Redesign Of Rupture Disc Cross-Cut Type On The Condensor Steam Turbine Using Aluminium Materials

., Marwan (2026) Redesign Of Rupture Disc Cross-Cut Type On The Condensor Steam Turbine Using Aluminium Materials. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pada tahun 2018 sistem jaringan listrik di Sumatera Selatan mengalami gangguan yang menyebabkan pemadaman listrik secara luas. Seluruh pembangkit listrik termasuk PLTGU Indralaya turut terdampak oleh gangguan tersebut. Untuk melindungi peralatan utama pada sistem kondensor dari kondisi tekanan berlebih (overpressure), digunakan perangkat pengaman berupa rupture disc. Komponen ini harus mampu menahan tekanan vakum operasi kondensor serta pecah secara terkontrol ketika terjadi tekanan berlebih di dalam kondensor. Penelitian ini bertujuan untuk melakukan analisis dan perancangan ulang rupture disc yang aman dan efektif melalui pendekatan simulasi numerik, perhitungan analitik, dan pengujian eksperimental. Simulasi numerik dilakukan menggunakan metode elemen hingga (Finite Element Method) melalui perangkat lunak ANSYS dengan pendekatan static structural. Perhitungan analitik dilakukan menggunakan persamaan Salarvand untuk memprediksi tekanan pecah (burst pressure) secara teoritis. Validasi dilakukan melalui pengujian vacuum pressure pada rupture disc aktual dan pengujian overpressure pada prototipe rupture disc skala 1:10. Hasil penelitian menunjukkan bahwa kedalaman alur dan jumlah pola goresan berpengaruh terhadap nilai burst pressure, tegangan, dan deformasi rupture disc. Peningkatan kedalaman alur menyebabkan penurunan burst pressure akibat berkurangnya ketebalan efektif dan meningkatnya konsentrasi tegangan pada area alur. Pada pengujian aktual, rupture disc dengan kedalaman alur 1,5 mm mengalami kegagalan sebelum mencapai tekanan vakum operasi -0,086 MPa, sedangkan rupture disc dengan kedalaman alur 0,5 mm mampu mempertahankan integritas struktur pada tekanan tersebut. Hasil simulasi overpressure pada model aktual menunjukkan bahwa konfigurasi kedalaman alur 0,5 mm dengan 8 goresan menghasilkan burst pressure sebesar 0,129 MPa. Pada prototipe skala 1:10, hasil simulasi menunjukkan burst pressure sebesar 0,103-0,126 MPa, sedangkan hasil pengujian eksperimental berada pada kisaran 0,080-0,090 MPa. Kedua pendekatan menunjukkan kecenderungan yang konsisten, yaitu semakin besar kedalaman alur maka tekanan pecah semakin rendah. Berdasarkan hasil tersebut, rupture disc berbahan Aluminium Alloy 1100 dengan kedalaman alur 0,5 mm dan jumlah goresan 8 dapat direkomendasikan sebagai alternatif desain yang aman dan efektif untuk sistem kondensor PLTGU. Konfigurasi ini mampu menahan tekanan vakum operasi, memberikan fungsi proteksi saat terjadi overpressure, serta menghasilkan pola bukaan yang lebih terarah melalui distribusi alur goresan yang lebih merata. Dengan memanfaatkan material yang tersedia di perusahaan, desain ini juga berpotensi menjadi alternatif pengganti komponen OEM dengan biaya pemeliharaan yang lebih efisien.
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In 2018, the electrical power system in South Sumatra experienced a major disturbance that caused a widespread blackout. All power plants, including the Indralaya Combined Cycle Power Plant (CCPP), were affected by this disturbance. To protect the main equipment in the condenser system from overpressure conditions, a safety device known as a rupture disc is employed. This component must be capable of withstanding the condenser operating vacuum pressure and rupturing in a controlled manner when excessive pressure occurs inside the condenser. This study aims to analyse and redesign a safe and effective rupture disc through numerical simulation, analytical calculation, and experimental testing. The numerical simulation was conducted using the Finite Element Method (FEM) through ANSYS software with a static structural approach. The analytical calculation was performed using the Salarvand equation to theoretically predict the burst pressure. Validation was carried out through vacuum pressure testing on the actual rupture disc and overpressure testing on a 1:10 scale rupture disc prototype. The results show that groove depth and the number of groove patterns affect the burst pressure, stress, and deformation behaviour of the rupture disc. Increasing the groove depth reduces the burst pressure due to the reduction in effective thickness and the increase in stress concentration in the groove region. In the actual test, the rupture disc with a groove depth of 1.5 mm failed before reaching the operating vacuum pressure of −0.086 MPa, while the rupture disc with a groove depth of 0.5 mm was able to maintain its structural integrity at the same pressure. The numerical simulation of the actual model showed that the configuration with a groove depth of 0.5 mm and 8 grooves produced a burst pressure of 0.129 MPa. In the 1:10 scale prototype, the numerical simulation results showed burst pressure values ranging from 0.103 MPa to 0.126 MPa, while the experimental test results ranged from 0.080 MPa to 0.090 MPa. Both approaches showed a consistent trend, indicating that a greater groove depth results in a lower burst pressure. Based on these results, the rupture disc made of Aluminium Alloy 1100 with a groove depth of 0.5 mm and 8 grooves can be recommended as a safe and effective alternative design for the condenser system of the CCPP. This configuration is able to withstand the operating vacuum pressure, provide protection during overpressure conditions, and produce a more directed opening pattern through a more uniform groove distribution. By utilising material available within the company, this design also has the potential to serve as an alternative replacement for the OEM component with more efficient maintenance costs.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Rupture disc, Aluminium 1100, Kondensor, Burst pressure, Finite Element Method, ANSYS.
Subjects:	T Technology > TJ Mechanical engineering and machinery > TJ164 Power plants--Design and construction T Technology > TJ Mechanical engineering and machinery > TJ230 Machine design
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21101-(S2) Master Thesis
Depositing User:	Marwan Marwan
Date Deposited:	01 Aug 2026 02:35
Last Modified:	01 Aug 2026 02:36
URI:	http://repository.its.ac.id/id/eprint/141000

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