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All Journal Rotasi Rekayasa Mesin International Journal of Mechanical Engineering Technologies and Applications (MECHTA)
Nugraha, Ariyana Dwiputra
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Automotive Engineering Energy Engineering Industrial & Manufacturing Engineering Mechanical Engineering

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A RECENT REVIEW ON THE FAILURE ANALYSIS OF BOILER TUBE Utomo, Faris Fadhil; Rashyid, Muhammad Ibnu; Nugraha, Ariyana Dwiputra; Muflikhun, Muhammad Akhsin
Jurnal Rekayasa Mesin Vol. 15 No. 2 (2024)
Publisher : Jurusan Teknik Mesin, Fakultas Teknik, Universitas Brawijaya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/jrm.v15i2.1392

Abstract

The failure analysis in the industrial systems i.e. power plan, oil, and gas companies, has been reported by many researchers. One of the most reported has occurred in the Boiler system. Among the components of the boiler, problems, and failures often took place in the tube. The purposes of the recent study are to describe, classify, and review the latest update of the failure behavior of the boiler tube. The failure was formed by overheating, creep, stress corrosion, cracking, erosion, oxidation, and post-weld heat treatment (PWHT). The current works are listed based on the methods used to identify the failures, failure observations, and case studies updated from the boiler tube failure condition. The research suggests that to replace the failure tubes, analysis related to the stress induced outside and inside the tube, environment conditions, and lifetime maintenance works need to be considered.
Asesmen Kondisi Tube Boiler Final Superhater SA 213 91 Kapasitas 315 MW Akibat Efek Kebocoran Kondenser Harianto, Harianto; Nugraha, Ariyana Dwiputra; Suprihanto, Agus; Sulardjaka, Sulardjaka
ROTASI Vol 26, No 3 (2024): VOLUME 26, NOMOR 3, JULI 2024
Publisher : Departemen Teknik Mesin, Fakultas Teknik, Universitas Diponegoro

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.14710/rotasi.26.3.30-36

Abstract

Penelitian dilakukan pada pembangkit listrik tenaga uap (PLTU) Rembang Semarang Unit 2, Indonesia kapasitas 315 MW. PLTU ini mulai beroperasi pada tahun 2011 dan sudah berjalan hingga saat ini kira-kira 13 tahun atau di atas 100.000 jam EOH (equievalent operating hours). Pada awal tahun 2022 PLTU ini mengalami kebocoran kondenser sehinga perlu dilakukan asesmen pada material tube boiler. Pada studi ini akan dilakukan asesmen yaitu tube final superheater jenis SA 213 T91. Penelitian ini dilakukan untuk menjawab kecurigaan adanya indikasi degradasi atau kegagalan pada material tube akibat efek kebocoran kondenser. Analisis yang digunakan adalah dengan melakukan asesmen tube as received yaitu meliputi pemeriksaan visual, uji komposisi kimia tube, pengukuran ketebalan, pengukuran kekerasan, uji metalografi, dan analisis kandungan kimia scale pada inner tube.Dari hasil hasil pengujian dan dilakukan analisis bahwa material tube secara pengamatan visual masih dalam kondisi relatif baik tetapi pada inner tube (steam side) dan outer tube (fire side) telah mengalami korosi dan terdapat scale. Hasl uji kompoisi kimia tube sesuai dengan desainya yaitu SA 213 T91. Pengukuran ketebalan tube yaitu 6.04 mm s.d. 8.60 mm. Nilai kekerasan masih dalam batas yang diizinkan yaitu 200.08 HV s.d. 224.11 HV. Hasil pemeriksaan struktur mikro berupa martensit temper yang telah mengalami sperodisasi akibat overheating dan jika dilakukan pendekatan stadium kerusakan creep cracks (cavities) berdasarkan ERA teknologi masih masuk kategori 2 (dua) yaitu kerusakan berada pada 33% dan memiliki sisa umur yaitu 66%. Hasil ketebalan scale pada pada outer tube terukur 216.00 µm dan inner scale 232.32 µm. Hasil pengujian SEM EDX menunjukkan bahwa kandungan scale yang ada pada  inner tube yaitu carbon, oxygen dan ferrous (unsur pembentuk oxide scale). Adapun unsur lainnya seperti natrium (sodium), magnesium aluminium, dan unsur lainnya berasal dari kontaminasi air pengisi boiler (feed water) akibat efek kebocoran kondenser.
Material characteristics and failure prediction of SA 213 Superheater Boiler tube in power plant with 315 MW capacity Nugraha, Ariyana Dwiputra; Harianto, Harianto; Suprihanto, Agus; Sulardjaka, Sulardjaka
ROTASI Vol 26, No 4 (2024): VOLUME 26, NOMOR 4, OKTOBER 2024
Publisher : Departemen Teknik Mesin, Fakultas Teknik, Universitas Diponegoro

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.14710/rotasi.26.4.1-5

Abstract

This study was conducted at the Rembang Semarang Unit 2 power plant in Indonesia, with a capacity of 315 MW. The plant has been in operation since 2011, totaling about 13 years or over 100,000 equivalent operating hours (EOH). High-temperature operations can damage tube materials due to temperature, corrosive environment, pressure, and stress. At the end of 2022, a condenser leak at the plant necessitated an assessment of the boiler tube material. This study focuses on evaluating the SA 213 T91 (chromium (Cr) and molybdenum (Mo) alloy steel) superheater tube, a known for its excellent high-temperature mechanical and thermal properties and corrosion resistance. The research aims to assess potential failures in the boiler tube and guide future operational and maintenance plans. The analysis includes destructive testing, SEM, EDX metallography, and creep rupture testing. Results show corrosion and hard scale deposition inside the tube. Its is shown that creep strength decreases significantly at high temperatures, leading to faster material rupture.
THE UTILIZATION OF GEOTHERMAL SILICA WASTE IN ADDITIVE MANUFACTURING WITH STEREOLITHOGRAPHY RESIN FOR DETAILED PROTOTYPING PROCESS Tanbar, Fefria; Darmawan, Muhammad Rakhadzaky Indra; Wibisono, Muhammad Maheswara; Ariyadi, Hifni Muchtar; Nugraha, Ariyana Dwiputra; Wiranata, Ardi; Muflikhun, Muhammad Akhsin
International Journal of Mechanical Engineering Technologies and Applications Vol. 6 No. 2 (2025)
Publisher : Mechanical Engineering Department, Engineering Faculty, Brawijaya University

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/MECHTA.2025.006.02.5

Abstract

Silica deposit powder from geothermal waste often becomes material waste that difficult to utilize and re-use. The characterization of silica deposit powder has a significant part in understanding its structure, composition, and potential application. Using silica as a filler system in additive manufacturing is one of the processes that can utilize silica deposit powder. This material has the potential to be used to create prototype product with stereolithography resin for 3D printing. The present study discusses the ability to mix specimens of silica (size 600 microns) and resin with a composition ratio of 1:100. The turbidity test revealed that the specimen mixed in the resin contents showing after 30- and 40-minutes examination from spectrophotometer. In the hardness test, by adding filler materials, it is shown that the filler decreased the hardness more than 46%. This research also successfully examines the most effective particle sizes to the length of time required for the mixing and curing processes in order to obtain the most optimal results.
A RECENT REVIEW ON THE FAILURE ANALYSIS OF BOILER TUBE Utomo, Faris Fadhil; Rashyid, Muhammad Ibnu; Nugraha, Ariyana Dwiputra; Muflikhun, Muhammad Akhsin
Jurnal Rekayasa Mesin Vol. 15 No. 2 (2024)
Publisher : Jurusan Teknik Mesin, Fakultas Teknik, Universitas Brawijaya

Show Abstract | Download Original | Original Source | Check in Google Scholar | DOI: 10.21776/jrm.v15i2.1392

Abstract

The failure analysis in the industrial systems i.e. power plan, oil, and gas companies, has been reported by many researchers. One of the most reported has occurred in the Boiler system. Among the components of the boiler, problems, and failures often took place in the tube. The purposes of the recent study are to describe, classify, and review the latest update of the failure behavior of the boiler tube. The failure was formed by overheating, creep, stress corrosion, cracking, erosion, oxidation, and post-weld heat treatment (PWHT). The current works are listed based on the methods used to identify the failures, failure observations, and case studies updated from the boiler tube failure condition. The research suggests that to replace the failure tubes, analysis related to the stress induced outside and inside the tube, environment conditions, and lifetime maintenance works need to be considered.
Co-Authors Agus Suprihanto Ardi Wiranata Ariyadi, Hifni Muchtar Darmawan, Muhammad Rakhadzaky Indra Harianto Harianto Muhammad Akhsin Muflikhun Rashyid, Muhammad Ibnu Sulardjaka Sulardjaka Tanbar, Fefria Utomo, Faris Fadhil Wibisono, Muhammad Maheswara