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ITS » Undergraduate Theses » Teknik Bangunan Kapal
Posted by tondoindra@gmail.com at 16/10/2012 13:54:15  •  1588 Views


APLIKASI TEMPER BEAD WELDING TBW UNTUK MENGHINDARI PROSES POST WELD HEAT-TREATMENT PWHT PADA SAMBUNGAN TUBE STUB TO PIPE HEADER - PRESSURE PART BOILER DI PT. DINAMIKA ENERGITAMA NUSANTARA SURABAYA

TEMPER BEAD WELDING TBW APLICATIONS TO AVOID POST WELD HEAT-TREATMENT PWHT PROCESS AT WELDING JOINT TUBE STUB TO PIPE HEADER - PRESSURE PART BOILER IN PT. DINAMIKA ENERGITAMA NUSANTARA SURABAYA

Author :
AMIR, FAISAL  ( 6707040006 )




ABSTRAK

PT. Dinamika Energitama Nusantara DEN adalah sebuah perusahaan lokal dengan akses global yang bergerak pada bidang Steam Generator. Saat ini PT. DEN sedang memproduksi Boiler Stoker. Sesuai dengan Inspection and Test Plan ITP dalam proyek PLTU Maluku Utara 2x7 MW bagian Wall Header mendapat perlakuan khusus yaitu proses PWHT. Menurut Welding Technology Institute of Australia WTIA salah satu cara untuk menghindari proses PWHT adalah dengan teknik Temper Bead Welding TBW. Teknik TBW dikembangkan dengan tujuan untuk mensimulasikan efek tempering pada PWHT. Material yang digunakan adalah plat SA 36 sebagai tes kupon untuk pembuatan WPS dan PQR dan 3 set sambungan pengelasan tube SA 192 dengan pipa SA 106 gr.B. Proses pengelasan yang dilakukan adalah GTAW dan SMAW. Variabel yang digunakan adalah non-PWHT PWHT dan TBW. Dari literatur yang ada dilakukan pengujian makro pengujian mikro pengujian kekerasan dan simulasi tegangan sisa menggunakan metode elemen hingga MEH pada setiap set benda kerja untuk melihat perbedaan antara ketiganya. Hasil yang diperoleh dari data pengelasan benda kerja plat adalah dokumen WPS dan PQR untuk teknik TBW. Dilihat dari hasil uji makro ketiga objek dengan variabel Non-PWHT PWHT dan TBW terdapat cacat incomplete fusion dan slag inclusion namun tidak mengindikasikan retak. Dilihat dari hasil uji mikro struktur mikro daerah HAZ pada objek non-PWHT paling besar diantara objek lainnya. Untuk objek PWHT terlihat struktur pada daerah HAZ lebih merata dari fusion line menuju base metal. Sedangkan pada objek TBW terlihat butiran-butiran struktur daerah HAZ masih begitu besar dengan semakin mendekati fusion line. Dilihat dari hasil uji kekerasan dari objek Non-PWHT terjadi penurunan nilai kekerasan akibat perlakuan proses PWHT. Prosentase penurunan kekerasan rata-rata 1014 pada daerah mahkota las. Sedangkan dengan teknik TBW prosentase penurunan kekerasan rata-rata 501 pada daerah mahkota las. Dilihat dari hasil simulai MEH nilai tegangan sisa pada objek non- PWHT sangat besar sekali. Dengan diberlakukannya teknik TBW akan dapat menurunkan nilai tegangan sisa akhir dari besar 865 MPa menjadi 302 MPa.


ABSTRACT

PT. Dinamika Energitama Nusantara DEN is a local company with global access that moves on the field of Steam Generator. Currently PT. DEN is Stoker Boiler manufacturing. In accordance with the Inspection and Test Plan ITP in PLTU Maluku Utara 2x7 MW Project the Wall Header got special treatment namely the process of PWHT. According to the Welding Technology Institute of Australia WTIA one way to avoid PWHT process is a Temper Bead Welding TBW technique. TBW technique was developed to simulate the effect of tempering at the PWHT. The material used is plate SA 36 as a test coupon for the manufacture of WPS and PQR and 3 sets of tube SA 192 connection with a pipe SA 106 gr.B. Welding process is carried out GTAW and SMAW. The variable used is a non- PWHT PWHT and TBW. From the existing literature conducted testing of macro micro testing hardness testing and simulation of residual stress using the finite element method FEM to each set of the workpiece to see the difference between the three. The results obtained from the welding data plate workpiece is a document WPS and PQR for TBW techniques. Judging from the results of the macro test the three objects with a variable non-PWHT PWHT and TBW there is incomplete fusion defects and slag inclusions but does not indicate cracks. Judging from the results of the test micro micro structure of the HAZ on the non-PWHT object is greatest among other objects. For the PWHT object visible structures in the HAZ region more evenly from fusion line to the base metal. While on TBW object visible granules HAZ region structure is still so great with getting closer to fusion line. Judging from the results of hardness test the Non-PWHT object to be impaired due to the treatment process PWHT. Percentage decrease in violence on average 10.14 in the weld crown area. While the TBW technique the percentage decrease in the average hardness 5.01 in the crown area. Judging from the results of FEM simulations the value of residual stress in a non-PWHT object is immense. With the enactment of TBW techniques it can reduce the value of residual stress from the large 8.65 MPa end of a 3.02 MPa.PT. Dinamika Energitama Nusantara DEN is a local company with global access that moves on the field of Steam Generator. Currently PT. DEN is Stoker Boiler manufacturing. In accordance with the Inspection and Test Plan ITP in PLTU Maluku Utara 2x7 MW Project the Wall Header got special treatment namely the process of PWHT. According to the Welding Technology Institute of Australia WTIA one way to avoid PWHT process is a Temper Bead Welding TBW technique. TBW technique was developed to simulate the effect of tempering at the PWHT. The material used is plate SA 36 as a test coupon for the manufacture of WPS and PQR and 3 sets of tube SA 192 connection with a pipe SA 106 gr.B. Welding process is carried out GTAW and SMAW. The variable used is a non- PWHT PWHT and TBW. From the existing literature conducted testing of macro micro testing hardness testing and simulation of residual stress using the finite element method FEM to each set of the workpiece to see the difference between the three. The results obtained from the welding data plate workpiece is a document WPS and PQR for TBW techniques. Judging from the results of the macro test the three objects with a variable non-PWHT PWHT and TBW there is incomplete fusion defects and slag inclusions but does not indicate cracks. Judging from the results of the test micro micro structure of the HAZ on the non-PWHT object is greatest among other objects. For the PWHT object visible structures in the HAZ region more evenly from fusion line to the base metal. While on TBW object visible granules HAZ region structure is still so great with getting closer to fusion line. Judging from the results of hardness test the Non-PWHT object to be impaired due to the treatment process PWHT. Percentage decrease in violence on average 10.14 in the weld crown area. While the TBW technique the percentage decrease in the average hardness 5.01 in the crown area. Judging from the results of FEM simulations the value of residual stress in a non-PWHT object is immense. With the enactment of TBW techniques it can reduce the value of residual stress from the large 8.65 MPa end of a 3.02 MPa.



KeywordsPWHT ; TBW ; Uji makro ; Uji mikro ; Uji kekerasan ; Metode elemen hingga (MEH)
 
Subject:  Ketel uap
Contributor
  1. MOH. MIFTACHUL MUNIR, ST., MT.
  2. I PUTU SINDHU ASMARA, ST., MT.
Date Create: 09/08/2011
Type: Text
Format: pdf
Language: Indonesian
Identifier: ITS-Undergraduate-670011200001018
Collection ID: 670011200001018
Call Number: 621.183 Ami a


Source
Undergraduate Thesis, Welding Engineering,621.183 Ami a, 2012

Coverage
ITS Community

Rights
Copyright @2011 by ITS Library. This publication is protected by copyright and per obtained from the ITS Library prior to any prohibited reproduction, storage in a re transmission in any form or by any means, electronic, mechanical, photocopying, reco For information regarding permission(s), write to ITS Library




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  1.  ITS-Undergraduate-21516-6707040006-Abstract_id.pdf - 180 KB
  2.  ITS-Undergraduate-21516-6707040006-Abstract_en.pdf - 180 KB
  3.  ITS-Undergraduate-21516-6707040006-Conclusion.pdf - 182 KB




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