MATERIAL DAN PEMBUATAN

KOMPONEN/PERALATAN MEKANIK PEMBANGKIT

 MATERIAL KOMPONEN/PERALATAN MEKANIK PEMBANGKIT LISTRIK
JENIS PEMBANGKIT PERALATAN DAN TEMPERATUR OPERASI
A) PEMBANGKIT THERMAL o Boiler (ambient/room temperature, moderate
 PLTU and high temperature)
o Steam Turbine (high temperature)
 PLTG o Compressor (ambient/room temperature to
moderate temperature)
o Combustor (high temperature)
o Vanes/Nozzles and Bucket/Rotating Blades
(high temperature)
 PLTGU/HRSG o HRSG dan Steam Turbine (hampir serupa
seperti pada PLTU)
 PLTP o Rotor, Blades dan Steam Turbine (hampir
serupa seperti pada PLTU, tetapi pada suhu
yang relatif lebih rendah)
 PLTD o Engine Components (ambient/room
temperature, moderate and high temperature)
B) PEMBANGKIT LISTRIK o Penstock, Turbine Casing/Housing, Turbine
TENAGA AIR (PLTA) Runner, etc. (ambient/room temperature)
JENIS MATERIAL
Cast iron, carbon steel,
low-alloy steel, high alloy
steel/stainless steel
Cast iron, carbon steel,
low-alloy steel, stainless
steel and Ni/Co-based
super alloys
Cast iron, carbon steel,
low-alloy steel, high alloy
steel/stainless steel
Cast iron, carbon steel,
low-alloy steel, high alloy
steel/stainless steel
Cast iron, carbon steel,
low-alloy steel, high alloy
steel/stainless steel
Cast iron, carbon steel,
low-alloy steel, high alloy
steel/stainless steel
 LOGAM DAN PADUAN
Komponen/Peralatan Pembangkit
PEMBAGIAN LOGAM MENURUT KOMPOSISI KIMIA:
 LOGAM BESI/BAJA (Ferrous Metals & Alloys)
 LOGAM BUKAN BESI/BAJA (Non-Ferrous Metals & Alloys)
PEMBAGIAN PRODUK LOGAM MENURUT PROSES
PEMBUATAN:
 PRODUK TUANG (Castings)
 PRODUK TEMPA (Mill or Wrought Products)
A. Pembagian Logam Besi Baja (Ferrous Metals & Alloys)
1. Besi Tuang (Cast Iron)
• Besi Tuang Kelabu (Grey Cast Iron)
• Besi Tuang Ulet (Ductile/Nodular Cast Iron)
• Besi Tuang Malleable (Malleable Cast Iron)
• Besi Tuang Putih (White Cast Iron)
• Besi Tuang Paduan (Alloy Cast Iron)
2. Baja Karbon (Carbon Steel)
• Baja Karbon Ekstra Rendah (C<0.08%)
• Baja Karbon Rendah (0.08-0.35% C)
• Baja Karbon Sedang (0.35-0.50% C)
• Baja Karbon Tinggi (0.55-1.7% C)
3. Baja Paduan Rendah (Low Alloy Steel)
(Bila Unsur Pemadu ≤ 8%)
• Baja untuk komponen mesin (roda gigi, poros, baut, dll)
• Baja untuk boiler dan bejana tekan (pressure vessels)
 A.Pembagian Logam Besi Baja (Ferrous Metals & Alloys)
lanjutan
4. Baja Paduan Tinggi (High Alloy Steel)
(Bila Unsur Pemadu > 8%)
• Baja Tahan Korosi (Corrosion Resistant Steel)
Stainless steels
 Tipe austenit
 Tipe feritik
 Tipe martensit
 Tipe duplek/superduplek
 Tipe PH (precipitation hardening)
• Baja Tahan Panas (Heat Resistant Steel)
(Jenis baja ini juga banyak menggunakan stainless steel tipe austenit)
• Baja Tahan Aus (Wear Resistant Steel)
5. Baja Spesial untuk perkakas/pahat potong dan cetakan logam (Tool Steels)
- High speed tool steels - Shock resisting tool steels
- Hot work tool steels - Low carbon mold steels
- Cold work tool steels - Special purpose tool steels
6. Baja Super Paduan (Iron Base Superalloys)
(Penamaan didasarkan pada trade-mark)
B. LOGAM BUKAN BESI / BAJA (NON-FERROUS METALS & ALLOYS)

1. Logam Aluminium dan Paduan

• Jenis yang tidak bisa dikeraskan dengan proses laku panas
(Non-Heat Treatable Aluminium Alloys)
• Jenis yang dapat dikeraskan dengan proses laku panas (Heat-
Treatable Aluminium Alloys)
2. Logam Tembaga dan Paduan (Coppers and High Copper Alloys,
Brasses, Bronzes, Cupronickel, dll)
3. Paduan Nikel (Nickel-Base Superalloys)
4. Paduan Titanium
5. Paduan Cobalt (Cobalt-Base Superalloys)
6. Dan lain-lain
MATERIALS SCOPE FOR POWER PLANT COMPONENTS/EQUIPMENT
 Cast Irons (grey, malleable, nodular/ductile and white)
 Carbon Steels (low, medium and high carbon)
 Low-Alloy Steels
 Mo Steels
 Cr-Mo Steels
 Cr-Ni-Mo Steels, Etc
 Wrought Stainless Steels
 Austenitic types
 Ferritic types
 Martensitic types
 Duplex /superduplex types
 Precipitation-hardening (PH) types
 Cast Stainless Steels
 Corrosion-resistant cast stainless steels
 Heat-resistant cast stainless steels
 Superalloys (Casting, Wrought & P/M)
 Iron-base superalloys
 Nickel-base superalloys
 Cobalt-base superalloys
PERBANDINGAN KOMPOSISI KIMIA LOGAM / PADUAN BESI DAN BAJA
Kadar Unsur (% Berat)
Jenis Logam /
Paduan C Mn Si P S Unsur Lainnya Fe

Besi Tuang (Cast

2,5-4,0 0,2-1,0 1,0-3,0 0,02-1,0 0,02-0,25 - Balance
Iron) / BT Kelabu
Baja Karbon
0,06-1,0 0,3-1,0 0,15-0,35 0,05 (max) 0,05 (max) - Balance
(Carbon Steel)
Baja Paduan
Cr; Mo; Cr + Mo;
Rendah (Low-Alloy 0,1-0,5 0,4-1,9 0,15-0,35 0,05 (max) 0,05 (max) Balance
Cr + Ni; Ni + Cr + Mo, dll
Steel)
Baja Tahan Karat
(Stainless Steel)
Balance
a) Produk Mill 0,03-0,25 2 (max) 1 (max) 0,05 (max) 0,05 (max) (16 →25 Cr) + (8→14 Ni)
b) Produk Tuang 0,20-0,70 1-2 1-2,5 0,05 (max) 0,05 (max) (12-30 Cr) + (1-30 Ni) + dll
Mo : 1-10
W : 1-19
Baja Perkakas
0,3-1,25 0,15-0,70 0,15-0,65 0,05 (max) 0,05 (max) V : 1-4 Balance
(Tool Steel)
Co : 0-10
Ni : 0,3
Baja Paduan Super Ni : 20-40
(Iron Base 0,04-0,05 0,5-1,0 0,15-0,50 0,05 (max) 0,05 (max) Cr : 12,5-23,5 Balance
Superalloy) Mo : Al; Ti, dll
 BEBERAPA NAMA STANDAR / SPESIFIKASI
LOGAM DAN PADUAN
1) SNI = Standar Nasional Indonesia
2) AISI = American Iron and Steel Institute
3) ASTM = American Standard for Testing and
Materials
(spesifikasi ASTM umumnya identik dengan
ASME, dimana spesifikasi ASTM biasanya
diawali dengan huruf A)
4) ASME = American Society of Mechanical
Engineers
(Penamaan untuk ASME diawali dengan
huruf SA untuk Ferrous dan SB untuk
Non-Ferrous)
5) JIS = Japanese Industrial Standard
6) ACI = Alloy Casting Institute
7) AA = Aluminum Association
8) API = American Petroleum Institute
9) AWS = American Welding Society
10) DIN (Standar Jerman)
11) Dan Lainnya (nominal composition, trade name, etc)
 PROSES MANUFAKTUR DAN FABRIKASI KOMPONEN/PRODUK LOGAM

 PENGECORAN (FOUNDRY/CASTING) CAST PRODUCT (CASTING)

 TEMPA (FORGING) FORGING (WROUGHT/MILL PRODUCT)
 PENGEROLAN (ROLLING) PELAT/LEMBARAN/BATANG/PROFIL (WROUGHT/MILL)
 PEMBUATAN PIPA (PIPE/TUBE MANUFACTURE) • ELECTRIC RESISTANT WELDED PIPE/TUBE
• SEAMLESS PIPE/TUBE
• SPIRAL WELDED PIPE
 EKSTRUSI (EXTRUSION) SEAMLESS TUBE (WROUGHT/MILL)
 PEMBUATAN BAUT MILL (WROUGHT)
 FORMING/BENDING U-BEND & ELBOW TUBE/PIPE (MILL/WROUGHT)
 PEMBUATAN KAWAT (WIRE DRAWING) KAWAT (MILL/WROUGHT)
 PENGELASAN (WELDING)
 PERMESINAN (MACHINING)
 PERLAKUAN PANAS (HEAT TREATMENT)
 FINISHING (SURFACE COATING & SURFACE TREATMENT)
 BENTUK PRODUK (PRODUCT FORMS)

 Castings  Cast Pipe

 Forgings  Forged Pipe
 Bar  Welded Pipe
 Plate  Seamless Pipe
 Sheet/Strip  Cast Tube
 Rod  Welded Tube
 Wire  Seamless Tube
 Structural Shape  Seamless &
 Fittings Welded Fittings
 Hubungan Struktur, Sifat dan Kinerja Material

 Struktur Sifat Material Kinerja/Performance

 Cacat in Service
• Sifat Mekanis
 Residual
• Sifat Kimia •Fatigue Resistance
Stress
• Sifat Fisika •Heat Resistance
• Dll •Corrosion Resistance
•Impact Resistance
 Komposisi Kimia
•Wear Resistance
 Manufaktur/
•Erosion Resistance
Fabrikasi
•Formability
 Heat Treatment/
•Weldability
Surface Treatment
•Machinability
 Shipping & Handling
 PROSES PEMBUATAN/MANUFAKTUR LOGAM PADA INDUSTRI HILIR

A. PROSES PELEBURAN/PEMADUAN DAN PENUANGAN

(Melting/Alloying/Refining/Casting)
B. PROSES SERBUK LOGAM (POWDER METALLURGY)

PRODUK TUANG (Cast

Products/Castings)
Komponen Setengah Jadi

Billet, Slab, Bloom

Proses Pembentukan Panas (Hot

Working)
- Pelat
- Profil/Beam
- Rel
- Baja Tulangan
-Pipa
-Komponen/Tempa
- Dll. Proses Pembentukan Dingin (Cold Working)

- Pelat tipis/lembaran
- Kawat
- Dll.
 PROSES FABRIKASI DAN FINISHING LOGAM
PADA INDUSTRI HILIR
Produk Setengah Jadi

 Komponen (Castings)
 Produk mill (wrought)

Proses Fabrikasi dan Finishing Pengesetan dan Perakitan/

Assembling
· Sheet metal working
(pengerjaan pelat)
-Pemotongan
- Pengepresan
- Tekuk, dll Produk Jadi
 Machining
· Pengelasan (welding) dan
teknik penyambungan lainnya
 Proses Laku Panas (Heat Treatment)
 Proses Pelapisan (Metal Coatings)
 Proses Perlakuan Permukaan
(Surface Treatment)
 Dll.
 Casting
Process in which molten metal flows
by gravity or other force into a
mold where it solidifies in the
shape of the mold cavity
• The term casting also applies to
the part made in the process
• Steps in casting seem simple:
1. Melt the metal
2. Pour it into a mold
3. Let it freeze
Rancangan Pola/Pattern Pembuatan Cetakan (Mold)
untuk Proses Pengecoran
 Features of a Sand Mold

Schematic illustration of a sand mold, showing various features.

Proses Penuangan
 Proses Tempa (Forging)

The board drop hammer is a forging machine which forms workpieces by high impact
blows. Forging also includes squeezing pressures
• Forging may be defined as a metal working process by which metals and alloys
are plastically deformed to desired shapes by the application of compressive
force. Forging may be done either hot or cold.

Forging

Hot forging,

open-die

[Heated] metal is beaten with a

heavy hammer to give it the
required shape
PROSES PENGELASAN
(WELDING)
MASUKAN PANAS (HEAT
INPUT)
PANA
HAZ
S
WM
BM

DINGIN

SIKLUS TERMAL

• PERUBAHAN STRUKTUR
METALURGI
• CACAT LAS (WELD DEFECTS)
• TEGANGAN
TERMAL/TEGANGAN SISA
(RESIDUAL STRESS)
PEAK TEMP. (Tp) TEMP. (°C)

2000
LIQUID (L)
1800

1600 +L
(a)
1400
(b) + L+
1200

(c) 1000
+ + Fe3C
(d) 800

(e) 600

400
+ Fe3C
200

0,2 1,0 2,0

WT % C
(a)PARTLY MOLTEN ZONE; Tp CLOSE TOTHE MELTING POINT
(b) COARSE-GRAINED REGION; 1150°C Tp 1450°C
(c)GRAIN-REFINED REGION; Ac3 Tp < 1150°C
(d) INTERCRITICAL REGION; Ac1 Tp < Ac3
(e)SUBCRITICAL REGION; 550°C Tp < Ac1
Pengaruh temperatur las terhadap struktur-mikro sambungan las pelat baja karbon
rendah.
JENIS-JENIS CACAT LAS (WELD DEFECTS)
Welding and Inspection (menurut API 610)
PROSES MACHINING AND FINISHING
 Turning
 Shaping
 Milling
 Drilling / Boring
 Reaming
 Tapping
 Sawing
 Honing
 Various Finishing Processes
KOMPONEN DAN PERALATAN PLTU/ HRSG
BOILER & AUXILIARY  Tube Retaining Brackets
 Heat Exchanger - Feed Water Heater
 Pipe - Main Feed Water Pipe - Air Preheater
- Boiler Feed Water Pipe  Fan - Forced Draft Fan
- Headers - Induced Draft Fan
- Downcomer  Shoot Blower
- Connecting Pipe  Burner & Wind Box
- Main Steam Pipe  Coal Pulverizer
 Coal & Ash Handling System
- Pipe Elbow, U bend, dll
 Electrostatic Precipitator
 Tube - Condenser Tube  Stack
- Furnace Wall Tube  Boiler Water Treatment Plant
- Economizer Tube  Dan lain-lain
- Reheater Tube STEAM TURBINE
- Superheater Tube
 HP-IP Rotor/Disk
- Riser Tube
 LP Rotor/Disk
- Tube Elbow, U bend, dll  HP-IP Blade
 Drum - Steam Drum  LP Blade
 Pump - Boiler Feed Pump  Fix Vanes (Nozzles)
- Condensate Pump  Casing, Steam Chest, Valves
- Sea Water Pump  Bolts
 JENIS MATERIAL DAN PROSES MANUFAKTUR/FABRIKASI
BEBERAPA KOMPONEN PLTU/HRSG
Jenis Komponen Jenis Material
 Pipe  Baja Karbon (Carbon Steel)
 Baja Paduan Rendah (Low Alloy
Steel)
 Tube  Baja Karbon (Carbon Steel)
 Baja Paduan Rendah (Low Alloy
Steel)
 Baja Paduan Tinggi (Stainless
Steel)
 Cupro Nickel; Titanium; Brass;
Stainless Steel untuk Condenser
Tube
 Drum  Baja Karbon/Baja Paduan
Rendah
 Pump  Besi Tuang Kelabu (Gray Cast
Iron) untuk Pump
Casing/Housing
 Baja Tahan Karat (Stainless
Steel) untuk Impeler
 Baja Karbon/Baja Paduan
Rendah untuk Shaft
Proses Manufaktur/Fabrikasi
o ERW (Electric Resistance Welded) Pipe
o Seamless Pipe
o Penyambungan dengan pengelasan (welding)
o Elbow dibuat dengan Bending
o ERW Tube
o Seamless Tube
o Penyambungan dengan pengelasan (welding)
o Elbow/U Bend Tube dibuat dengan proses bending.
o Pelat (Plate)
o Tempa (Forging)
o Pengelasan (Welding)
o Proses Pengecoran (Casting) dan Machining
o Proses Pengecoran dan Machining
o Proses Rolling, Machining dan Surface Treatment
 JENIS MATERIAL DAN PROSES MANUFAKTUR/FABRIKASI (lanjutan)
Jenis Komponen Jenis Material Proses Manufaktur/Fabrikasi
 Tube Retaining  Baja tuang tahan panas (Heat o Proses Pengecoran (Casting)
Bracket Resistant Cast Stainless Steel)
 Fan  Shaft dibuat dari baja karbon o Proses Forging/Rolling, Machining and Surface
medium/baja paduan rendah Treatment
 Bantalan Jalan (Journal Bearing) o Pelat baja dibentuk dengan bending, babbiting/bronze
: dibuat dari Tri-metal (Babbit + dengan casting/ welding/electroplating
bronze + steel)
 Burner  Stainless Steel Nozzle o Proses Pengecoran (Casting)
 Stainless Steel Tube o Proses Rolling/Seamless Tube
o Proses Welding
 Steam Turbine
• HP-IP Rotor  High Alloy Steel o Forging + Machining + Heat Treatment
• LP Rotor  Low Alloy Steel o Forging + Machining + Heat Treatment
• HP-IP Blade  Stainless Steel o Casting/Forging + Machining + Heat Treatment
• LP Blade  Stainless Steel o Casting/Forging + Machining + Heat Treatment
• Casing  Cast Iron/Cast Steel o Casting + Machining
• Bolt  Low Alloy/High Alloy Steel o Forging / Heat Treatment
 Generator  High Alloy Steel (Magnetic o Casting/Forging
• Rotor Permeability)
• Retaining Ring  High Alloy Steel (Mn-Cr Steel) o Casting/Forging
dengan sifat Non-Magnetic
 Cast Iron/Cast Steel
• Casing  Enameled Cu Wire o Casting & Machining
• Winding o Drawing & Enameling