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Konservasi Energi pada Pompa dan Kompresor
Mochammad Fa’iq Khasmadin – Magister energi
Magister Energi
Daftar Isi
01 Konservasi Energi dan Regulasinya
02 Konservasi Energi Peralatan Pompa
03 Konservasi Energi Peralatan Kompresor
Konservasi Energi dan Regulasinya
Definisi Konservasi Energi (UU No. 30 Tahun 2007 dan PP No. 70 Tahun 2009)
Sumber : Ditjen EBTKE, 2018
Cascading Konservasi Energi
Program
Audit Energi di
Industri dan
Bangunan
Penerapan Sistem
Manajemen Energi
Penerapan
Teknologi Efisien
Penerapan
Standar dan Label
Hemat Energi
Awareness &
Sosialisasi Hemat
Energi
Pembiayaan
Efisiensi Energi
Insentif dan
Disentif
Audit Energi &
Investment Grade
Audit
Sistem Manajemen
Energi
Penerapan Teknologi Hemat
dan SNI pada Peralatan
Pemanfaatan Energi
SKEM & Label
AC & CFL
Awareness Hemat Energi
Berpotensi Menurunkan
Penggunaan Energi 5-10%
Sumber : Ditjen EBTKE, 2018
Cascading Konservasi Energi
Output
Efisiensi Energi
Penyedia Energy
(Supply Side)
Efisiensi Energi Pengguna Energi (Demand Side)
Sektor Pembangkit Sektor Industry Sektor Komersil Sektor Rumah
Tangga
Sektor Transportasi
(Potensi Penghematan
1% (5,4 Juta SBM)
(Potensi Penghematan
10% (23,2 Juta SBM)
(Potensi Penghematan
10% (4,2 Juta SBM)
(Potensi Penghematan
10% (4,2 Juta SBM)
(Potensi Penghematan
15% (54,3 Juta SBM)
Sumber : Ditjen EBTKE, 2018
Cascading Konservasi Energi
IMPACT
Sumber : Ditjen EBTKE, 2018
- Penghematan Energi
- Penurunan Intensitas 1%
- Penurunan Elastisitas
Pertumbuhan Ekonomi
Dan Daya Saing
Ketahanan
Energi
Perubahan
Iklim
Regulasi Konservasi Energi
PP No.70/2009
Tentang Konservasi
Energi
Permen ESDM
No.14/2012
Tentang
Manajemen Energi
PerMen ESDM
No.18/2014
Tentang
Pembubuhan Label
Tanda Hemat
Energi untuk Lampu
Swabalast
UU No.30/2007
Tentang Energi
Perpres
No.61/2011
Tentang Rencana
Aksi Nasional
Penurunan Emisi
Gas Rumah Kaca
PerMen ESDM
No.1/2013
Tentang
Pengendalian
Penggunaan Bahan
Bakar Minyak
2014
2013
2012
2011
2009
2007
Inpres No
9/1982
Tentang Konservasi
Energi
1982
Permen ESDM
No.14/2012
Tentang
Penghematan
Penggunaan Air
Tanah
PP No.79/2014
Tentang Kebijakan
Energi Nasional
Sumber : Ditjen EBTKE, 2018
Regulasi Konservasi Energi
Perpres No.22/2017
Tentang Rencana Umum Energi Nasional
2017
Perpres No.38/2015
Tentang Kerjasama Pemerintah dengan
Badan Usaha dalan Penyediaan
Infrastruktur
2015
PerMen ESDM No.57/2017
Tentang Penerapan SKEM dan Pencatuman Label
Tanda Hemat Energi untuk Peranti Pengkondisi
udara
PerMen PUPR No.02/PRT/M/2015
Tentang Bangunan Gedung Hijau
PerMen ESDM No.41/2015
Tentang Pemberlakuan Standar Kompetensi
Kerja Nasional Indonesia Kategori Jasa
Profesional, Ilmiah dan Teknis Golongan Pokok
Jasa Profesional, Ilmiah dan Teknis Lainnya
pada Jabatan Manajer Energi di Industri dan
Bangunan Gedung
Sumber : Ditjen EBTKE, 2018
Standar Konservasi Energi
Standar Sistem Manajemen Energi
• SNI ISO 50001:2018 tentang Sistem Manajemen Energi
Persyaratan daengan pedoman Penggunaan
• SNI ISO 50002:2014 tentang Audit Energi
Persyaratan dengan panduan penggunaan
• SNI ISO 50006:2014 tentang Mengukur Kinerja Energi dengan menggunakan
Baseline Energi (EnB) dan Indikator Kinerja Energi (EnPI)
Prinsip umum dan pedoman
• SNI ISO 50015:2014 tentang Sistem Manajemen Energi
Pengukuran dan verifikasi kinerja energi organisasi
Prinsip dan panduan umum
Sumber : Ditjen EBTKE, 2018
Konservasi Energi
Peralatan Pompa
Definisi
Peralatan Pompa
Komponen Utama Sistem Pompa
Komponen utama sistem pompa adalah :
• Pompa
• Mesin penggerak: motor listrik, mesin diesel atau sistim udara Pemipaan, digunakan untuk membawa
fluida
• Kran, digunakan untuk mengendalikan aliran dalam sistim
• Sambungan, pengendalian dan instrumentasi lainnya
• Peralatan pengguna akhir, yang memiliki berbagai persyaratan (misalnya tekanan, aliran) yang
menentukan komponen dan susunan sistim pemompaan.Contohnya adalah alat penukar panas, tangki
dan mesin hidrolik
Mesin yang digunakan untuk mengsirkulasikan cairan sekitar sistem (misal air
pendingin atau pelumas) untuk memidahkan fluida dari satu tempat ke tempat
lainnya (misal air dari equifer bawah tanah ke tangki penyimpanan air) yang
merupakan konversi energi mekanik penggerak menjadi energi fluida
Daya batang torak pompa (Ps) adalah daya HP yang dikirimkan ke batang torak pompa
Daya Hidrolik adalah Daya Hp Fluida yang dikirimkan oleh pompa
Menghitung Kinerja Pompa
Kerja yang ditampilkan oleh sebuah pompa merupakan fungsi dari head total dan berat
cairan yang dipompa dalam jangka waktu yang diberikan.
𝐏𝐒 =
𝑫𝒂𝒚𝒂 𝑯𝒊𝒅𝒓𝒐𝒍𝒊𝒌 (𝒉𝒑)
𝑬𝒇𝒊𝒔𝒊𝒆𝒏𝒔𝒊 𝑷𝒐𝒎𝒑𝒂
𝐃𝐚𝐲𝐚 𝐇𝐢𝐝𝐫𝐨𝐥𝐢𝐤 = 𝐐 . 𝐡𝐝 − 𝐡𝐬 .  . 𝐠 /𝟏𝟎𝟎𝟎
𝐐 = Debit Aliran (m3/s)
Hd = head pembuangan (m)
Hs = head penghisapan (m)
 = massa jenis fluida (kg/m3)
𝐠 = percepatan Gravitasi (m/s3)
Peluang Efisiensi Energi
Langkah penghematan energi meliputi:
1. Memilih pompa yang Apropriate
2. Mengendalikan debit aliran dengan variasi
kecepatan
3. Pompa dalam susunan paralel untuk memenuhi
permintaan yang beragam
4. Membuang kran pengendali aliran
5. Membuang kendali by-pass
6. Kendali start/stop pompa
7. Memperbaiki keseimbangan impeler
PEMELIHARAAN PADA POMPA
Kinerja pompa akan menurun akibat faktor waktu Oleh karena itu perawatan/pemeliharaan
pompa diperlukan. Meskipun perawatan telah dilakukan dengan baik efisiensi pompa
seperti semula (baru) tidak mungkin diperoleh. Dengan kata lain selalu ada penurunan
efisiensi.
Preventive dan Predictive Maintenance
Preventive maintenance adalah tindakan pemeliharaan yang dilakukan
secara berkala sesuai dengan anjuran pada instruction manual atau
pengalaman operasi crew maintenance (dan operator) terhadap equipment
yg bersangkutan.
Misalnya, penggantian oli yang dilakukan setiap 6 bulan atau penggantian
grease setiap 8000 running hours.
Predictive maintenance adalah salah satu metode pemeliharaan yang
didasarkan pada kondisi equipment yang sedang dicheck. Predictive
maintenance membutuhkan bantuan alat-alat presisi seperti
Vibration Analyzer, Oil Analysis, dan Thermal Imager
Thermograhpy
• Normal : s/d 10°C diatas
reference or baseline
• Sedang : antara 10°C -
20°C diatas reference or
baseline
• SERIOUS : antar 20°C -
40°C di atas reference or
baseline
• CRITICAL : lebih besar dari
40°C diatas reference or
baseline
Sumber : NETA Maintenance Testing Specification for Electrical and/or Mechanical Equipments
Vibration Analysis
Pengamatan vibrasi dari sistem unit
perlatan rotating equipment dilakukan
pada posisi drive end (dekat dengan
driver/penggerak) dan non-drive end
(jauh dari driver/ penggerak)
Sumber : NETA Maintenance Testing Specification for Electrical and/or Mechanical Equipments
NDE position
DE position
Standar Vibration Analysis
Standar vibrasi mengacu pada ISO 10816-3. Sebaiknya motor tidak melebihi standar kategori range
B agar beroperasi dengan baik. Berikut ini grafik /table standar vibrasi berdasarkan referensi ISO
10816-3 dan ISO 10816-7 pada type pompa.
Sumber : ISO 10816-3 dan ISO 10816-7
Standar Vibration Analysis
Dari gambar sebelumnya dilihat untuk getaran di katagorikan kepada 4 zona yaitu:
Zona A berwarna biru, getaran dari mesin sangat baik dan dibawah getaran yang
diijinkan.
Zona B berwarna hijau, getaran dari mesin baik dan dapat dioperasikan tanpa
larangan.
Zona C berwarna kuning, getaran dari mesin dalam batas toleransi dan hanya
dioperasikan dalam waktu terbatas.
Zona D berwarna merah, getaran dari mesin dalam batas berbahaya dan dapat
terjadi kerusakan sewaktu-waktu
Sumber : ISO 10816-3 dan ISO 10816-7
Konservasi Energi
Peralatan Kompresor
Kompresor
Category
Kompressor digunakan pada
system udara tekan dengan teka
nan discharge > 20 psi. (rasio
tekanan > 1.36 karena apabila <
1.36 termasuk kategori blower/fa
n
Power
Input Daya mulai dari 5 hp
hingga lebih dari 50,000 hp
Definisi
Kompressor berfungsi untuk menaikkan
tekanan udara atau gas dari level rendah
menjadi tekanan sama atau sedikit
di atas level yang dibutuhkan.
Jaringan
Sistem
Udara
Tekan
Sumber : US DOE, 2003
Komponen Sistem Udara Tekan
Intake Air Filters, menjaga debu masuk ke dalam kompresor. Debu bisa mengakibatkan
penyumbatan pada valve, berakibat abrasi pada cylinder dan menyebabkan korosif.
Inter-stage Coolers, berguna untuk menurunkan temperatur udara sebelum masuk ke
stage berikutnya, sehingga meringankan kerja kompresor (kompresor lebih efisien).
Biasanya berupa water cooled type.
After-Coolers, bertujuan untuk menurunkan kandungan mositure dalam udara tekan
dengan adanya penurunan temperatur.
Air-dryers, Sisa kelembaban (moisture) setelah after-cooler dihilangkan dengan
menggunakan pengering udara (air dryers). Hal ini disebabkan karena persyaratan udara
tekan untuk peralatan instrumen dan pneumatik memiliki tingkat moisture tertentu
Jenis-Jenis Kompresor
Compressor
Positive Displacement
Reciprocating
Single-Acting
Double-Acting
Rotary
Helical-Screw Liquid-Ring Scroll
Sliding-Valve Lobe
Dynamic
Centrifugal Axial
Sumber : US DOE, 2003
Type Kompresor
Kompresor Torak/Piston
Pada kompressor tipe torak, sejumlah gas atau
udara dikurung dalam suatu ruangan dan volumenya
secara mekanik dikurangi sehingga menyebabkan
tekananya naik sebelum kemudian dialirkan. Tipe
kompressor ini tersedia dengan berbagai konfigurasi
dan paling sering adalah horizontal, vertikal. Tipe
Kompressor Vertical digunakan untuk kapasitas : 50
– 150 cfm (Cubic Feet Minute).
Horizontal balance opposed compressors digunakan
untuk kapasitas : 200 – 5000 cfm dengan disain
multi-stage dan sampai dengan 10,000 cfm dengan
disain single stage.
Sentrifugal kompressor adalah kompressor
dinamis. Energi dari impeller yang berputar dengan
kecepatan tinggi ditransfer ke udara dengan cara
merubah kecepatan dan tekanan. Kecepatan udara
yang tinggi dirubah menjadi tekanan dengan cara
mengurangi kecepatan pada difuser stasioner. Tipe
kompressor ini cocok untuk kapasitas besar yaitu di
atas 12.000 cfm.
Kompresor Sentrifugal
Kompresor High Speed Single Stage
1. Udara masuk kedalam Inlet Kompresor.
2. Udara terkompresi oleh First Stage Impeler.
3. Panas dibuang pada Intercooler pertama.
4. Udara akan dikomprosei pada second stage
impeller.
5. Panas akan dibuang pada Intercooler kedua.
6. Udara dikompresi untuk mejadi tekanan final
pada third stage Impeler.
7. Udara keluar ke After cooler dan sistem udara
pada plant.
Kompresor Ulir
Kompressor ulir adalah mesin positif
displacement dengan menggunakan sepasang
rotor yang bersesuaian sebagai pengganti
piston untuk menghasilkan tekanan. Ukurannya
umumnya sekitar 30 hingga 200 hp atau 22 ke
150 kW.
Konservasi Energi pada Kompresor
 Operasikan pada tekanan serendah mungkin.
 Bersihkan filter dan heat exchanger secara teratur.
 Usahakan udara masuk termperaturnya rendah.
 Gunakan flat belt yang efisien energi.
 Gunakan soft stater yang hemat energi.
 Lakukan reengineering proses untuk menurunkan
penggunaan udara bertekanan
 Turunkan kebocoran.
 Pisahkan tekanan tinggi dan rendah jika mungkin.
 Pasang solenoid valve untuk menutup udara bertekanan
pada Mesin saat tidak beroperasi dan Seluruh bagian-
bagian jaringan .
 Jalur yang tidak berguna supaya dibongkar.
 Gunakan tipe non purge air drayer.
 Mengoptimumkan frekwensi auto drain trap.
 Memanfaatkan air pendingin dari kompresor.
 Matikan jika tidak diperlukan
 Gunakan transvector nozzle(venturi) pada pembersihan
• Biasanya digunakan udara tekanan 6 bar tetapi 2,5 bar
sebenarnya cukup
• Pasang compresor tersendiri dengan operasi on/of
• Transvector nozzle akan menghisap udara luar 30%.
 Peralatan listrik menghemat 30% energi dibandingkan
Pneumatik
 Penggantian udara tekan
• Root blower dapat digunakan untuk agitas
• Blower dapat digunakan untuk pendinginan.
 Pemisahan jaringan udara bertekanan rendah jika total
kebutuhan L.P (low pressure) >30 %.
Kategori LP Compressor : 2.5 to 3.5 bar
Kategori HP Compressor : > 3.5 bar
Area Penghematan Kompresor
Dryer Filter
Economical Pipe
Size
Facility
Facility
Facility
Minimum Air
Leakage
Minimum Pressure &
Volume
Integrating of Another
air Comprersor
Periodical
Maintenance
Effecetive Capacity
Control
Reduction of
Unloadloss
Reduction of Delivery
Presure
Compressor
Receiver Tank
Efficient Tank
Low Inlet Air
Temperature
Sumber : Uplift Training Material – Hand Book
Metode Pencegahan Kebocoran
Mendeteksi Kebocoran
 Gunakan ultrasonik detector yang dapat mendeteksi desis frekuwensi tinggi yang disebabkan oleh
kebocoran udara.
 Metoda sederhana yaitu dengan mengoleskan air sabun dengan kuas pada tempat yang diduga bocor.
Menutup Kebocoran (perbaikan)
 Pilih fiting yang kwalitas baik, disconnects, hose, turbin dan pasang secara benar dengan seal yang baik.
 Jalur ke peralatan yang tidak dioperasikan segera ditutup.
 Menurunkan tekanan udara meminimkan kebocoran
 Setelah dilakukan perbaikan lakukan evaluasi penghematan.
Program Pencegah Kebocoran Program
pencegahan kebocoran yang baik meliputi hal-hal sebagai berikut:
 Identifikasi, penelusuran, perbaikan, verifikasi
 Melibatkan karyawan pada fasilitas (bagian) yang menggunakan udara bertekanan harus dilibatkan /bentuk
tim penanggulangan.
Minimize Suhu Udara Intake
Suhu udara masuk kompressor (intake) berpengaruh significant terhadap konsumsi daya compressor, Udara intake yang
panas atau yang terkontaminasi mempengaruhi kinerja kompressor yang mengakibatkan konsumsi energi dan biaya
pemeliharaan meningkat. Kehadiran moiture (uap air), debu maupun kotoran lainnya pada udara intake akan menempel
pada komponen dalam kompressor seperti valve, impeller dan rotor. Hal ini dapat mengurangi kapasitas dan
menimbulkan keausan pada compressor.
“Setiap kenaikan suhu udara intake 4 C akan mengakibatkan konsumsi daya meningkat 1 %
untuk menghasilkan output yang sama”
Pengurangan Pressure Drop
Kelebihan pressure drop akibat ukuran pipa,
filter, kopling dan hose yang tidak cocok
adalah reprensentasi pemborosan energi.
Mengurangi pressure drop dengan cara
menggunakan sistem tertutup (loop) dengan
dua jalur aliran .
Seperti pada pipa, fitting juga merupakan sumber
pressure drop. Pressure tipikal pada berbagai fitting
diperlihatkan pada tabel diatas
Optimalisasi Sistem Transmisi
Sistem transmissi V-belt efisiensinya berkisar antara 70-90%, dengan bertambahnya usia akan
mengalami kemunduran atau pengurangan efisiensi sekitar 4 % jika tidak terpelihara dengan
baik.
Hindari tegangan belt tidak sesuai (terlalu kendor maupun terlalu kencang), hal ini akan
mengakibatkan rugi-rugi energi. Demikian juga multiple belt, jika salah satu dari multiple belt
gagal atau rusak , maka seluruh belt harus diganti.
Hindari sedapat mungkin adanya perbedaan dari masing-masing multiple belt. Ukuran belt
oversizing atau undersizing akan menghasilkan rugi-rugi energi tambahan.
Sistem transmissi bertingkat pada motor - kompressor seperti tampak pada gambar berikut
akan menimbulkan rugi-rugi transmissi bertambah besar (sebaiknya dihindari).
POMPA DAN KOMPRESSOR
KONSERVASI ENERGI
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[PPT] - Sistem Konversi Energi pada Motor Listrik dan Kompressor.pptx

  • 1. Konservasi Energi pada Pompa dan Kompresor Mochammad Fa’iq Khasmadin – Magister energi Magister Energi
  • 2. Daftar Isi 01 Konservasi Energi dan Regulasinya 02 Konservasi Energi Peralatan Pompa 03 Konservasi Energi Peralatan Kompresor
  • 3. Konservasi Energi dan Regulasinya
  • 4. Definisi Konservasi Energi (UU No. 30 Tahun 2007 dan PP No. 70 Tahun 2009) Sumber : Ditjen EBTKE, 2018
  • 5. Cascading Konservasi Energi Program Audit Energi di Industri dan Bangunan Penerapan Sistem Manajemen Energi Penerapan Teknologi Efisien Penerapan Standar dan Label Hemat Energi Awareness & Sosialisasi Hemat Energi Pembiayaan Efisiensi Energi Insentif dan Disentif Audit Energi & Investment Grade Audit Sistem Manajemen Energi Penerapan Teknologi Hemat dan SNI pada Peralatan Pemanfaatan Energi SKEM & Label AC & CFL Awareness Hemat Energi Berpotensi Menurunkan Penggunaan Energi 5-10% Sumber : Ditjen EBTKE, 2018
  • 6. Cascading Konservasi Energi Output Efisiensi Energi Penyedia Energy (Supply Side) Efisiensi Energi Pengguna Energi (Demand Side) Sektor Pembangkit Sektor Industry Sektor Komersil Sektor Rumah Tangga Sektor Transportasi (Potensi Penghematan 1% (5,4 Juta SBM) (Potensi Penghematan 10% (23,2 Juta SBM) (Potensi Penghematan 10% (4,2 Juta SBM) (Potensi Penghematan 10% (4,2 Juta SBM) (Potensi Penghematan 15% (54,3 Juta SBM) Sumber : Ditjen EBTKE, 2018
  • 7. Cascading Konservasi Energi IMPACT Sumber : Ditjen EBTKE, 2018 - Penghematan Energi - Penurunan Intensitas 1% - Penurunan Elastisitas Pertumbuhan Ekonomi Dan Daya Saing Ketahanan Energi Perubahan Iklim
  • 8. Regulasi Konservasi Energi PP No.70/2009 Tentang Konservasi Energi Permen ESDM No.14/2012 Tentang Manajemen Energi PerMen ESDM No.18/2014 Tentang Pembubuhan Label Tanda Hemat Energi untuk Lampu Swabalast UU No.30/2007 Tentang Energi Perpres No.61/2011 Tentang Rencana Aksi Nasional Penurunan Emisi Gas Rumah Kaca PerMen ESDM No.1/2013 Tentang Pengendalian Penggunaan Bahan Bakar Minyak 2014 2013 2012 2011 2009 2007 Inpres No 9/1982 Tentang Konservasi Energi 1982 Permen ESDM No.14/2012 Tentang Penghematan Penggunaan Air Tanah PP No.79/2014 Tentang Kebijakan Energi Nasional Sumber : Ditjen EBTKE, 2018
  • 9. Regulasi Konservasi Energi Perpres No.22/2017 Tentang Rencana Umum Energi Nasional 2017 Perpres No.38/2015 Tentang Kerjasama Pemerintah dengan Badan Usaha dalan Penyediaan Infrastruktur 2015 PerMen ESDM No.57/2017 Tentang Penerapan SKEM dan Pencatuman Label Tanda Hemat Energi untuk Peranti Pengkondisi udara PerMen PUPR No.02/PRT/M/2015 Tentang Bangunan Gedung Hijau PerMen ESDM No.41/2015 Tentang Pemberlakuan Standar Kompetensi Kerja Nasional Indonesia Kategori Jasa Profesional, Ilmiah dan Teknis Golongan Pokok Jasa Profesional, Ilmiah dan Teknis Lainnya pada Jabatan Manajer Energi di Industri dan Bangunan Gedung Sumber : Ditjen EBTKE, 2018
  • 10. Standar Konservasi Energi Standar Sistem Manajemen Energi • SNI ISO 50001:2018 tentang Sistem Manajemen Energi Persyaratan daengan pedoman Penggunaan • SNI ISO 50002:2014 tentang Audit Energi Persyaratan dengan panduan penggunaan • SNI ISO 50006:2014 tentang Mengukur Kinerja Energi dengan menggunakan Baseline Energi (EnB) dan Indikator Kinerja Energi (EnPI) Prinsip umum dan pedoman • SNI ISO 50015:2014 tentang Sistem Manajemen Energi Pengukuran dan verifikasi kinerja energi organisasi Prinsip dan panduan umum Sumber : Ditjen EBTKE, 2018
  • 12. Definisi Peralatan Pompa Komponen Utama Sistem Pompa Komponen utama sistem pompa adalah : • Pompa • Mesin penggerak: motor listrik, mesin diesel atau sistim udara Pemipaan, digunakan untuk membawa fluida • Kran, digunakan untuk mengendalikan aliran dalam sistim • Sambungan, pengendalian dan instrumentasi lainnya • Peralatan pengguna akhir, yang memiliki berbagai persyaratan (misalnya tekanan, aliran) yang menentukan komponen dan susunan sistim pemompaan.Contohnya adalah alat penukar panas, tangki dan mesin hidrolik Mesin yang digunakan untuk mengsirkulasikan cairan sekitar sistem (misal air pendingin atau pelumas) untuk memidahkan fluida dari satu tempat ke tempat lainnya (misal air dari equifer bawah tanah ke tangki penyimpanan air) yang merupakan konversi energi mekanik penggerak menjadi energi fluida
  • 13. Daya batang torak pompa (Ps) adalah daya HP yang dikirimkan ke batang torak pompa Daya Hidrolik adalah Daya Hp Fluida yang dikirimkan oleh pompa Menghitung Kinerja Pompa Kerja yang ditampilkan oleh sebuah pompa merupakan fungsi dari head total dan berat cairan yang dipompa dalam jangka waktu yang diberikan. 𝐏𝐒 = 𝑫𝒂𝒚𝒂 𝑯𝒊𝒅𝒓𝒐𝒍𝒊𝒌 (𝒉𝒑) 𝑬𝒇𝒊𝒔𝒊𝒆𝒏𝒔𝒊 𝑷𝒐𝒎𝒑𝒂 𝐃𝐚𝐲𝐚 𝐇𝐢𝐝𝐫𝐨𝐥𝐢𝐤 = 𝐐 . 𝐡𝐝 − 𝐡𝐬 .  . 𝐠 /𝟏𝟎𝟎𝟎 𝐐 = Debit Aliran (m3/s) Hd = head pembuangan (m) Hs = head penghisapan (m)  = massa jenis fluida (kg/m3) 𝐠 = percepatan Gravitasi (m/s3)
  • 14. Peluang Efisiensi Energi Langkah penghematan energi meliputi: 1. Memilih pompa yang Apropriate 2. Mengendalikan debit aliran dengan variasi kecepatan 3. Pompa dalam susunan paralel untuk memenuhi permintaan yang beragam 4. Membuang kran pengendali aliran 5. Membuang kendali by-pass 6. Kendali start/stop pompa 7. Memperbaiki keseimbangan impeler
  • 15. PEMELIHARAAN PADA POMPA Kinerja pompa akan menurun akibat faktor waktu Oleh karena itu perawatan/pemeliharaan pompa diperlukan. Meskipun perawatan telah dilakukan dengan baik efisiensi pompa seperti semula (baru) tidak mungkin diperoleh. Dengan kata lain selalu ada penurunan efisiensi.
  • 16. Preventive dan Predictive Maintenance Preventive maintenance adalah tindakan pemeliharaan yang dilakukan secara berkala sesuai dengan anjuran pada instruction manual atau pengalaman operasi crew maintenance (dan operator) terhadap equipment yg bersangkutan. Misalnya, penggantian oli yang dilakukan setiap 6 bulan atau penggantian grease setiap 8000 running hours. Predictive maintenance adalah salah satu metode pemeliharaan yang didasarkan pada kondisi equipment yang sedang dicheck. Predictive maintenance membutuhkan bantuan alat-alat presisi seperti Vibration Analyzer, Oil Analysis, dan Thermal Imager
  • 17. Thermograhpy • Normal : s/d 10°C diatas reference or baseline • Sedang : antara 10°C - 20°C diatas reference or baseline • SERIOUS : antar 20°C - 40°C di atas reference or baseline • CRITICAL : lebih besar dari 40°C diatas reference or baseline Sumber : NETA Maintenance Testing Specification for Electrical and/or Mechanical Equipments
  • 18. Vibration Analysis Pengamatan vibrasi dari sistem unit perlatan rotating equipment dilakukan pada posisi drive end (dekat dengan driver/penggerak) dan non-drive end (jauh dari driver/ penggerak) Sumber : NETA Maintenance Testing Specification for Electrical and/or Mechanical Equipments NDE position DE position
  • 19. Standar Vibration Analysis Standar vibrasi mengacu pada ISO 10816-3. Sebaiknya motor tidak melebihi standar kategori range B agar beroperasi dengan baik. Berikut ini grafik /table standar vibrasi berdasarkan referensi ISO 10816-3 dan ISO 10816-7 pada type pompa. Sumber : ISO 10816-3 dan ISO 10816-7
  • 20. Standar Vibration Analysis Dari gambar sebelumnya dilihat untuk getaran di katagorikan kepada 4 zona yaitu: Zona A berwarna biru, getaran dari mesin sangat baik dan dibawah getaran yang diijinkan. Zona B berwarna hijau, getaran dari mesin baik dan dapat dioperasikan tanpa larangan. Zona C berwarna kuning, getaran dari mesin dalam batas toleransi dan hanya dioperasikan dalam waktu terbatas. Zona D berwarna merah, getaran dari mesin dalam batas berbahaya dan dapat terjadi kerusakan sewaktu-waktu Sumber : ISO 10816-3 dan ISO 10816-7
  • 22. Kompresor Category Kompressor digunakan pada system udara tekan dengan teka nan discharge > 20 psi. (rasio tekanan > 1.36 karena apabila < 1.36 termasuk kategori blower/fa n Power Input Daya mulai dari 5 hp hingga lebih dari 50,000 hp Definisi Kompressor berfungsi untuk menaikkan tekanan udara atau gas dari level rendah menjadi tekanan sama atau sedikit di atas level yang dibutuhkan.
  • 24. Komponen Sistem Udara Tekan Intake Air Filters, menjaga debu masuk ke dalam kompresor. Debu bisa mengakibatkan penyumbatan pada valve, berakibat abrasi pada cylinder dan menyebabkan korosif. Inter-stage Coolers, berguna untuk menurunkan temperatur udara sebelum masuk ke stage berikutnya, sehingga meringankan kerja kompresor (kompresor lebih efisien). Biasanya berupa water cooled type. After-Coolers, bertujuan untuk menurunkan kandungan mositure dalam udara tekan dengan adanya penurunan temperatur. Air-dryers, Sisa kelembaban (moisture) setelah after-cooler dihilangkan dengan menggunakan pengering udara (air dryers). Hal ini disebabkan karena persyaratan udara tekan untuk peralatan instrumen dan pneumatik memiliki tingkat moisture tertentu
  • 25. Jenis-Jenis Kompresor Compressor Positive Displacement Reciprocating Single-Acting Double-Acting Rotary Helical-Screw Liquid-Ring Scroll Sliding-Valve Lobe Dynamic Centrifugal Axial Sumber : US DOE, 2003
  • 27. Kompresor Torak/Piston Pada kompressor tipe torak, sejumlah gas atau udara dikurung dalam suatu ruangan dan volumenya secara mekanik dikurangi sehingga menyebabkan tekananya naik sebelum kemudian dialirkan. Tipe kompressor ini tersedia dengan berbagai konfigurasi dan paling sering adalah horizontal, vertikal. Tipe Kompressor Vertical digunakan untuk kapasitas : 50 – 150 cfm (Cubic Feet Minute). Horizontal balance opposed compressors digunakan untuk kapasitas : 200 – 5000 cfm dengan disain multi-stage dan sampai dengan 10,000 cfm dengan disain single stage.
  • 28. Sentrifugal kompressor adalah kompressor dinamis. Energi dari impeller yang berputar dengan kecepatan tinggi ditransfer ke udara dengan cara merubah kecepatan dan tekanan. Kecepatan udara yang tinggi dirubah menjadi tekanan dengan cara mengurangi kecepatan pada difuser stasioner. Tipe kompressor ini cocok untuk kapasitas besar yaitu di atas 12.000 cfm. Kompresor Sentrifugal
  • 29. Kompresor High Speed Single Stage 1. Udara masuk kedalam Inlet Kompresor. 2. Udara terkompresi oleh First Stage Impeler. 3. Panas dibuang pada Intercooler pertama. 4. Udara akan dikomprosei pada second stage impeller. 5. Panas akan dibuang pada Intercooler kedua. 6. Udara dikompresi untuk mejadi tekanan final pada third stage Impeler. 7. Udara keluar ke After cooler dan sistem udara pada plant.
  • 30. Kompresor Ulir Kompressor ulir adalah mesin positif displacement dengan menggunakan sepasang rotor yang bersesuaian sebagai pengganti piston untuk menghasilkan tekanan. Ukurannya umumnya sekitar 30 hingga 200 hp atau 22 ke 150 kW.
  • 31. Konservasi Energi pada Kompresor  Operasikan pada tekanan serendah mungkin.  Bersihkan filter dan heat exchanger secara teratur.  Usahakan udara masuk termperaturnya rendah.  Gunakan flat belt yang efisien energi.  Gunakan soft stater yang hemat energi.  Lakukan reengineering proses untuk menurunkan penggunaan udara bertekanan  Turunkan kebocoran.  Pisahkan tekanan tinggi dan rendah jika mungkin.  Pasang solenoid valve untuk menutup udara bertekanan pada Mesin saat tidak beroperasi dan Seluruh bagian- bagian jaringan .  Jalur yang tidak berguna supaya dibongkar.  Gunakan tipe non purge air drayer.  Mengoptimumkan frekwensi auto drain trap.  Memanfaatkan air pendingin dari kompresor.  Matikan jika tidak diperlukan  Gunakan transvector nozzle(venturi) pada pembersihan • Biasanya digunakan udara tekanan 6 bar tetapi 2,5 bar sebenarnya cukup • Pasang compresor tersendiri dengan operasi on/of • Transvector nozzle akan menghisap udara luar 30%.  Peralatan listrik menghemat 30% energi dibandingkan Pneumatik  Penggantian udara tekan • Root blower dapat digunakan untuk agitas • Blower dapat digunakan untuk pendinginan.  Pemisahan jaringan udara bertekanan rendah jika total kebutuhan L.P (low pressure) >30 %. Kategori LP Compressor : 2.5 to 3.5 bar Kategori HP Compressor : > 3.5 bar
  • 32. Area Penghematan Kompresor Dryer Filter Economical Pipe Size Facility Facility Facility Minimum Air Leakage Minimum Pressure & Volume Integrating of Another air Comprersor Periodical Maintenance Effecetive Capacity Control Reduction of Unloadloss Reduction of Delivery Presure Compressor Receiver Tank Efficient Tank Low Inlet Air Temperature Sumber : Uplift Training Material – Hand Book
  • 33. Metode Pencegahan Kebocoran Mendeteksi Kebocoran  Gunakan ultrasonik detector yang dapat mendeteksi desis frekuwensi tinggi yang disebabkan oleh kebocoran udara.  Metoda sederhana yaitu dengan mengoleskan air sabun dengan kuas pada tempat yang diduga bocor. Menutup Kebocoran (perbaikan)  Pilih fiting yang kwalitas baik, disconnects, hose, turbin dan pasang secara benar dengan seal yang baik.  Jalur ke peralatan yang tidak dioperasikan segera ditutup.  Menurunkan tekanan udara meminimkan kebocoran  Setelah dilakukan perbaikan lakukan evaluasi penghematan. Program Pencegah Kebocoran Program pencegahan kebocoran yang baik meliputi hal-hal sebagai berikut:  Identifikasi, penelusuran, perbaikan, verifikasi  Melibatkan karyawan pada fasilitas (bagian) yang menggunakan udara bertekanan harus dilibatkan /bentuk tim penanggulangan.
  • 34. Minimize Suhu Udara Intake Suhu udara masuk kompressor (intake) berpengaruh significant terhadap konsumsi daya compressor, Udara intake yang panas atau yang terkontaminasi mempengaruhi kinerja kompressor yang mengakibatkan konsumsi energi dan biaya pemeliharaan meningkat. Kehadiran moiture (uap air), debu maupun kotoran lainnya pada udara intake akan menempel pada komponen dalam kompressor seperti valve, impeller dan rotor. Hal ini dapat mengurangi kapasitas dan menimbulkan keausan pada compressor. “Setiap kenaikan suhu udara intake 4 C akan mengakibatkan konsumsi daya meningkat 1 % untuk menghasilkan output yang sama”
  • 35. Pengurangan Pressure Drop Kelebihan pressure drop akibat ukuran pipa, filter, kopling dan hose yang tidak cocok adalah reprensentasi pemborosan energi. Mengurangi pressure drop dengan cara menggunakan sistem tertutup (loop) dengan dua jalur aliran . Seperti pada pipa, fitting juga merupakan sumber pressure drop. Pressure tipikal pada berbagai fitting diperlihatkan pada tabel diatas
  • 36. Optimalisasi Sistem Transmisi Sistem transmissi V-belt efisiensinya berkisar antara 70-90%, dengan bertambahnya usia akan mengalami kemunduran atau pengurangan efisiensi sekitar 4 % jika tidak terpelihara dengan baik. Hindari tegangan belt tidak sesuai (terlalu kendor maupun terlalu kencang), hal ini akan mengakibatkan rugi-rugi energi. Demikian juga multiple belt, jika salah satu dari multiple belt gagal atau rusak , maka seluruh belt harus diganti. Hindari sedapat mungkin adanya perbedaan dari masing-masing multiple belt. Ukuran belt oversizing atau undersizing akan menghasilkan rugi-rugi energi tambahan. Sistem transmissi bertingkat pada motor - kompressor seperti tampak pada gambar berikut akan menimbulkan rugi-rugi transmissi bertambah besar (sebaiknya dihindari).
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