Analisis Instalasi Sistem Udara Bertekanan pada Ruang Produksi Komersial PT Japfa Comfeed Indonesia Tbk, Unit Buduran Sidoarjo

Nugroho, Aldi Prastyo (2026) Analisis Instalasi Sistem Udara Bertekanan pada Ruang Produksi Komersial PT Japfa Comfeed Indonesia Tbk, Unit Buduran Sidoarjo. Other thesis, Institut Teknologi Sepuluh Nopember.

Text 2039221024_Undergraduate_Thesis.pdf Restricted to Repository staff only Download (9MB) | Request a copy

Abstract

Sistem udara bertekanan merupakan utilitas vital yang berperan dalam menunjang kelancaran proses produksi di PT Japfa Comfeed Indonesia Tbk Unit Buduran Sidoarjo, khususnya dalam menyuplai energi pada berbagai peralatan kebutuhan tekanan operasi sebesar 6 bar. Namun, dalam kondisi existing, meskipun sistem dioperasikan dengan tekanan kompresor sebesar 7,8 bar, masih terjadi penurunan tekanan secara tiba-tiba yang menyebabkan ketidakstabilan suplai udara. Hasil evaluasi menunjukkan bahwa permasalahan tidak hanya berasal dari jaringan perpipaan, tetapi juga beberapa komponen utama, seperti temperatur kompresor yang tinggi akibat kondisi lingkungan power house yang kurang mendukung, kinerja aftercooler yang tidak optimal karena penggunaan fan yang tidak sesuai spesifikasi, terjadinya freezing pada air dryer akibat tingginya kandungan uap air serta tata letak komponen yang tidak tepat, serta penggunaan motor listrik yang tidak sesuai dengan spesifikasi pabrikan. Selain itu, pada sistem distribusi ditemukan adanya penurunan tekanan yang signifikan tanpa indikasi kebocoran langsung yang mengarah pada losses akibat konfigurasi pipa dan komponen sistem, serta pola operasi kompresor yang bekerja secara terus-menerus tanpa siklus unload sehingga menyebabkan konsumsi energi listrik yang tinggi. Seiring dengan rencana pemindahan pusat operasional ke Unit Lamongan, dilakukan analisis dan perancangan ulang sistem distribusi udara bertekanan melalui identifikasi kebutuhan udara, evaluasi instalasi existing, serta pengukuran ulang jaringan perpipaan untuk memperoleh data aktual konfigurasi sistem. Hasil analisis menunjukkan bahwa total kebutuhan udara bertekanan sebesar 7,31 m³/menit, dengan nilai pressure drop pada kondisi awal mencapai 1,74 bar yang melebihi batas rekomendasi Compressed Air Challenge (2010) yaitu maksimal 10% dari tekanan kerja kompresor. Melalui perancangan ulang dengan optimasi diameter pipa pada jalur kritis, nilai pressure drop berhasil diturunkan menjadi 0,0634 bar sehingga berada dalam batas yang diizinkan. Selain dilakukan perbaikan tata letak komponen dengan menempatkan air dryer setelah air receiver, hasil perhitungan dengan rekomendasi penambahan tekanan 9 bar menunjukkan kebutuhan air receiver sebesar 3,84 m³ sehingga kapasitas existing 6 m³ tidak perlu ditingkatkan. Berdasarkan corrected flow rate sebesar 248 L/s, dipilih air dryer tipe Atlas Copco FX250 (E13) berkapasitas 250 L/s dan motor induksi tiga fasa 90 kW. Kondensat yang terbentuk sebesar 164 liter/hari menyebabkan akumulasi air setinggi 11,4 cm/hari, sehingga digunakan sistem drainase otomatis DRAINMASTER DC Auto Drain Valve 1 inch dengan frekuensi pembuangan ±5 kali per hari setiap 4,26 jam. Sistem juga menggunakan dua unit kompresor screw berkapasitas 15,6 m³/menit yang dioperasikan bergantian selama 12 jam per hari, sehingga mampu meningkatkan efisiensi energi dan menurunkan biaya operasional dari Rp946.080.000 per tahun menjadi Rp898.776.000 per tahun atau setara dengan penghematan sebesar Rp47.304.000 per tahun (5,00%) dengan payback period 4,14 tahun pada investasi sebesar Rp195.617.987, sehingga layak diterapkan baik dari aspek teknis maupun ekonomi.
==================================================================================================================================
A compressed air system is a vital utility that plays an important role in supporting the production process at PT Japfa Comfeed Indonesia Tbk, Buduran Sidoarjo Unit, particularly in supplying energy to various equipment requiring an operating pressure of 6 bar. However, under existing operating conditions, although the system is supplied by a compressor operating at 7.8 bar, sudden pressure drops still occur, causing instability in the compressed air supply. The evaluation results indicate that these problems originate not only from the piping network but also from several major components, including high compressor temperatures caused by unfavorable power house environmental conditions, suboptimal aftercooler performance due to the use of an underspecified fan, freezing in the air dryer resulting from high moisture content and improper component layout, and the use of an electric motor that does not comply with the manufacturer's specifications. In addition, the distribution system experiences significant pressure losses without evidence of direct leakage, indicating that the losses are mainly caused by the piping configuration, system components, and a compressor operating pattern that continuously runs without an unload cycle, leading to excessive electrical energy consumption. In line with the planned relocation of the operational center to the Lamongan Unit, an analysis and redesign of the compressed air distribution system were carried out through compressed air demand identification, evaluation of the existing installation, and remeasurement of the piping network to obtain accurate system configuration data. The analysis results show that the total compressed air demand is 7.31 m³/min, with an initial pressure drop of 1.74 bar, exceeding the recommendation of the Compressed Air Challenge (2010), which limits pressure drop to a maximum of 10% of the compressor operating pressure. By optimizing the pipe diameters along critical sections, the pressure drop was successfully reduced to 0.0634 bar, bringing it within the recommended limit. In addition, relocating the air dryer downstream of the air receiver improved the system layout. Based on a recommended operating pressure of 9 bar, the required air receiver volume was calculated to be 3.84 m³, indicating that the existing 6 m³ air receiver is sufficient and does not require replacement. Based on a corrected airflow rate of 248 L/s, an Atlas Copco FX250 (E13) air dryer with a capacity of 250 L/s and a 90 kW three-phase induction motor were selected. The condensate generated by the system amounts to 164 liters per day, resulting in water accumulation of approximately 11.4 cm per day; therefore, an automatic drainage system using a DRAINMASTER DC 1-inch Auto Drain Valve was selected, with an estimated discharge frequency of five times per day at intervals of approximately 4.26 hours. The redesigned system also employs two screw compressors with a combined capacity of 15.6 m³/min, operated alternately for 12 hours per day, thereby improving energy efficiency and reducing annual operating costs from IDR 946,080,000 to IDR 898,776,000, representing annual savings of IDR 47,304,000 (5.00%). With a payback period of 4.14 years for an investment of IDR 195,617,987, the proposed design is technically and economically feasible.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Sistem Udara Bertekanan, Kompresor, Pressure Drop, Efisiensi Energi.
Subjects:	T Technology > T Technology (General) T Technology > TJ Mechanical engineering and machinery
Divisions:	Faculty of Vocational > Mechanical Industrial Engineering (D4)
Depositing User:	Aldi Prastyo Nugroho
Date Deposited:	08 Jul 2026 01:53
Last Modified:	08 Jul 2026 01:53
URI:	http://repository.its.ac.id/id/eprint/134455

Actions (login required)

View Item