser N/ m

  2 ƒc

  Faktor Koreksi _ Pd Daya Rencana HP τ

  a

  Tegangan Geser Ijin Bahan Kg/mm² T Momen Torsi Nm