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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