materi pt di
TRANSCRIPT
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TEKNIK PEMBUATAN TABUNG CNG
Disiapkan oleh :
Direktur Teknologi dan Pengembangan PT Dirgantara Indonesia (PTDI)
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KERANGKA BAHASAN
•Pendahuluan
• Evaluasi Regulasi
•Design Analisis
•Prototipe Produksi
•Sertifikasi Test
•Serial Produksi
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PENDAHULUAN
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SPIN-OFF KOMPETENSI
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CONVERTER KIT CNG
1. CNG Filling valve
2. Cylinder Valve
3. CNG Cylinder
4. Reducer
5. Filter
6. Injector
7. Gas ECU
8. Change Over Switch
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TABUNG CNG
Type 1 Type 2
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TABUNG CNG, cont…
Type 3 Type 4
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EVALUASI REGULASI
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EVALUASI REGULASI
Ada 2 Regulasi besar yg mengatur pembuatan
Tabung :
ECE R110
ISO 11439
Regulasi menentukan syarat Minimum Aspek
Safety, yaitu :
Design Analisis
Produksi
Sertifikasi Test
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DESIGN ANALISIS
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DESIGN ANALISIS
Mendesign Tabung harus memenuhi ketentuan yg
dipersyaratkan oleh regulasi :
1. Design and Safety Analisis
2. Material Analisis dan Proses Produksi
3. Stress Analisis
4. Drawing
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DESIGN ANALISIS (cont …)
1. Design & Safety Analisis
ECE R110 mensyaratkan Pembuatan Dokumen yg menjelaskan :
Spesifik Komponen Secara Detail.
Temperatur Range (Temp. Gas : -40°C s/d +65°C / Temp. Tabung : -40°C s/d
+82°C)
Pencegahan Api (Fire Protection)
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DESIGN ANALISIS (cont …)
2. Material Analisis & Proses Production
ECE R110 mensyaratkan Pembuatan Dokumen yg menjelaskan :
Material
Data Test Material
Detail Proses Pembuatan
Inspeksi dan Pengujian
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DESIGN ANALISIS (cont …)
3. Stress Analisis
ECE R110 mensyaratkan Pembuatan Dokumen yg menjelaskan :
Finite Element Stress Analisis or Stress Analisis Lainnya
Stress Analisis Menentukan Ketebalan Minimum Dinding Tabung.
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DESIGN ANALISIS (cont …)
4. Drawing
ECE R110 mensyaratkan Pembuatan Drawing yg menjelaskan :
Spesifikasi Komponen dan Scala Gambar
Judul, Number Drw, Tanggal, Revisi, Toleransi, Regulasi, dll
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PROTOTIPE PRODUKSI
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PROTOTIPE PRODUKSI
Prototipe produksi adalah Trial Produksi sebelum
mendapatkan sertifikasi
Drawing and Dokumen Proses Produksi sebagai
acuan dalam memproduksi Tabung.
Sebagai contoh proses Produksi “Tabung Type 4”,
sbb :
1. Liner Produksi
2. Neck Ring Produksi
3. Winding Proses
4. Curing Proses
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PROTOTIPE PRODUKSI (cont …)
LINER NECK RING
CURING WINDING
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SERTIFIKASI TEST
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SERTIFIKASI TEST
Pemenuhan tabung sesuai ECE R110 didemonstrasikan melaui :
Sertifikasi Test (Prosedur Test & Pelaksanaan Test)
Sertifikasi Data (Hasil Test Analisis)
1. ProSedur Test
Dokumen Test Procedur sebagai acuan pelaksanaan
test utk menunjukkan pemenuhan regulasi.
Quality Inspector akan mengecek kesesuaian
rangkaian peralatan test mengacu pada Doc.
Prosedur Test.
Peralatan Test harus terkalibrasi.
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SERTIFIKASI TEST (cont …)
2. PELAKSANAAN TRIAL Test
Dimungkinkan adanya kesalahan dan perbaikan
sampai memenuhi Regulasi.
Dimungkinkan adanya perbaikan Dokumen dan
Drawing.
Jenis Test tergantung dari Type Tabung,
diantaranya : Hydrostatic Test, Burst Test, Cycling
Test, Bonfire test, Penetration Test, dll.
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SERTIFIKASI TEST (cont …)
3. Pelaksanaan sertifikasi Test
Disaksikan dengan Authority guna menunjukkan
produksi tabung memenuhi persyaratan.
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SERTIFIKASI TEST (cont …)
ECE R110 mensyaratkan :
Minimum burst pressure lebih dari 450 bar
Burst Test Execution
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SERTIFIKASI TEST (cont …)
Cycling Test Execution
ECE R110 mensyaratkan :
Tekanan Cycle antara ≤ 20 bar dan ≥ 260 bar dengan rate ≤ 10 cycle per min
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SERTIFIKASI TEST (cont …)
Bonfire Test Execution
ECE R110 mensyaratkan :
Tabung terpasang fire protection system (cylinder valve, pressures relief device
(PRD) and/or integral thermal insulation)
Gas keluar lewat lubang pressure relief device.
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SERTIFIKASI TEST (cont …)
Penetration Test Execution
ECE R110 mensyaratkan :
Tabung ditembus peluru berdiameter minnmal 7.62 mm pada bagian dinding
tabung dengan sudut 45°
Tidak terjadi pecah berkeping
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SERTIFIKASI TEST (cont …)
Drop Test Execution
ECE R110 mensyaratkan :
Tabung dijatuhkan pada posisi Horisontal, Vertikal dan sudut 45°
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SERTIFIKASI TEST (cont …)
4. HASIL TEST ANALISIS
Hasil prototipe test memuaskan,
Authority mengeluarkan Test
Certifiacte
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SERIAL PRODUKSI
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SERIAL PRODUKSI
ECE R110 mensyaratkan selama serial produksi dilakukan :
Produksi Test (Hydrostatic Test, Leak Test, dll)
Sampling / Batch Test (Burst Test, Cycling Test, dll)
Hydrostatic Test Leak Test
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SERIAL PRODUKSI (cont …)
LINER INSTALL NECK
RING & SUPPORT WINDING
WINDING CURING
BETCH TEST ?
HYDROSTATIC TEST
DRYER
INSTALL CYLINDER VALVE LEAK TEST PACKAGING
BURST TEST & CYCLING TEST (per 200 unit)
NO
YES
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NATIONAL GAS AUTHORITY
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Synergy Among Industries – Authority – R&D
MANISTRY OF LABOR
MINISTRY OF INDUSTRY
MINISTRY OF ENERGY
MINISTRY OF TRANSPORTATION
KEM.ESDM KEM.ESDM
INDUSTRIES
KEM.ESDM KEM.ESDM TEST HOUSE &
LABORATORIES
USER#A USER#B USER#C USER#D
UNIVERSITIES AND
R&D INSTITUTIONS
NATIONAL GAS AUTHORITY
PTDI PROPOSAL