Inovasi Cold Start
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Transcript of Inovasi Cold Start
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Kerja sama dan diskusiMenghasilkan mutu dan effisiensi
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Latar BelakangMemenuhi target waktu start unit Sering terjadi gangguan penyalaan ign burner pada saat start unit
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Maksud dan Tujuan Mengurangi Biaya Start unitMemperkecil waktu plant outageMemenuhi target EAFMemenuhi schedule pemeliharaan
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Metode PenelitihanData performance testInstruction ManualTermodinamika dan Heat Transfer
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Landasan TeoriThermal stress Low Cycle Fatigue Index
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Pembahasan InovasiBoiler Persiapan start dengan kondisi Drum Metal 100CSirkulasi air pengisi Boiler Dengan dipanasi Aux Steam
Turbin Chest warming lebih awal dengan MSP40 kg/cm MSTemp 300C
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Batasan OperasiBoiler 1. Laju kenaikan temp. Drum metal 100 C dibatasi 55 C/jam 3. Perbedaan atas &bawah Drum metal 90 CTurbin 1.CV Chest warming intalphi >672 kcal /kg warming selesai bila cv outlet >230 C atau warming selama 1 jam 2. Turbin rolling 3. Mismatch 111 C ..+167C Idial mismactch +28 C +56C
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Tahapan Operasi BoilerBoiler Filling (72 ton)Sirkulasi air pengisi Boiler dan menaikan temp. secara pelan pelan melalui setting pada Mixing Heater hingga drum metal tercapai 100CLangkah berikutnya sesuai SOP
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Tahapan operasi Turbin Aux steam inservicePerapat turbin inserviceVacuum up Turbin resetChest warming MSP 40 kg/cm2 temp300CStart turbin ..MSP60 kg/cm2,temp 340 C900 rpm lakukan low speed heat time(90minit)3000 rpm lakukan high speed heat time(60minit)Langkah selanjutnya sesuai SOP
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Sirkulasi aliran Boiler DrumeconomicerHeater mixSirkulasi pumpLP Aux staem7kg temp 275 C
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DATA DRUMDrumKetinggian Drum : 37100 mmDiameter dalam : 1675 mmKetebalan : 162 /154 mmPanjang : 11580 mmLevel indikator : + 350 / - 350 mmVolume : 24790 literVolume NWL : 12395 literVolume boiler ( Drum NWL ) : 110000 literVolume boiler ( Drum 150 mm ) : 105 000 literTarget sirkulasi : Drum level 150 mm dengqn temperatur air 120 CIsi awal boiler : 95000 l dengan temperatur air 40 C
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KEBUTUHAN PERALATAN Kebutuhan peralatan .Sebuah pompa sirkulasi dengan spesifikasi :1. PompaType : Horizontal single suction volute typeKapasitas : 80 ton / jamTotal head : 60 mMotor penggerak:Type : Totally enclosed fan cooled typeCapacity : 22 kwVoltage : 440 V Material :Pipa STPG 38 , 125 A dengan panjang 50 mPipa STPT 42 , 100 A dengan panjang 50 m2 ( satu buah ) reducer 1 ( satu buah ) gate valve .1 ( satu buah ) gate valve . 2 ( dua ) buah pipa T ukuran 125 A dan 100 A
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Manfaat InovasiMengurangi mintenance outage hours selama 3,5 jamMengurangi biaya startMengurangi pemakaian bahan bakar selama 3,5 Jam sebesar :3,5 x 800 L x Rp 950 = Rp 2.660.000 ,-Mengurangi kerugian KWH selama 3,5 jam sebesar 56 MW ( di hitung beban initial dan beban terendah ditahan ).3,5 x 56000 x Rp 279 = Rp 54.684.000 ,-Penghematan KWH alat bantu sebesar Rp1.739.704 ,50 Jadi total keuntungan yang didapat sebesar Rp 54.684.000 + Rp 2.660.000 + Rp 1.739.704,50 = Rp59.083.704,50 ,-Biaya Operasi Produksi Uap Aux Sebanyak 33.354 Kg Setara Rp 3.348.731,00KWH Pompa sirkulasi selama 3.5 jam = Rp 21.483,00Total biaya Rp 3.370.214,00 JADI keuntungan Bersih Rp 59.083.704.50 3.370.214,00= Rp 55.713.490,50
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Kesimpulan Dengan mensirkulasikan air boiler untuk menyiapkan metal drum > 100C ketika boiler hendak firing dan melaksnakan chest warming lebih awal yakni pada tekanan main steam 40 kg/cm dan temperatur 300 C yang sebelumnya dilakukan pada tekanan main steam 60 kg/cm , temperatur 340C , di dapat keuntungan seperti tersebut pada manfaat inovasi.
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CYCLIC DAMAGE CURVE OF ROTORApply to rate of temp. change vs amountof change anticipated for varous cyclic life expenditure.Rotor section :High press. section Rotor Nominal Deameter :508.0 mm (20)Thermocouple location : first Stage shell inner 40035030015020025010050 50 100150200250300350
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ALLOWABLE TEMPERATUR DIFFERENCE CONTROL VALVE CASING ( TWO SIDE INLET NOTES:
bsolute Limit is based on the thermal fatique strength of 7000 cycles and do not be exceededNormal operation is to be done under limitation of standart limit . If this is exceeded , continous observation is requaired and some operation such as unit hold is necessary when Absolute Limit is being approached.If absolute limit is reached , it is most desirable to wait until the condition is improved in that state and some amendments on operation procedures including boiler characteristics is necessary.
100200300400500140130120110100908070TEMP.DIFF.& OUTER SUFACE THERMOCOPLETEMPERATUR OF INNER SURFACE THERMOCOPLE
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Grafik cold start
Sheet1
CSTARTING CURVE - COLD START
600
Kg/cmMWmmhg
200200
760
400Rpm
1501506003000
1001004002000
200
50502001000
00000
012345678789101112
Boiler light offTurbin rolling
Vacuum upTurbin RollingSyncrone
Chest WarmingChest warming
CSTARTING CURVE - COLD START
600INOVASI
Kg/cmMWmmhg
200200
760
400Rpm
1501506003000
1001004002000
200
50502001000
Drum metal 100 C
400 RPM
00000
012345456789
Boiler light offTurbin rollingSyncrone
Vacuum upTurbine Rolling
Chest warming
`
DIAGRAM SIRKULASI AIR BOILER
STEAM DRUMTV - 95
Y
10 Kg/cm , 340 C
Y
: Line modif
Y
FROM FEED WATER
CSTARTING CURVE - COLD START
600
Kg/cmMWmmhg
200200
760
400Rpm
1501506003000
1001004002000
200
50502001000
00000
012345678789101112
Boiler light offTurbin rolling
Vacuum upTurbin RollingSyncrone
Chest WarmingChest warming
28 C
55C
MAX
SAT. TEMP
340C
60 Kg/cm
900 RPM
3000 RPM
538C
169 Kg/cm
6 MW
14 MW
50 MW
100 MW
200 MW
VACUUM HIGHER THAN 635 MMHG
55C
MAX
SAT. TEMP
340C
60 Kg/cm
900 RPM
3000 RPM
538C
169 Kg/cm
6 MW
14 MW
50 MW
100 MW
200 MW
VACUUM HIGHER THAN 635 MMHG
MIXING HEATER
PI95-1
PI95-2
TC95
PI95-3
TW95
TI95
PC95
AH-3A
AH-3B
TO UNIT IV
CONN.FOR FURAND ECCO
L.P.AUX.STEAM HEADER FROM #3
ECONOMIZER
PV - 95
TO UNIT IV
FIRE WATER
EXITING
FOR SAMPLING
T
TO BLOW DOWN TANK
TO PIT
TO PIT
POMPA
40 Kg/cm
400 RPM
28 C
55C
MAX
SAT. TEMP
340C
60 Kg/cm
900 RPM
3000 RPM
538C
169 Kg/cm
6 MW
14 MW
50 MW
100 MW
200 MW
VACUUM HIGHER THAN 635 MMHG
400 RPM
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Cold start inovasi
Sheet1
CSTARTING CURVE - COLD START
600
Kg/cmMWmmhg
200200
760
400Rpm
1501506003000
1001004002000
200
50502001000
00000
012345678789101112
Boiler light offTurbin rolling
Vacuum upTurbin RollingSyncrone
Chest WarmingChest warming
CSTARTING CURVE - COLD START
600INOVASI
Kg/cmMWmmhg
200200
760
400Rpm
1501506003000
1001004002000
200
50502001000
Drum metal 100 C
400 RPM
00000
012345456789
Boiler light offTurbin rollingSyncrone
Vacuum upTurbine Rolling
Chest warming
`
DIAGRAM SIRKULASI AIR BOILER
STEAM DRUMTV - 95
Y
10 Kg/cm , 340 C
Y
Ket:
: Line modif
Y
FROM FEED WATER
CSTARTING CURVE - COLD START
600
Kg/cmMWmmhg
200200
760
400Rpm
1501506003000
1001004002000
200
50502001000
00000
012345678789101112
Boiler light offTurbin rolling
Vacuum upTurbin RollingSyncrone
Chest WarmingChest warming
28 C
55C
MAX
SAT. TEMP
340C
60 Kg/cm
900 RPM
3000 RPM
538C
169 Kg/cm
6 MW
14 MW
50 MW
100 MW
200 MW
VACUUM HIGHER THAN 635 MMHG
55C
MAX
SAT. TEMP
340C
60 Kg/cm
900 RPM
3000 RPM
538C
169 Kg/cm
6 MW
14 MW
50 MW
100 MW
200 MW
VACUUM HIGHER THAN 635 MMHG
MIXING HEATER
PI95-1
PI95-2
TC95
PI95-3
TW95
TI95
PC95
AH-3A
AH-3B
TO UNIT IV
CONN.FOR FURAND ECCO
L.P.AUX.STEAM HEADER FROM #3
ECONOMIZER
PV - 95
TO UNIT IV
FIRE WATER
EXITING
FOR SAMPLING
T
TO BLOW DOWN TANK
TO PIT
TO PIT
POMPA
40 Kg/cm
400 RPM
28 C
55C
MAX
SAT. TEMP
340C
60 Kg/cm
900 RPM
3000 RPM
538C
169 Kg/cm
6 MW
14 MW
50 MW
100 MW
200 MW
VACUUM HIGHER THAN 635 MMHG
400 RPM
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FIRST STAGETO LPTURBINER FROM FSHTO REHEATERFROM FSHHP TURBINELP TURBINEABCD KETERANGAN
A:CV STEAM CHEST OUTER METALTEMPB:CV STEAN CHEST INNER METAL TEMPC:REHEAT BOWL INNER METAL TEMPD:REHEAT BOWL OUTER METAL TEMPE:FIRST STAGE INNER METAL TEMP. E