Disusun Oleh:
i
ii
LEMBAR PENGESAHAN LAPORAN
PRAKTEK KERJA INDUSTRI
PT. KRAKATAU STEEL
Disusun Oleh :
Menyetujui,
Mengetahui,
iii
KATA PENGANTAR
Puji syukur kami ucapkan kepada Allah SWT atas limpahan rahmat dan
karunia-Nya sehingga kami dapat menyelesaikan Laporan kerja praktek di PT.
Krakatau Steel, Tbk. yang dilaksanakan mulai tanggal 7 Juli 2014 sampai dengan
tanggal 7 Agustus 2014 dengan judul Analisis Aliran Daya dan Harmonisa
dengan Menggunakan Harmonic Filter 250C/s dan 350 C/s di Wire Rod Mill
(WRM), PT. Krakatau Steel (Persero), Tbk.
Kerja praktek merupakan salah satu syarat wajib kelulusan pada jenjang
pendidikan S-1 di Jurusan Teknik Elektro Fakultas Teknologi Industri Institut
Teknologi Sepuluh Nopember ( ITS ) Surabaya. Mahasiswa saat ini tidak hanya
dituntut untuk ahli dalam keilmuan teoritis di dalam dunia idealita kampus, namun
juga harus mengetahui dan belajar tentang permasalahan realita lapangan. Sesuai
dengan bidang keilmuan yang dipelajari di kampus.
Dalam penyelesaian kerja praktek ini, penulis mendapatkan banyak
dukungan dan bantuan dari berbagai pihak. Oleh karena itu, penulis mengucapkan
terima kasih kepada:
1. Allah SWT, atas segala rahmat dan kasih karunia-Nya.
2. Orang tua dan seluruh keluarga penulis yang telah memberi dukungan
dalam pelaksanaan kerja praktek.
3. Dr. Tri Arief Sardjono, ST., MT., selaku Ketua Jurusan Teknik Elektro
ITS.
4. Dr. Margo Pujiantara, ST., M.T., selaku dosen pembimbing kami.
5. Semua Pihak yang ada di PT. Krakatau Steel, terutama kepada Pak Imam
Nugroho, Pak Rahmat Sofyan, Pak Didi Turmudi, Pak Sugeng Waluyo,
Pak Singgih, Pak Tatang, Mas Cipta yang membimbing kami selama di
pabrik.
6. Kepada Bu Hani, Pak Medi yang memberikan kami tempat tinggal selama
di Cilegon.
7. Rekan-rekan sesama praktikan Kerja Praktek dari ITS, Unpas, Untad , dan
UNY atas kebersamaannya dalam beberapa kesempatan selama di kota
Cilegon.
8. Dan semua pihak yang telah membantu kami dalam menyelesaikan kerja
praktek ini.
Demikian Laporan Kerja Praktek ini disusun. Penulis menyadari masih
terdapat beberapa kekurangan. Oleh karena itu penulis mengharapkan adanya
masukan dari semua pihak demi penyempurnaan laporan kerja praktek ini.
Semoga laporan ini dapat bermanfaat bagi kita semua dan dapat memberi
masukan bagi siapa saja yang mempergunakannya.
iv
DAFTAR ISI
v
3.3.2.6 Roll Bench ....................................................................... 38
3.3.2.7 Pendulum Shear S-04 ...................................................... 39
3.3.2.8 Deviator ........................................................................... 39
3.3.2.9 Double Roller Table (RT 1.1/RT 1.2) ............................. 39
3.3.2.10 Double Mount Shear ..................................................... 40
3.3.2.11 Horizontal Roughing Mill ............................................. 40
3.3.2.12 Shear 10......................................................................... 41
3.3.2.13 Lowering Trough .......................................................... 41
3.3.2.14 Horizontal Intermediate Mill......................................... 42
3.3.2.15 Intermediate Mill........................................................... 42
3.3.2.16 Up Looper, I, II, III, dan IV .......................................... 43
3.3.2.17 Side Looper (Before Pre-Finishing) .............................. 43
3.3.2.18 Snap Shear (Before Pre-Finishing) ............................... 43
3.3.2.19 Pre-Finishing Block ...................................................... 44
3.3.2.20 Water Box (Before Finishing Block) ............................ 44
3.3.2.21 Crop/Divide (Cd) Shear ................................................ 44
3.3.2.22 Trough Switch ............................................................... 45
3.3.2.23 Chopping Shear ............................................................. 45
3.3.2.24 Side Looper (Before Finishing) .................................... 45
3.3.2.25 Snap Shear (Before Finishing Block) ........................... 46
3.3.2.26 Finishing Block ............................................................. 46
3.3.2.27 Equalization & Water Boxes (After Finishing Block) .. 47
3.3.2.28 Pinch Roll ...................................................................... 48
3.3.2.29 Laying Hand .................................................................. 48
3.3.2.30 Stelmor Conveyor ......................................................... 48
3.3.2.31 Reforming Station ......................................................... 49
3.3.2.32 Coil Transfer Car........................................................... 50
3.3.2.33 Coil Handling ................................................................ 50
3.3.2.34 Compactor ..................................................................... 51
3.4 Tahapan Proses Pembuatan Wire Rod ..................................................... 51
3.4.1 Tahap Pre-Heating Furnace ......................................................... 51
3.4.2 Tahap Reduksi ............................................................................. 52
3.4.3 Tahap Transformasi ..................................................................... 53
BAB VI LANDASAN TEORI.............................................................................. 56
4.1 Segitiga Daya ........................................................................................... 56
4.1.1 Daya Aktif ................................................................................... 56
4.1.2 Daya Reaktif ................................................................................ 56
4.1.3 Daya Nyata .................................................................................. 57
4.1.4 Faktor Daya ................................................................................. 57
4.2 Macam-Macam Beban ............................................................................. 57
4.3 Harmonisa ................................................................................................ 58
4.3.1 Monitoring harmonisa ................................................................. 58
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4.3.2 Sumber-Sumber Harmonisa ....................................................... 59
4.3.2.1 Konverter......................................................................... 59
4.3.2.2 Tanur Busur Listrik ......................................................... 59
4.3.2.3 Transformator .................................................................. 60
4.3.2.4 Mesin-Mesin Berputar .................................................... 61
4.4 Pengaruh Harmonisa ................................................................................ 61
4.4.1 Pengaruh Pada Faktor Daya ....................................................... 61
4.4.2 Pengaruh Pada Saluran Transmisi .............................................. 61
4.4.3 Pengaruh Pada Transformator .................................................... 62
4.4.4 Pengaruh Pada Kapasitor Bank .................................................. 62
4.4.5 Resonansi .................................................................................... 62
4.4.5.1 Resonansi Paralel ............................................................ 62
4.4.5.2 Resonansi Seri ................................................................. 64
4.4.6 Pengaruh Pada Mesin-Mesin Berputar ....................................... 65
4.4.7 Pengaruh Paada Rele Pengaman ................................................. 65
4.4.8 Pengaruh Pada Peralatan Pemutus .............................................. 65
4.4.9 Pengaruh Pada Sistem Tenaga Yang Lain .................................. 66
4.5 Indeks Harmonisa .................................................................................... 66
4.5.1 Total Harmonic Distortion (THD) ............................................. 66
4.5.2 Total Demand Distortion (TDD) ................................................. 69
4.5.3 Total Harmonic Ratio (THR) ..................................................... 69
4.5.4 Distorsi Faktor Daya.................................................................... 69
4.6 Filter Harmonisa ...................................................................................... 70
4.5.1 Filter Harmonisa Pasif ................................................................. 70
4.5.2 Filter Harmonisa Aktif ................................................................ 74
4.7 Reaktor ..................................................................................................... 75
4.8 Derating Transformer .............................................................................. 76
4.9 K-Factor Transformer ............................................................................. 77
4.10 Phase Shifting Transformer ................................................................... 78
4.11 Over Neutral Conductor ........................................................................ 79
4.12 Perbandingan Biaya Investasi ................................................................ 79
4.13 ETAP (Electrical Transient Analysis Program) PowerStation ............. 80
4.13.1 Simulasi Load Flow Analysis ETAP PowerStation .................. 82
4.6.1.1 Studi Aliran Daya (Load Flow Study) ............................ 83
4.6.1.2 Metode Gauss Seidel dalam perhitungan aliran daya ..... 84
4.13.2 Simulasi Short Circuit Analysis ETAP PowerStation ............... 85
4.6.2.1 Memberi Gangguan Pada Bus ......................................... 85
4.6.2.2 Set Up Data Untuk Simulasi ........................................... 85
4.13.3 Data Untuk Analisa Aliran Daya dan Short Circuit .................. 86
4.13.4 Harmonic Load Flow Analysis .................................................. 87
4.13.5 Harmonic Frequency Scan Analysis ......................................... 87
4.14 Kode Warna Bus pada ETAP 7 Saat Load Flow ................................... 88
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4.15 Tap Changer ........................................................................................... 88
BAB V PEMBAHASAN ...................................................................................... 89
5.1 Distribusi Kelistrikan Wire Rod Mill (WRM) ......................................... 89
5.2 Komponen Utama Pada Saluran Distribusi Wire Rod Mill (WRM) ....... 89
5.2.1 Substation ................................................................................... 89
5.2.2 Transformator ............................................................................. 89
5.2.3 Switchgear .................................................................................. 90
5.2.4 Motor .......................................................................................... 90
5.2.5 Harmonic Filter .......................................................................... 90
5.3 Single Line Diagram Pabrik Wire Rod Mill (WRM) .............................. 90
5.4 Analisis Aliran Daya ................................................................................ 92
5.4.1 Pendistribusian Daya Dan Skema Kelistrikan Divisi WRM ...... 92
5.4.2 Aliran Daya Saluran Distribusi 30kV/60kV ............................... 93
5.2.3 Aliran Daya Saluran Distribusi 6kV ........................................... 94
5.5 Analisa Penggunaan Filter ..................................................................... 100
5.5.1 Filter Harmonisa Pasif .............................................................. 100
5.5.2 Analisis Saat Filter Tidak Digunakan (Kondisi Off) ................. 102
5.5.3 Analisis Dengan Filter Harmonisa Frekuensi 250 Hz ............... 105
5.5.4 Analisis Dengan Filter Harmonisa Frekuensi 350 Hz .............. 109
BAB VI PENUTUP ............................................................................................ 112
5.1 Kesimpulan ............................................................................................ 112
5.2 Saran ...................................................................................................... 112
DAFTAR PUSTAKA ......................................................................................... 114
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DAFTAR GAMBAR
Gambar 3.1 Lay-out Wire Rod & Strip Mill di tahun 1979 .................................. 29
Gambar 3.2 Lay-out Wire Rod Mill setelah modernisasi tahap 1 di tahun 1991. 31
Gambar 3.3 Lay-out Wire Rod Mill setelah modernisasi tahap 3 di tahun1997... 32
Gambar 3.4 Lay-out Wire Rod Mill setelah modernisasi tahap 4 di tahun 1998.. 33
Gambar 3.5 Lay-out Wire Rod Mill setelah modernisasi tahap 5 di tahun 1999.. 34
Gambar 3.6 Struktur Organisasi Divisi WRM ...................................................... 35
Gambar 3.7 Flow Process Wire Rod Mill ............................................................. 51
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Gambar 4.15 Page gangguan pada bus. ................................................................ 85
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Gambar 5.33 Bentuk Gelombang Sistem Keseluruhan dengan Filter Harmonisa
Orde Kelima ........................................................................................................ 109
Gambar 5.34 Load Flow Bus Utama dengan Filter Harmonisa Orde Ketujuh ... 110
Gambar 5.35 Spektrum Harmonisa Sistem Keseluruhan dengan Filter Harmonisa
Orde Ketujuh ....................................................................................................... 111
Gambar 5.36 Bentuk Gelombang Sistem Keseluruhan dengan Filter Harmonisa
Orde Ketujuh ....................................................................................................... 111
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DAFTAR TABEL
Tabel 3.1 Equipment Utama Wire Rod & Strip Mill di Tahun 1979................... 30
Tabel 3.2 Data Teknis Furnace ............................................................................ 37
Tabel 3.3 Data Teknis Roll Table After Furnace ................................................. 37
Tabel 3.4 Data Teknis High Pressure Water Descaler ......................................... 38
Tabel 3.5 Data Teknis Pinch Roll ........................................................................ 38
Tabel 3.6 Data Teknis Pre-Roughing Mill ........................................................... 38
Tabel 3.7 Data Teknis Roll Bench ....................................................................... 39
Tabel 3.8 Data Teknis Data Teknis Pendulum Shear S-04 .................................. 39
Tabel 3.9 Data Teknis Deviator ........................................................................... 39
Tabel 3.10Data Teknis Double Roller Table (RT1.1/RT 1.2) .............................. 40
Tabel 3.11Data Teknis Double Mount Shear ........................................................ 40
Tabel 3.12Data Teknis Horizontal Roughing Mill ............................................... 41
Tabel 3.13Data Teknis Shear 10 ........................................................................... 41
Tabel 3.14Data Teknis Lowering Trough ............................................................. 42
Tabel 3.15Data Teknis Horizontal Intermediate Mill ........................................... 42
Tabel 3.16Data Teknis Intermediate Mill ............................................................. 42
Tabel 3.17Data Line Produksi .............................................................................. 43
Tabel 3.18Data Data Teknis Up Looper I,II,III,IV ............................................... 43
Tabel 3.19Data Teknis Side Looper...................................................................... 43
Tabel 3.20Data Teknis Snap Shear ....................................................................... 44
Tabel 3.21Data Teknis Pre-Finishing Block ......................................................... 44
Tabel 3.22Data Teknis Water Box (Before Finishing Block)............................... 44
Tabel 3.23Data Teknis Crop/Divide (Cd) Shear ................................................... 45
Tabel 3.24Data Teknis Trough Switch ................................................................. 45
Tabel 3.25Data Teknis Chopping Shear ............................................................... 45
Tabel 3.26Data Teknis Side Looper...................................................................... 46
Tabel 3.27Data Teknis Snap Shear ....................................................................... 46
Tabel 3.28Data Teknis Finishing Block................................................................ 47
Tabel 3.29Data Teknis Equalization & Water Boxes ........................................... 48
Tabel 3.30Data Teknis Pinch Roll ........................................................................ 48
Tabel 3.31Data Teknis Laying Head .................................................................... 48
Tabel 3.32Pendinginan Stelmor Conveyor ........................................................... 49
Tabel 3.33Data Teknis Stelmor Conveyor ............................................................ 49
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Tabel 3.34Data Teknis Reforming Station............................................................ 50
Tabel 3.35Data Teknis Coil Transfer Car ............................................................. 50
Tabel 3.36Data Teknis Coil Handling .................................................................. 50
Tabel 3.37Data Teknis Compactor ....................................................................... 51
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