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FINAL CHECK MANAGEMENT TRAINEE ANGKATAN 34

10 April 2012

PT. WIJAYA KARYA (PERSERO). TBK

PERENCANAAN SISTEM BED MATERIAL HANDLING CFB BOILER DENGAN MEMANFAATKAN SISTEM YANG ADA PADA PLTU 2 SULUT 2 X 25 MW
Angjuang Adi Panji P Management Trainee 34 Pembimbing : Purwanta, S.T,

PLTU 2 Sulut 2 X 25 MW

CIRCULATED FLUIDIZED BED BOILER

BACKGROUND

Boiler start up

Saat start up, CFB Boiler membutuhkan tambahan (make up) bed material untuk membantu tercapainya equilibrum sirkulasi di dalam furnace

Manual Filling

Saat ini pengisian dilakukan secara manual melalui coal feeder dengan resiko keluarnya udara panas dari furnace

MENGAPA PERLU BED MATERIAL ?


Membantu proses sirkulasi dan perpindahan panas secara merata dari furnace ke water wall,platen Melindungi furnace air nozzle agar tidak rusak akibat over heat (bed density pressure dijaga agar tetap 4 Kpa) Saat proses peningkatan beban, untuk menjaga bed temperatur agar tidak over heat (950 oC Boiler trip)

Bed level and pressure


700 600 Level (mm) 500 400

300
200 100 0 0 2000 4000 Pressure (Pa) 6000 8000

Min level approx. 330mm (11,6 t of sand) Normally about 500-700mm (24,6 t of sand)

KONDISI SAAT INI


Pengisian secara manual melalui boiler furnace man hole (initial charging) Pengisian secara manual melalui coal feeder (make up)

Handling

Pengisian melalui coal feeder

Pengisian melalui man hole

TUJUAN dan MANFAAT


Merencanakan sistem pengisian bed material yang aman dan efisien dalam pengoperasiannya dengan memanfaatkan sistem yang ada

Pengisian bed meterial lebih Aman dan Terkontrol Mengurangi biaya pengangkatan dan pengisian menuju boiler Mengurangi biaya untuk pengadaan baru Waktu pengisian lebih cepat

TRANSFER BED MATERIAL

Opsi 1

Memanfaatkan sistem limestone

Opsi 2
Opsi 3 Opsi 4

Memanfaatkan sistem limestone dengan modifikasi 1 Memanfaatkan sistem limestone dengan modifikasi 2

Perencanaan sistem baru

OVERVIEW SISTEM LIMESTONE

SISTEM LIMESTONE UNIT 1


Root Blower 2x10,96 m3/min 0,78 Bar Compressor 1x7,3 m3/min 2 Bar

19 m To Furnace
92,8 m

From jetpack
From root blower

BED MATERIAL

Bed material requirement

Amount

Initial charging (h=0.7 m)


Make up

25.5 t
2.4 t/h

8000 7000 Kebutuhan material (kg)

Sand characteristic - Poor Air retention - Good Permeability - Bulk density = 1291 kg/m3 - Particle size = max 1mm, min 0.1mm

6000
5000 4000 3000 2000 1000 0 3 MW 7 MW 12 MW 17 MW 21 MW 25 MW

CONVEYING METHOD
Dilute phase

Medium dense phase

Dense phase

SILICA SAND

GOOD PERMEABILITY

POOR AIR RETENTION

DILUTE PHASE

PENGISIAN SILO
Conveying dari Jetpack truck menuju Silo
50 45 40

Conveying line pressure drop (Bar) 1.2 1

1.4

Solids loading ratio

35

30

Material mass flow rate (t/h)

35

25
30
25 20 15 10 5 0 0.1 0.15 0.2 0.25 0.3 0.35 0.4

0.8 0.6 20 15 0.4 10

Air mass flow rate (kg/s)

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

PENGISIAN MENUJU BOILER UNIT#1


Conveying from Silo to unit #1 Boiler
70

60

Conveying line pressure drop (Bar) 1.2 1

Solids loading ratio 20 1.4

Material mass flow rate (t/h)

50

15

40

0.8
30

0.6

10

Filling to Furnace boiler unit 1 (make up) mmaterial = 200 kg t filling = 5 min p = 3,28 t/h

20

0.4 5

10

0 0.2 0.4 0.6 0.8 1

Air mass flow rate (kg/s)

Opsi 1, Pipe bore 6 in, length 68,77 m P=0.4 Bar, Q=0,374 kg/s, p=19 t/h

PENGISIAN MENUJU BOILER UNIT#2


Conveying from Silo to unit #2 Boiler
70

Solids loading ratio Conveying line pressure drop (Bar) 1 0.8 10 20 1.4 1.2 15

60

Material mass flow rate (t/h)

50

40

30

0.6

Filling to Furnace boiler unit 2 (make up) mmaterial = 900 kg t filling = 27 min p = 2 t/h

20

0.4 5

10

0 0.2 0.4 0.6 0.8 1

Air mass flow rate (kg/s)

Opsi 1, Pipe bore 6 in, length 92,87 m P=0.4 Bar, Q=0,374 kg/s, p=17 t/h

PREDIKSI EROSI PERPIPAAN


Dpipe 6 in, Vel 20 m/s, p 2.4 t/h Pipe material carbon steel E = 0.000624 mm/h

Biaya,Mutu,Waktu
Solid feeding system Deskripsi sistem Air mover Flow rate udara Pressure Diameter pipa Panjang pipa p maximum Erosion rate (mm/h) Modifikasi pipa Option 1 Memanfaatkan sistem limestone Option 2 Memanfaatkan sistem limestone (modifikasi) Root blower 2 x 30 kW (1 Root blower 2x30 kW (2 run) stand by) 3/min 10.96 x 2 m 10.96 x 1 m3/min 0.78 Bar 0.78 Bar 6 in 4 in 92.87 m 92.87 m 19 0.000624 mm/h Tidak ada Kurang handal (tidak ada stand by blower) Jika terjadi blocking harus membongkar perpipaan Tidak ada 8 0.00485 mm/h Penambahan pipe clamp Handal (1 blower bekerja, 1 stand by Jika terjadi blocking pipa, dapat diatasi dengan membuka clamp Untuk pengadaan pipa dan fitting dan pengerjaan (Rp. 50.000.000) Option 3 Memanfaatkan sistem limestone (modifikasi) Root blower 3 x 30 kW (1 stand by) 10.96 x 2 m3/min 0.78 Bar 6 in 92.87 m 19 0.000624 mm/h Penambahan pipe clamp Handal (2 blower bekerja, 1 stand by) Jika terjadi blocking pipa, dapat diatasi dengan membuka clamp Penambahan 1 unit root blower (Rp. 70.000.000) Option 4 Sistem tersendiri Root Blowe 2 x 14.2 kW (1 stand by) 8.75 m3/min 0.68 Bar 4 in 92.87 m 9 0.310 mm/h Penambahan pipe clamp Handal (1 blower bekerja, 1 stand by Jika terjadi blocking pipa, dapat diatasi dengan membuka clamp Rp. 1.780.000.000,00 Dibutuhkan waktu untuk pengadaan dan instalasi (estimasi 6 Bulan) J-valve

Kehandalan

Biaya

Waktu Inlet material di boiler

Tidak dibutuhkan waktu untuk Estimasi 3 Bulan pengerjaan Furnace J-Valve

Estimasi 2 Bulan Furnace

MANAJEMEN RESIKO
No Causes Result Rate of Rate of Rating of Risk probability Effect risk Priority -supply of pressure and air flow will be reduce or stop One of Root blower out of -Supply of bed material will be decreased or stop (if Low High High service required, the boiler bed density will be decrease and) -Pipe blocking -Feeding of bed material will be stopped Rotary feeder is trip Moderate High Moderate -when required, the boiler density/pressure may increased result in over temperature -Slugging occurred and bed material getting difficult to droped down to rotary feeder Bed material inside of silo is -Blocking inside of rotary feeder result no material Low High High wet feed -Pipeline blocking -Reducing in air flow and pressure Pipeline leakage due to Moderat Moderate Low erosion (abrasive material) -when filling process, the material will be throw out e

MANAJEMEN RESIKO
No Risk Risk level before countermea sure High Countermeasure PIC Risk level Time after limit counterme asure Low

One of Root blower out of service/trip

Open the vale from service air line to main line immediately to provide pressured air. Restart the trip's root blower

Operator Lumintu

2 Rotary feeder is trip

Close sliding gate from silo discharge, restart the rotary feeder (if the thermal over load relay is trip, press the trip button to activated). Operator, Moderate Lumintu After run, open the sliding gate slowly to approx 30% and set the Engineering rotary feeder frequency to 15 hz Close sliding gate from silo discharge, run the aeration of silo system for several minutes. If the problem is still remain, dismantle Operator, Lumintu the expansion join and open sliding gate to discharge the wet Engineering material then closed again and fix the expansion joint

Low

Bed material inside of 3 silo is wet

High

Low

Pipeline leakage due 4 to erosion (abrasive material)

Adjust the flow rate material to minimum rate (to reducing the erosio rate), do the bends modifying (ex. by add an extra Moderate layer/lining to the bend, put the reinforced material, enlarge the bend's radius.)

Engineering Lumintu

Low

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

PT. WIJAYA KARYA (PERSERO). TBK

TERIMA KASIH

REFERENSI
1) Boiler Operation Manual for Indonesia Sulawesi Utara 225MW Coal Fired 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 system 5) Contract Document, PT PLN (Persero)-PLTU 2 Sulawesi Utara