Electronic Theses and Dissertation

Kegiatan pemeliharaan merupakan faktor krusial dalam menjaga kelancaran operasional di industri semen, di mana mesin-mesin bekerja di bawah tekanan tinggi dan suhu ekstrem. salah satu peralatan strategis adalah mesin roller press yang berfungsi menggiling bahan baku klinker dan gypsum melalui tekanan hidrolik tinggi. laporan ini bertujuan untuk mendokumentasikan prosedur teknis penggantian seal bearing pada unit roller press di pt solusi bangun andalas serta menganalisis efektivitas langkah-langkah pemeliharaan preventif yang dilakukan. permasalahan utama yang diidentifikasi adalah kerusakan parah pada seal bearing yang ditandai dengan retakan material elastomer dan kebocoran pelumas grease mencapai 30-40% dari kapasitas normal. hal ini menyebabkan kontaminasi debu klinker masuk ke sistem pelumasan yang dapat memicu keausan prematur pada bearing melalui fenomena three-body abrasion. proses perbaikan meliputi tahap persiapan, pemutusan sambungan hidrolik, pelepasan coupling drive shaft, hingga pemasangan seal baru tipe lip seal berbahan viton yang tahan suhu hingga 200°c. hasil pengujian setelah penggantian menunjukkan sistem kembali berfungsi optimal dengan efisiensi pelumasan pulih 100%, tingkat vibrasi di bawah 2 mm/s, dan suhu operasional di bawah 70°c. penerapan preventive maintenance yang tepat terbukti mampu mencegah kegagalan total komponen yang berpotensi menyebabkan kerugian produksi hingga 500 ton semen per hari. laporan ini merekomendasikan adopsi pemeliharaan prediktif berbasis iot untuk memantau parameter seal secara real-time guna meningkatkan keandalan jangka panjang mesin roller press. kata kunci :preventive maintenance, roller press, seal bearing, pt solusi bangun andalas, industri semen.

Maintenance activities are a crucial factor in ensuring smooth operations in the cement industry, where machinery operates under high pressure and extreme temperatures. One of the strategic pieces of equipment is the Roller Press machine, which functions to grind clinker and gypsum raw materials through high hydraulic pressure. This report aims to document the technical procedures for replacing the bearing seal on the Roller Press unit at PT Solusi Bangun Andalas and to analyze the effectiveness of the preventive maintenance measures implemented. The main problem identified was severe damage to the bearing seal, indicated by cracks in the elastomer material and grease lubricant leakage reaching 30–40% of normal capacity. This condition allowed clinker dust contamination to enter the lubrication system, potentially triggering premature bearing wear through the three-body abrasion phenomenon. The repair process included preparation stages, hydraulic line disconnection, removal of the drive shaft coupling, and installation of a new lip seal made of Viton material with heat resistance up to 200°C. Post-replacement testing results showed that the system returned to optimal operation, with lubrication efficiency fully restored to 100%, vibration levels below 2 mm/s, and operating temperatures maintained below 70°C. The proper implementation of preventive maintenance was proven effective in preventing total component failure that could potentially result in production losses of up to 500 tons of cement per day. This report recommends the adoption of IoT-based predictive maintenance to monitor seal parameters in real time in order to enhance the long-term reliability of the Roller Press machine. Keywords: Preventive Maintenance, Roller Press, Seal Bearing, PT Solusi Bangun Andalas, Cement Industry.