SATRIO, ERIK (2025) ANALISIS KEGAGALAN TURBOCHARGER SERI 7S1508 PADA LOKOMOTIF. S1 thesis, Universitas Mercu Buana Jakarta.
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Abstract
Based on a failure report from PT Kereta Api Indonesia revealed an incident where the 7S1508 series turbocharger on a locomotive experienced a failure that caused the locomotive to shut down. The inspection found friction between the turbocharger rotor and the air inlet blower casing which caused the turbocharger rotor to jam. So far, no analysis has been carried out to describe the failure and its impact on the locomotive. The purpose of this research is to identify the failure of the 7S1508 series turbocharger that occurred on the CC 206 locomotive, analyze the impact of the failure on the engine and provide suggestions for improvement. Failure analysis of the 7S1508 series turbocharger is carried out by several methods, namely identifying the physical inspection of the turbocharger, factors causing failure, self load data collection, previous research, journals, literature reviews and manual Documents from locomotive manufacturers. The results showed that pieces of victaulic rubber that clogged the turbocharger bearing lubrication channel caused the turbocharger bearings to be poorly lubricated and the bearings experienced wear that made the turbocharger rotor experience unbalance and ultimately made the rotor rotation unbalanced then the compressor wheel rubbed against the air inlet blower casing, the friction made the compressor wheel experience pengkisan and made the unbalance on the rotor even greater and caused the turbine-end bearing to crack and eventually the turbocharger rotor stuck. The turbocharger failure was detected through FAM Code 01-0121, which recorded the rotor speed below 600 rpm for 5 seconds, activating the locomotive protection system to prevent further damage. Based on the CC 206 locomotive's self load data, there is a significant correlation between Air density, boost pressure, torque, and engine rpm in determining engine performance. At Notch 1, the Air density was recorded at 0,93 kg/m³ with a boost pressure of 89632 Pa, producing 75 HP of power at 450 rpm and 875,3 Lb-ft of torque. As the Notch increases, the Air density increases until it reaches 3,10 kg/m³ at Notch 8 with a boost pressure of 303369 Pa, producing a maximum power of 2250 HP at 1050 rpm with a torque of 11254 Lbft. These results show that the boost pressure generated by the turbocharger greatly affects the density of air entering the combustion chamber, which enables more efficient fuel combustion and increases engine power. This finding confirms the importance of optimal turbocharger conditions and optimal maintenance and repair plans to maintain locomotive performance. Keywords: 7S1508 series turbocharger failure, Rotor unbalance, Locomotive, Boost pressure Berdasarkan laporan kegagalan dari PT Kereta Api Indonesia mengungkap insiden di mana turbocharger seri 7S1508 pada lokomotif mengalami kegagalan yang menyebabkan lokomotif mati, Inspeksi menemukan adanya gesekan antara rotor turbocharger dan air inlet blower casing yang menyebabkan rotor turbocharger macet. Selama ini belum ada analisis yang dilakukan untuk mendeskripsikan kegagalan tersebut serta dampaknya terhadap lokomotif. Tujuan penelitian ini dilakukan adalah untuk mengidentifikasi kegagalan pada turbocharger seri 7S1508 yang terjadi pada lokomotif CC 206, menganalisis dampak kegagalan terhadap mesin serta memberikan usulan perbaikan. Analisis kegagalan turbocharger seri 7S1508 ini dilakukan dengan beberapa metode yaitu melakukan identifikasi inspeksi fisik turbocharger, faktor penyebab kegagalan,pengambilan data self load, penelitian terdahulu,jurnal, tinjauan pustaka dan dokumen manual dari pabrikan lokomotif. Hasil penelitian menunjukan potongan karet victaulic yang menyumbat saluran pelumasan bearing turbocharger menyebabkan bearing turbocharger tidak terlumasi dengan baik dan bearing mengalami keausan yang membuat rotor turbocharger mengalami unbalance dan pada akhirnya membuat putaran rotor tidak seimbang kemudian compressor wheel bergesekan dengan air inlet blower casing, gesekan itu membuat compressor wheel mengalami pengkisan dan membuat unbalance pada rotor semakin besar dan menyebabkan bearing turbine-end mengalami keretakan dan pada akhirnya rotor turbocharger macet. rotor turbocharger macet dapat menyebabkan hilangnya boost pressure dan menyebabkan mesin lokomotif tidak dapat beroperasi. Kegagalan turbocharger terdeteksi melalui FAM Code 01-0121, yang mencatat kecepatan rotor di bawah 600 rpm selama 5 detik, mengaktifkan sistem perlindungan lokomotif untuk mencegah kerusakan lebih lanjut. Berdasarkan data self load lokomotif CC 206, terdapat korelasi signifikan antara densitas udara, boost pressure, torsi, dan rpm mesin dalam menentukan kinerja mesin. Pada Notch 1, densitas udara tercatat sebesar 0,93 kg/m³ dengan boost pressure 89632 Pa, menghasilkan daya 75 HP pada putaran mesin 450 rpm dan torsi 875,3 Lb-ft. Seiring dengan peningkatan Notch, densitas udara meningkat hingga mencapai 3,10 kg/m³ pada Notch 8 dengan boost pressure 303.369 Pa, menghasilkan daya maksimum 2250 HP pada 1050 rpm dengan torsi 11254 Lb-ft. Hasil ini menunjukkan bahwa boost pressure yang dihasilkan oleh turbocharger sangat mempengaruhi densitas udara yang masuk ke ruang bakar, yang memungkinkan pembakaran bahan bakar lebih efisien dan meningkatkan tenaga mesin. Temuan ini menegaskan pentingnya kondisi turbocharger yang optimal serta melakukan perwatan dan ususlan perbaikan yang optimal untuk mempertahankan performa lokomotif. Kata Kunci : Kegagalan turbocharger seri 7S1508, Rotor unbalance, Lokomotif, Boost pressure
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