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7/30/2019 Final Check 1
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FINAL CHECK MANAGEMENT TRAINEE
ANGKATAN 34
10 April 2012
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PERENCANAAN SISTEM BED MATERIALHANDLING CFB BOILER DENGANMEMANFAATKAN SISTEM YANG ADAPADA PLTU 2 SULUT 2 X 25 MW
Angjuang Adi Panji P
Management Trainee 34
Pembimbing : Purwanta, S.T,
PLTU2Sulut2X25M
W
PT. WIJAYA KARYA (PERSERO). TBK
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CIRCULATED FLUIDIZED BED BOILER
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BACKGROUND
Saat start up, CFB Boiler membutuhkantambahan (make up) bed material untukmembantu tercapainya equilibrumsirkulasi di dalam furnace
Boilerstart up
Saat ini pengisian dilakukan secaramanual melalui coal feeder denganresiko keluarnya udara panas darifurnace
ManualFilling
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Membantu proses sirkulasidan perpindahan panas
secara merata dari furnace
ke water wall,platen
Melindungi furnace air nozzle
agar tidak rusak akibat overheat (bed density pressure
dijaga agar tetap 4 Kpa)
Saat proses peningkatan
beban, untuk menjaga bedtemperatur agar tidak over
heat (950 oC Boiler trip)
Min level approx. 330mm (11,6 t of sand)Normally about 500-700mm (24,6 t of sand)
MENGAPA PERLU BED MATERIAL ?
0
100
200
300
400
500
600
700
0 2000 4000 6000 8000
L
evel(mm)
Pressure (Pa)
Bed level and pressure
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KONDISI SAAT INI
Pengisian secara manual melaluiboiler furnace man hole (initialcharging)
Pengisian secara manual melaluicoal feeder (make up)
Handling
Pengisian
melalui
man hole
Pengisian
melalui coal
feeder
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Merencanakan sistem pengisian bed materialyang aman dan efisien dalam pengoperasiannya
dengan memanfaatkan sistem yang ada
TUJUAN dan MANFAAT
Pengisian bed meterial lebihAman dan Terkontrol Mengurangi biaya pengangkatan dan pengisian
menuju boiler
Mengurangi biaya untuk pengadaan baru Waktu pengisian lebih cepat
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TRANSFER BED MATERIAL
Memanfaatkan sistem limestoneOpsi 1
Memanfaatkan sistem limestonedengan modifikasi 1Opsi 2
Memanfaatkan sistem limestonedengan modifikasi 2Opsi 3
Opsi 4 Perencanaan sistem baru
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OVERVIEW SISTEM LIMESTONE
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To Furnace
From rootblower
SISTEM LIMESTONE UNIT 1
From jetpack
19 m
92,8 m
Root Blower
2x10,96 m3/min0,78 Bar
Compressor
1x7,3 m3/min
2 Bar
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BED MATERIAL
Bed material requirement AmountInitial charging (h=0.7 m) 25.5 tMake up 2.4 t/h
Sand characteristic
- Poor Air retention
- Good Permeability
- Bulk density = 1291 kg/m3
- Particle size = max
1mm, min 0.1mm
0
1000
2000
3000
4000
5000
6000
7000
8000
Kebutuhanmaterial(kg)
3 MW
7 MW
12 MW
17 MW21 MW
25 MW
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Conveying dari Jetpack truck menuju Silo
PENGISIAN SILO
0
5
10
15
20
25
30
35
40
45
50
0.1 0.15 0.2 0.25 0.3 0.35 0.4
Materialmassflowrate(t/h)
Air mass flow rate (kg/s)
15
20
5
10
1.4
0.8
1
0.6
0.4
1.2
Conveying
line pressure
drop (Bar)
Solids
loading
ratio
30
25
35
Pipe bore 4 in, length 40,4 m
P=1.2 Bar, Q=0,308 kg/s, p= 9 t/h
Silo filling
mmaterial = 1,1 ton
t filling = 30 min
p = 2,2 t/h
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Conveying from Silo to unit #1 Boiler
PENGISIAN MENUJU BOILER UNIT#1
0
10
20
30
40
50
60
70
0.2 0.4 0.6 0.8 1
Materialma
ssflowrate(t/h)
Air mass flow rate (kg/s)
15
20
5
10
1.4
0.81
0.60.4
1.2
Conveying
line pressuredrop (Bar)
Solids
loadingratio
Opsi 1, Pipe bore 6 in, length 68,77 m
P=0.4 Bar, Q=0,374 kg/s, p=19 t/h
Filling to Furnace boiler unit 1 (make up)
mmaterial = 200 kg
t filling = 5 min
p = 3,28 t/h
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Conveying from Silo to unit #2 Boiler
0
10
20
30
40
50
60
70
0.2 0.4 0.6 0.8 1
Materialma
ssflowrate(t/h)
Air mass flow rate (kg/s)
15
20
5
10
1.4
0.81
0.6
0.4
1.2
Conveying
line
pressure
drop (Bar)
Solids
loadingratio
Opsi 1, Pipe bore 6 in, length 92,87 m
P=0.4 Bar, Q=0,374 kg/s, p=17 t/h
Filling to Furnace boiler unit 2 (make up)
mmaterial = 900 kg
t filling = 27 min
p = 2 t/h
PENGISIAN MENUJU BOILER UNIT#2
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PREDIKSI EROSI PERPIPAAN
Dpipe 6 in, Vel 20 m/s, p 2.4 t/h
Pipe material carbon steel
E = 0.000624 mm/h
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MANAJEMEN RESIKO
No Causes Result Rate ofprobability Rate ofEffect Rating ofrisk RiskPriority
1 One of Root blower out ofservice
-supply of pressure and air flow will be reduce orstop
Low High High 4-Supply of bed material will be decreased or stop (ifrequired, the boiler bed density will be decrease and)-Pipe blocking
2 Rotary feeder is trip -Feeding of bed material will be stopped Moderate High Moderate 4-when required, the boiler density/pressure mayincreased result in over temperature
3 Bed material inside of silo iswet
-Slugging occurred and bed material getting difficult
to droped down to rotary feederLow High High 2-Blocking inside of rotary feeder result no material
feed-Pipeline blocking
4 Pipeline leakage due toerosion (abrasive material)
-Reducing in air flow and pressureModerate Moderat
e Low 1-when filling process, the material will be throw out
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No Risk
Risk level
before
countermea
sure
Countermeasure PICTime
limit
Risk level
after
counterme
asure
1One of Root blower
out of service/tripHigh
Open the vale from service air line to main line immediately to
provide pressured air. Restart the trip's root blowerOperator Lumintu Low
2 Rotary feeder is trip Moderate
Close sliding gate from silo discharge, restart the rotary feeder (if
the thermal over load relay is trip, press the trip button to activated).
After run, open the sliding gate slowly to approx 30% and set the
rotary feeder frequency to 15 hz
Operator,
EngineeringLumintu Low
3Bed material inside of
silo is wetHigh
Close sliding gate from silo discharge, run the aeration of silo
system for several minutes. If the problem is still remain, dismantle
the expansion join and open sliding gate to discharge the wet
material then closed again and fix the expansion joint
Operator,
EngineeringLumintu Low
4
Pipeline leakage due
to erosion (abrasive
material)
Moderate
Adjust the flow rate material to minimum rate (to reducing the
erosio rate), do the bends modifying (ex. by add an extralayer/lining to the bend, put the reinforced material, enlarge the
bend's radius.)
Engineering Lumintu Low
MANAJEMEN RESIKO
S
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KESIMPULAN
- Sistem yang ada (limestone system) dapat digunakan untuk handling bed
material menuju boiler unit 1 dan 2 tanpa harus membuat sistem baru
- Sistem pengisian silo limestone mampu mentransfer bed material dengan laju
maximum sebesar 9 t/h
- Sistem limestone mampu mentransfer bed material dengan laju maximum
sebesar 19 t/h menuju boiler unit 1 dan 17 t/h menuju boiler unit 2
- Dari ke empat opsi dipilih opsi no.3 dimana memiliki faktor kehandalan yang
lebih baik dibandingkan opsi lainnya dan biaya yang lebih rendah
- Disarankan untuk memodifikasi elbow atau bends perpipaan untuk
memperpanjang usia elbow akibat pengikisan oleh bed material
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TERIMA KASIH
PT. WIJAYA KARYA (PERSERO). TBK
REFERENSI
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REFERENSI
1) Boiler Operation Manual for Indonesia Sulawesi Utara 225MW CoalFired Power Plant, NW Power & CUC
2) Black &Veatch, Power Plant Engineering, Springer, New York, 1996
3) David Mills, Pneumatic Conveying Design Guide, Elsevier
Butterworth-Heinemann,, Oxford 2004
4) As build drawing isometric limestone system5) Contract Document, PT PLN (Persero)-PLTU 2 Sulawesi Utara