Inovasi Cold Start

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  • Kerja sama dan diskusiMenghasilkan mutu dan effisiensi

  • Latar BelakangMemenuhi target waktu start unit Sering terjadi gangguan penyalaan ign burner pada saat start unit

  • Maksud dan Tujuan Mengurangi Biaya Start unitMemperkecil waktu plant outageMemenuhi target EAFMemenuhi schedule pemeliharaan

  • Metode PenelitihanData performance testInstruction ManualTermodinamika dan Heat Transfer

  • Landasan TeoriThermal stress Low Cycle Fatigue Index

  • 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

  • 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

  • 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

  • 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

  • Sirkulasi aliran Boiler DrumeconomicerHeater mixSirkulasi pumpLP Aux staem7kg temp 275 C

  • 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

  • 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

  • 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

  • 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.

  • 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

  • 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

  • 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

  • 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

  • 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