A CASE STUDY ON THE TECHNICAL FEASIBILITY OF FABRICATING A 700-BAR PRESSURE VESSEL USING THE DESIGN-BY-ANALYSIS (DBA) APPROACH AT PT PLN (PERSERO)
Keywords:
Design-by-Analysis, Finite Element Analysis, Hydrogen Storage, PLN PUSHARLIS, Pressure Vessel.Abstract
Green-hydrogen deployment requires storage vessels capable of sustaining very high pressure while maintaining structural integrity and manufacturability. This study evaluates the technical feasibility of manufacturing a Type II hydrogen pressure vessel at PT PLN (Persero) PUSHARLIS using a Design-by-Analysis approach supported by finite element analysis. The study integrates engineering standards, material screening, workshop observations, design calculations, ANSYS simulation, manufacturing review, and hydrostatic-test planning. The proposed vessel uses an AISI 4130 steel liner with a 49 mm wall and a 14 mm composite hoop-wrapping layer under a 70 MPa (700 bar) internal pressure. Simulation produced a maximum von Mises stress of 381.75 MPa, below the 1,186 MPa yield strength adopted for the liner, with a minimum safety factor of approximately 3.05. The hydrostatic-test scheme uses 910 barg, equivalent to 1.3 times the design pressure. Local ASTM A36 can support prototype manufacturing-process development, but its lower strength makes it unsuitable for long-term high-pressure hydrogen storage. The results indicate a feasible domestic manufacturing pathway provided that high-pressure code qualification, material compatibility, testing capability, and quality assurance are strengthened.
Downloads
References
Air, A., Shamsuddoha, M., & Prusty, B. G. (2023). A review of Type V composite pressure vessels and automated fibre placement based manufacturing. Composites Part B: Engineering, 253, 110573. https://doi.org/10.1016/j.compositesb.2023.110573
Digwijaya, W., et al. (2026). Advanced structural analysis of Type IV hydrogen tank walls for hydrogen vehicles: Effects of temperature and material variations with failure criterion evaluation using finite element method. Energy Storage and Saving. https://doi.org/10.1016/j.enss.2025.07.008
Elsheikh, A., Ali, A., Essa, F. A., Omer, M. A. E., Abou-Ali, M. G., & Ma, N. (2026). Hydrogen embrittlement in storage tank materials and welded joints. Materials Today Sustainability, 33, 101282. https://doi.org/10.1016/j.mtsust.2025.101282
Imron, J. (2025). Analisis desain dan keandalan bejana bertekanan pada industri energi: Pendekatan numerik dan eksperimental. Jurnal Riset Rumpun Ilmu Teknik, 4(1), 48-59. https://doi.org/10.55606/jurritek.v4i1.4474
Kabir, M. Z. (2000). Finite element analysis of composite pressure vessels with a load sharing metallic liner. Composite Structures, 49(3), 247-255.
Khan, S., & Kumar, A. (2025). Manufacturing challenges in advanced cylindrical composite pressure vessels for hydrogen storage: A comprehensive review. Energy Storage, 7(7), e70263. https://doi.org/10.1002/est2.70263
Li, J., et al. (2024). Small-scale high-pressure hydrogen storage vessels: A review. Materials, 17(3). https://doi.org/10.3390/ma17030721
Liang, C.-C., Chen, H.-W., & Wang, C.-H. (2002). Optimum design of dome contour for filament-wound composite pressure vessels based on a shape factor. Composite Structures, 58(4), 469-482.
Marini, V., Aydin, B., Anatone, M., & Mancini, E. (2025). Safety and design aspects for high-pressure hydrogen storage tanks: Importance of design by analysis. ASME Pressure Vessels and Piping Conference. https://doi.org/10.1115/PVP2025-151757
Mehrabianbardar, A., Shirinbayan, M., Jendli, Z., Gillet, S., Nouira, S., & Fitoussi, J. (2025). A review: Challenges, processes, and innovations in high-pressure hydrogen storage technologies (Vol. 18, No. 3). Springer Paris. https://doi.org/10.1007/s12289-025-01934-3
Park, J.-S., Hong, C.-S., Kim, C.-G., & Kim, C.-U. (2002). Analysis of filament wound composite structures considering the change of winding angles through the thickness direction. Composite Structures, 55(1), 63-71.
Sayman, O. (2005). Analysis of multi-layered composite cylinders under hygrothermal loading. Composites Part A: Applied Science and Manufacturing, 36(7), 923-933.
Takeichi, N., et al. (2003). Hybrid hydrogen storage vessel: A novel high-pressure hydrogen storage vessel combined with hydrogen storage material. International Journal of Hydrogen Energy, 28(10), 1121-1129.
American Society of Mechanical Engineers. (1989). Rules for construction of pressure vessels. ASME Boiler and Pressure Vessel Code.
Laporan Penelitian. (2024). Laporan penelitian desain engineering serta assesmen tingkat kesiapan industri dalam proses manufaktur penyimpanan gas hidrogen tekanan tinggi (Vol. 7980235, No. 30).
