449 1805 1 PB
449 1805 1 PB
449 1805 1 PB
METALURGI
Available online at www.ejurnalmaterialmetalurgi.com
Masuk tanggal : 24-10-2018, revisi tanggal : 25-12-2018, diterima untuk diterbitkan tanggal : 09-01- 2019
Intisari
Pipa baja sering digunakan untuk menyalurkan uap bertekanan tinggi dari sebuah ketel uap menuju ke unit turbin uap atau ke
unit produksi lainnya. Tulisan ini menyajikan penelitian metalurgi yang dilakukan pada sejumlah pipa uap bertekanan tinggi pada
sebuah pabrik yang baru dibangun untuk menyalurkan uap bertekanan tinggi dari sebuah ketel uap menuju ke pabrik pengolahan
minyak ke-lapa sawit. Tujuannya adalah untuk memastikan bahwa keterpaduan material pipa uap memiliki kesesuaian dengan
spesifikasi dan kehandalan yang diinginkan. Disamping itu, tujuannya juga ada-lah untuk memperkirakan umur layan pipa uap
tersebut. Pengujian metalurgi dilakukan dengan mempersiapkan sejumlah benda uji yang diambil dari tiga potongan pipa uap
yang diterima, yaitu meliputi : analisa kimia, uji metalografi dan uji kekerasan serta uji tarik pada suhu 300 °C. Disamping itu,
analisa umur juga dibuat menggunakan persamaan yang diambil dari ASME Boiler dan BPVC (pressure vessel code) dan dari
data standar API 530. Hasil pengujian metalurgi yang diperoleh menun-jukkan bahwa pipa uap bertekanan tinggi yang dibuat
dari material ASTM A-106 Gr. B seluruhnya dalam kondisi baik, baik dari segi struktur mikro maupun dari segi sifat mekanis.
Hasil pengujian juga menunjukkan bahwa pada struktur mikro tidak diketemukan adanya cacat yang berarti, dan seluruh (ke tiga)
pipa uap yang di uji tersebut diperkirakan dalam keadaan siap untuk dioperasikan. Pada tekanan operasi 70 bar(g) dan temperatur
operasi maksimum 300 °C yang direncanakan, diperkirakan bahwa pipa uap tersebut dapat memberikan umur desain hingga 25
tahun atau lebih dengan laju korosi 0,2 - 0,3mm/tahun.
Kata Kunci: Ketel uap, pengujian metalurgi dan analisa umur, pipa uap bertekanan tinggi
Abstract
Steel pipes are commonly used for transporting high pressure steam from a steam generating unit or boiler to a steam
turbine or other processing unit. This paper presents a metallurgical examination performed on HP steam pipes of a newly
constructed plant for transporting high pressure steam from a boiler to a palm oil processing plant. The aim was to assure that
the material integrity of the steam pipes meet the intended specification and reliability. In addition, the aim was also to determine
the estimated service life of the steam pipes. The metallurgical examination was conducted by preparing a number of specimens
from the as-received three pieces of HP steam pipes. Various laboratory exam-inations were performed including chemical
analysis, metallographic examination, hardness testing and tensile testing at 300 °C. In addition, a life-time analysis was also
made using an equation based on the ASME Boiler and Pressure Vessel Code (BPVC) and data obtained from the API Standard
530. Results of the metallurgical examination obtained showed that the HP steam pipes which were made of ASTM A-106 Gr. B
were all in good condition, either in microstructure or mechanical property. There were no any significant defect observed, and
all the three HP steam pipes were assumed being ready to place in service. Under the intended operating pressure and
temperature of 70 bar(g) and 300 °C (max), respectively it can be estimated that the HP steam pipes may likely reach some
design life up to 25 years or more with the corrosion rate approximately 0.2 - 0.3 mm/year.
Keywords: Boiler, metallurgical examination and life-time analysis, high-pressure (HP) steam pipe
Figure 1. A newly built boiler construction and its corresponding HP steam piping system, connected to a
palm oil processing unit at location approximately on the right hand side (not seen)
Figure 2. The as received sections of new HP steam pipes of different diameters (Ø 4,” Ø 6,” and Ø 10") for
laboratory examination
Table 1. Results of chemical analysis obtained from the new HP steam pipe material
in comparison with the standard material.
Composition, wt.-%
Table 2. Results of hardness test obtained from the three different HP steam pipes
Figure 3. The three broken tensile test specimens after being tested at 300 °C
Table 4. Results of tensile test at 300 °C obtained from the HP steam pipe materials
Test Temperature: 300°C
Pipe
Diameter Sample TS
Ao Fm
Diameter ɛ (%)
(mm²) (kN) (N/mm2) (kgf/mm2)
(mm)
Ø 10” 8.58 57.8 29.0 502 51.1 29.0
For HP steam pipe of 6" diameter, the minimum If the maximum corrosion rate (CR) is estimated
allowable wall thickness is as follows: about 0.3 mm/year, the life-time (LT) of HP
(0.714).(152.4) steam pipe material of 4" diameter can be
tmin 0.005(152.4),
2(12.025) (0.714) calculated as follows:
or t min 5.152mm t0 - t min 9.15 - 1.5
LT 25.5 year
CR 0.3
For design life is assumed of 25 years, corrosion where t0 = 9.15 mm is the initial wall thickness
rate (CR) can be calculated as follows: of HP steam pipe of 4" diameter.