Laporan Akhir Industri Root Cause Failure Analisis Air Heater Leakage Pada PT. PLN Nusantara Power UP Paiton

Prabowo, Zufar Hakim (2025) Laporan Akhir Industri Root Cause Failure Analisis Air Heater Leakage Pada PT. PLN Nusantara Power UP Paiton. Project Report. [s.n.]. (Unpublished)

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Abstract

Laporan magang industri ini disusun berdasarkan pelaksanaan Magang Industri di PT PLN Nusantara Power Unit Pembangkitan Paiton Unit 1 & 2 selama periode 20 Januari 2025 hingga 20 Mei 2025, dengan fokus utama pada analisis akar penyebab kebocoran (leakage) pada Air Heater menggunakan metode Root Cause Failure Analysis (RCFA). Berdasarkan data operasional, tingkat kebocoran pada Air Heater A tercatat sebesar 8,62% dan Air Heater B sebesar 7,26%, melebihi batas aman sebesar 5%. Analisis menggunakan diagram fishbone mengidentifikasi bahwa penyebab utama kebocoran adalah keausan seal serta korosi pada elemen basket, khususnya cold end basket, akibat kondensasi asam dari gas buang. Kebocoran tersebut menimbulkan kerugian bahan bakar sebesar 342.150,82 ton batu bara per tahun atau setara Rp321.423.663.814. Sebagai rekomendasi, dilakukan evaluasi finansial menggunakan metode Kajian Kelayakan Finansial (KKF) terhadap dua opsi penggantian seal, yaitu brush seal dan metallic strip seal. Hasil analisis menunjukkan bahwa brush seal merupakan pilihan yang lebih unggul dengan nilai NPV sebesar Rp645.747.683, payback period 1,03 tahun, serta mampu menekan tingkat kebocoran hingga di bawah 10%, sehingga direkomendasikan sebagai solusi untuk meningkatkan efisiensi termal dan keandalan operasional pembangkit.
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This industrial internship report was prepared based on the internship program conducted at PT PLN Nusantara Power Paiton Generation Unit 1 & 2 from January 20, 2025, to May 20, 2025, with the main focus on analyzing the root cause of Air Heater leakage using the Root Cause Failure Analysis (RCFA) method. Based on operational data, the leakage rate of Air Heater A was recorded at 8.62% and Air Heater B at 7.26%, exceeding the safe limit of 5%. Analysis using a fishbone diagram identified worn seals and corrosion on the basket elements, particularly the cold end basket caused by acid condensation from flue gas, as the main causes of leakage. This leakage resulted in fuel losses of 342,150.82 tons of coal per year, equivalent to IDR 321,423,663,814. As a recommendation, a financial evaluation was carried out using the Financial Feasibility Study (KKF) method on two seal replacement options: brush seal and metallic strip seal. The analysis results show that the brush seal is the superior option, with an NPV of IDR 645,747,683, a payback period of 1.03 years, and the ability to reduce the leakage rate to below 10%. Therefore, the brush seal is recommended as a solution to improve the thermal efficiency and operational reliability of the power plant.

Item Type:	Monograph (Project Report)
Uncontrolled Keywords:	Air Heater, leakage, Root Cause Failure Analysis, brush seal, Paiton coal-fired power plant, thermal efficiency, Air Heater, kebocoran, Root Cause Failure Analysis, brush seal, PLTU Paiton, efisiensi termal.
Subjects:	T Technology > TJ Mechanical engineering and machinery T Technology > TJ Mechanical engineering and machinery > TJ263 Heat exchangers
Divisions:	Faculty of Vocational > Mechanical Industrial Engineering (D4)
Depositing User:	Zufar Hakim Prabowo
Date Deposited:	20 Jul 2026 04:14
Last Modified:	20 Jul 2026 04:14
URI:	http://repository.its.ac.id/id/eprint/135671

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