IK-BJ-5.1.3.01.01 IK Cold Start Up Unit - Rev 0

PT PEMBANGKITAN JAWA BALI SERVICES No.Dokumen : IK-BJ-5.1.3.
01
SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016
INSTRUKSI KERJA Revisi : 00
COLD START UP Halaman : 0 dari 21
SIAP INTEGRATED MANAGEMENT SYSTEM
SIAP-IMS
INSTRUKSI KERJA
COLD START UP
UNIT JASA O&M PLTU BANJARSARI
NOMOR DOKUMEN : IK-BJ-5.1.3.01
PT PEMBANGKITAN JAWA BALI SERVICES

ServiceOriented Integrity- ActiveLearning- Professional
PT PEMBANGKITAN JAWA BALI SERVICES No.Dokumen : IK-BJ-5.1.3.01
I. FUNG SI SO P :
- Sebagai pedoman operator dalam melaksanakan operasi pembangkit PLTU BANJARSARI
sehingga dapat terlaksana secara aman,efisien,handal dan tepat waktu.
II. APD YANG DIGUNAKAN :

- Safety Helm
- Safety shoes
- Safety glasses
- Sarung tangan
- Masker
- Ear muff atau ear plug
III. PERALATAN YANG DIGUNAKAN :

- Radio komunikasi (HT)
- Kunci yang sesuai dg kebutuhan lokal (untuk operator lokal)
- Senter
IV. PELAKSANACOLD START-UP :

- Operator Control Room
- Operator Lokal
V. SUPERVISI :
- Pelaksanaan start / stop di supervisi oleh leader shift produksi
VI. SPESIFIKASI PERALATAN :
a. Parameter Boiler
Items Unit BMCR
Drum Working Pressure Mpa.g 15.05
Superheated Steam Flow Rate t/h 440
Superheated Steam Outlet Pressure Mpa.g 13.8
oC
Superheated Steam Outlet Temperature 540
Reheated Steam Flow t/h 359
Reheated Steam Outlet Pressure Mpa.g 2.44
Reheated Steam Inlet Pressure Mpa.g 2.59
oC
Reheated Steam Outlet Temperature 540
oC
Reheated Steam Inlet Temperature 326
oC
Feed Water Temperature 249
oC
Exhaust Gas Temperature 140
oC
Air Temperature at Air Heater Inlet 35
b. Parameter Turbine
Parameter Unit Normal Minimum Maksimum Shutdown Keterangan
Temperatur main 450 Shutdown
C 530-545 510 549
steam >563 manual
Pressure main
MPa 13.2 13.9
steam
Pressure reheat
MPa 2.3-2.5 2.7
steam
Temp.reheat 450 Shutdown
C 530-543 520 549
steam >563 manual
Temp.exhaust HP
C
casing
Temp.exhaust LP 80
Shutdown
casing C (auto water 120
manual
spray)
Pressure
kPa 7 147 196
condenser
Diff. expansion HP -3.2
mm -3 +6
& IP +6.2
Diff. expansion LP mm +8 +8.2
Axial displacement -1.05 -1.65
mm
+0.6 +1.2
Vibrasi shaft mm 0.076 0.125 0.25
Vibrasi cover Shutdown
mm 0.03 0.05 0.08
bearing manual
Pressure lube oil 0.115 0.07
0.03
0.14- AC oil DC oil
MPa Turning gear
0.18 pump auto pump auto
stop
start start
Pressure EH oil 11.2
MPa 13-14 12.5 14 9.5 Interlock start
pompa
Temp.lube oil C 40-45
Temp. oil return
C < 65 75
bearing
Level Condenser mm 600 400 1100 Trip CEP
Level Deaerator 1900-
mm 1900 2300 1200 Trip BFP
2300
Pressure 0.9
Deaerator MPa 0.816 0.85 Safety valve
kerja
c. Start-up state classification of steam turbin
Start up classification berdasarkan inner wall metal temperature of governing stage of HP

inner casing :
Title Unit Data
Cold State Start Up C 150
Warm State start Up C 150~300
Hot State Start Up C 300~400
Super Hot State Start C 400
VII. BATASAN OPERASI :
a. Parameter Cold Start-Up Unit

Title Unit Data
The ignition air duct wall temperature C 1150
Steam Drum defference Temperature C 50
Steam Drum wall Tempereture change Ratio C/h <50
Temperature Change ratio of the saturated steam C/h <56
Bed Temperature Change Ratio C/h <60-<80
Temperature Change Ratio of Cyclone Separator C/h <70
When Steam Drum Pressure is <5 Mpa, increase ratio of Mpa/min
0.02 0.05
Main Steam Pressure
When Steam Drum Pressure is >5 Mpa, increase ratio of Mpa/min
0.05 0.10
Main Steam Pressure
Decrease Ratio of Main Steam Pressure Mpa/min 0.02 0.05
Superheat Steam Flow of Boiler t/h 440
b. Boiler MFT Operation Condition

Items Condition
Manual MFT Operation
All ID Fan Shutdown
All PA Fan Shutdown
All SA Fan Shutdown
All HP Seal Blower Fan Shutdown
Steam Drum Level Reaches Level HH high value
Steam Drum Level Reaches Level LL low Value
Low Total air Volume <25%
Low Pressure of HP Fluidized air Header 50Kpa
High Bed Temperature in Lower Furnace 990C
Low Bed Temperature In Lower Furnace 650C
Low Bed Temperature In Lower Furnace 540C
Furnace Pressure HH +2489
Furnace Pressure LL -2489
Turbine Trips
Logic Control System Power Off
After Purging, Ignitor not Produce Flame 15min
Cyclon Separator Level Time Delay 5s
c. Normal Operation Regulation Boiler

Title Unit Data
Superheated steam flow t/h 440
Superheated steam pressure MPa 13.80.1
Superheated steam temperature C 540
Reheat steam flow t/h 359
Reheated steam inlet pressure MPa 2.59
Reheated steam outlet pressure MPa 2.44
Reheated steam inlet temperature C 326
Reheated steam outlet temperature C 540
Feedwater temperature C 249
Steam drum water level mm 50
Normal bed temperature C 790 - 920
Oxygen content of flue gas 3.05
d. Speed Increasing Rate

Title Unit Data
Cold State Start Up r/min 100 r/min
Warm State start Up r/min 150r/min
Hot State Start Up r/min 250 r/min
Incritical Rotating Speed r/min 500 r/min
e. Jangka Waktu Start

Rolling to Rated Sinkron to Rated Rolling to Rated
Startup state
Speed (menit) Load (menit) Load (menit)
Cold state 80 220 330
Warm state 33 65 98
Hot state 22 38 60
Super Hot state 20 25 45
VIII. Persiapan Cold Start-Up Unit
No Item Aktifitas Foto

1 Pastikan
persediaan batu
bara cukup
2 Pastikan
persediaan
minyak solar
cukup
3 Pastikan Level
bed sand (pasir
kuarsa) di
furnace cukup.
Ketinggian
800mm dengan
ukuran pasir
0.3mm
4 Pastikan
persediaan air
demin cukup
(Boiler Water
Treatment
System in
service)
5 Pastikan Power Close 6.3 KV incoming line (6.3 KV

supply posisi in section 1 Bus)
service (6.3 kV Close 6.3 KV incoming line (6.3 KV
UAT A & B section 2)
voltage normal) Open 6.3 KV section switch gear (jika
salah satu dari incoming line section 1
atau section 2 ada yang open section
switch gear harus closeKarena ini
merupakan breacker BUS TIE
Normalkan semua power supply 6.3KV
system (switch gear 6.3KV)
Normalkan semua power supply 400V
Normalkan UPS system
Normalkan power supply DC system
Emergency Diesel posisi standby
6 Pastikan Lube oil AC oil pump start

dan control oil Jacking oil Pump start
system in service EH oil pump start
7 Pastikan Turning Turning Gear motor start

Gear main (speed 4.5r/min)
turbine in service
8 MBFP dan Lubrication auxiliary pump start

A
lubrication oil C
system inservice
O
I
L
P
U
M
P
9 Pastikan system W Pump start

pendingin (water Filling condensate storage tank dari
cooling system) demin tank
posisi in service OCCWP pump start
CCCWP pump start
10 Pastikan Air Air instrument air compresor start

Instrument Air dryer start
System posisi in
service
11 Pastikan Conveying air compresor start

Conveying air Air dryer start
compresor posisi
in service
(service air in
service)
12 Filling Steam Check dan Tutup :

Drum (drum level Water wall blowdown Valve
normal) Down comer blowdown valve
Steam drum emergency discharge valve
Steam drum connection valve
Feedwater pipe drain valve
Economizer drain Valve
Check dan Buka :
Vent valve boiler proper
Superheater drain valve
Reheater drain Valve
Check dan put inservice :
Drum water level meter
Electric contact water level meter dan
balancing vessel water level meter
Infokan operator turbine untuk start
water filling pump atau feedwater pump
Gunakan feedwater bypass untuk
mengisi air ke steam drum, buka penuh
electric valve sebelum bypass valve dan
manually valve kemudian control flow
pengisian air ke steam drum.
tutup vent valve economizer setelah
pengisian berlangsung
Setelah level drum di -100mm, stop
pengisian air dan buka recirculation
water valve economizer.
13 Filling Dearator Pastikan level condensate storage tank

(Dearator level normal
normal) Start boiler fill-up pump
Stop condensate pump jika level
dearator normal 1075mm
(Note : hindari filling dearator dari

condensate storage tank jika extraction
sudah inservice).
14 Pengisian Hot Pastikan level condensate storage tank

Well (condenser normal
hotwell level Filling Hot Well condenser
normal) menggunakan air demin sampai level
cukup menggunakan boiler fill up pump
15 Condensate A/B Condensate pump A/B Start

in service
IX. PELAKSANAAN START :
a. COLD START-UP UNIT

No Items Aktifitas Foto
I Boiler Start-
Up
1 Boiler a. ID Fan A/B Start

Ventilation dan b. High Fluidized Fan A & C
furnace Start
purging start c. PA fan A/B start
d. SA fan A/B start
Note :
- Total air flow >25%
- Bed temperature
<540
- Furnace pressure
normal
- Drum level normal
- All burner valve close
- All coal feeder stop
- No MFT
- purging time 300 sec
2 Fuel oil leak a. Lower oil leakage test step:

test start - Buka inlet lower valve,
a. Lower oil tutup lower oil return
leakage test - Tutup Lower inlet valve
start setelah 10 sec
b. Upper oil b. Upper oil leakage test step:
leakage test - Buka inlet lower valve,
start tutup lower oil return
- Tutup Lower inlet valve
setelah 10 sec
Note:
- Supply oil pressure
normal >3.2Mpa,
- Waktu untuk oil leakage
test adalah 120 sec
- Total air flow >25% B-
MCR
- Primary air flow > critcal

fluidization air flow
3 MFT Reset a. Furnace purging

complete
b. Fuel Oil Leak test
Complete
Note :
- All SA fan control
damper minimum open
5%
- Total air flow min
68248NM3/h by adjusting
SA fan inlet damper
4 Startup boiler a. Boiler ignition :

burner: - Fuel oil Forwarding pump
a. Boiler posisi in service, set press
ignition antara 2,8 3,2 Mpa
- Start In-duct burner OG 1
& OG 3.
- Start In-duct burner OG 2
& OG 4.
- Jika burner sudah menyala
normal buka recirculation
shut-off valve dari inlet
economizer ke
downcomer.
- Tutup dan buka drain
valve :
Rear pass lower
header drain
LTR outlet header
drain
HTS inlet header
drain
HTR inlet header
drain
LTR inlet header
drain
- Amati pembakaran,
monitor perubahan oxygen
(O2) dan atur volume
udara untuk memastikan
pembakaran stabil.
- Atur pembakaran dan
kenaikan temperature bed
boiler antara 60-80C/h.
- Atur outlet flue gas
temperature air duct burner
920 dan air chamber
temperature harus di bawah
950C dan drum wall
temperature ratio t<50/h
untuk menjaga over
temperature di pipa SH/RH.
b. Warming-Up :
b. Warming-up - Setelah proses ignition
(Pressure selesai, segera buka
Rise) turbine bypass system.
- Bukaperlahan bypass
valve untuk menaikkan
pressure steam
- Ketika pressure steam
drum di 0.069- 0.103Mpa,
fully close venting valve
dan drain valve:
Drum venting
Rear pass roof wall
header vent
LTS outlet header vent
PSH outlet header vent
LTR outlet header vent
PRH inlet header vent
HTS outlet header vent
Rear pass lower header
drain
Drain lower header left
dan right roof wall
PSH inlet header drain
HTS inlet header drain
HTR inlet header drain
LTR inlet header drain
- Close SH dan RH air

exhaust valve dan
posisikan in service.
- Posisikan in service drum
continuous blowdown
berdasarkan referensi
chemical dan buka
intermittent blowdown
valve bila diperlukan
- Ketika SH steam flow lebih
dari 10% B-MCR, close
semua drain valve.
- Posisikan in service
desuperheating water
sesuai kebutuhan.
- Infokan dengan operator
turbine untuk starting feed
water pump, isi air ke
boiler melalui bypass
sesuai kondisi steam drum
water level.
- Infokan ke operator turbine
untuk rolling turbine pada
saat : SH pressure 1.0 -
2Mpa, SH temperature
300C, Reheat steam
temperature 237C
II Turbine Start
Preparation
1 Gland Seal a. Jika pressure main steam

Steam start sudah mencapai 2Mpa
b. Start gland steam condensor
exhauster fans ( 1 running, 1
standby)
c. Atur pressure dan temp
gland steam 0.095MPa
0.127Mpa dan 150 C ~ 200
C
d. Main negatif pressure gland
steam return -5kpa(g)
2 Vacuum a. Pastikan Gland seal steam

Condensor exhaust fan A/B start
start b. Pastikan pressure gland
seal steam header
0.095MPa 0.127Mpa
c. Pastikan condensor vacuum
break close
d. Start vacuum pump A dan
posisikan standby vacuum
pump B
e. Jika vacuum condensor
tidak mencapai -56 - -
60Kpa, start vacuum pump
B
3 HPT Warming Setelah temperature 1st stage

start inner metal turbine di 150C
naik ke 220C
4 CV Warming Waktu untuk CV warming

start adalah 1 jam sampai
temperature CV outlet metal
naik ke 180C
5 Start coal a. Pastikan Bed temperature

feeder >560C
b. Start Coal feeder (CF#1 dan
CF#4)
c. Atur flow coal feeder di 10
t/h, tahan selama 2 menit
dan kemudian stop coal
feeder
d. Monitor average bed
temperature dan O2, restart
coal feeder ( CF#1 dan
CF#4) atur flow di 10t/h dan
tahan selama 2 menit.
e. Setelah average bed
temperature naik di 760C

maka coal feeder bisa di
operasikan normal
III Turbine Start
1 ROLLING 1.1 KlikLatch ON

TURBINE Amati MSV HP dan LP
Start, kondisi: Turbin Full Open
- Main steam
pressure 1.0
2Mpa
- Main steam
temperature 1.2 Kliktombol control GV
280C - Settarget speed 500 rpm
300C Set speed up ratio 100
rpm/min lalu klik ON
- Condenser
Cold state : 100
vacuum
rpm/min
41.325Kpa Warm state : 150
rpm/min
Hot state : 250
rpm/min
1.3 Amati pembukaan governing

valve
dankenaikanputaranturbin
1.4 Setelah turbin berputar

(putaran >4 rpm,turning
gear disengage dan motor
auto stop)
1.5 Setelah putaran 500 rpm

tercapai, tahanselama 5
menit, lakukan Rub Check
untuk pemeriksaan
gesekan,pelumasan temp.
bearing,dll
1.6 Pertahankantekananvaccum
di nilai normal
2 SPEED UP 1 2.1 Naikkan putaran ke 1200

rpm
Set speed target 1200 rpm
Set speed up ratio
100 rpm/min lalu klik ON
2.2 Ketikaputaran
mencapai1200 rpmtahan
sekitar 30 menit,
lakukaninspeksi unit
secarakeseluruhan
2.3 Amati perbedaantemperatur

upper dan lower inner
casing < 50C
2.4 Ketikaputaran>1200 rpm,

pastikan jacking oil pump
stop otomatis

rpm
Enter speed set 2400 rpm
Set speed up ratio 100
rpm/min lalu klik ON
3.2 Pada putaran 1300 s/d 1800

rpm terjadi putan kritis.
Perhatikan vibrasi
bearing,biasanya naik tapi
masih dalam batas aman
3.3 Tutup HPdan LP bypass
3.4 Pada putaran2400 rpm

tahan selama 30 menit,
amatiperbedaantemperatur
casing < 50C

rpm.
Masukkanspeed target 3000
rpm
Set speed rate 100 rpm/min
lalu klik GO
4.2 Ketikamencapai putaran

2850 rpm, pastikan Main Oil
Pump
beroperasiotomatisdan stop
AC Oil Pump, tekanan oil
0.14 0.18 MPa
4.3 Tutupsemua drain valve

yang menujuke vessel
4.4 Setelah putaran 3000 rpm

tahan selama 30 menit
4.5 Amati temperatur upper dan

lower inner casing > 150C
danperbedaantemperatur
casing < 50C
5 MOVEMENT
TEST MSV DAN
GOVERNING
VALVE (GV)
6 PERSIAPAN Pastikan temp winding Generator

SINKRON normal danpendingin
generatornormal
6.1 Informasikan ke P3B bahwa

unit siapSyncrone
6.2 Pada panel AVR close MCB

DC power, AC powerCH A
Dan CH B
6.5 Pada selector switch

chanel pilihCH A atau CH B
6.6 Switch chanel posisikan ON
6.7 Atur tegangan generator ke

13.8kV
7 PELAKSANAAN Generator Syncron Control switch

SINKRON posisikan Start Up
7.2 Syncrone check Control

switch posisikan Permit
7.3 Syncrone Switch Mode

posisikan Auto
7.4 PMT generator posisikan

ON
7.5 Perhatikan sycronouscope,

jika Tegangan,Frequency
dan Phasa Generator sama
dengan line, PMT
Generator Auto Close, dan
sycroun 5% load ( 7 MW )
8 LOAD UP I 8.1 Setelah paralel naikkan

beban sebesar 10% rated
load dengan load rate
5 MW/mnt
8.2 Aktifkan LP Heater
8.1 Tutup semua drain

extraction steam kecuali
extraction yg ke deaerator
atau no 3,2,1
8.2 Setelah beban tercapai,

tahan 10 menit untuk
meratakan temperatur
stator winding & rotor, serta
perhatikan sytem
pelumasan,vibrasi,main
steam pressure main steam
temperatur & atur
pembakaran boiler
9 LOAD UP 2 9.1 Naikkan beban ke 20% rated

load, dengan load rate 5
MW/mnt
9.2 Buka extraction steam ke

deaerator
9.3 Aktifkan HP Heater 1 dan 2
9.4 Buka sekundair drain antara

LPH 2 dan HPH 4 (drain ke
deaerator)
10 LOAD UP 3 10.1Naikkan beban ke 30% rated

load dengan load rate set 5
MW/mnt
10.2 Jika kondisi normal

konfirmasikan ke P3B
bahwa unit siap naik beban
N/A
X. START / STOP DARI DCS :

- TEKAN PUSH BUTTOM MERAH UNTUK START / RUN
- TEKAN PUSH BUTTOM HIJAUUNTUK STOP
KETERANGAN :
WarnaMERAH di DCS tanda START / RUN &WarnaHIJAU tanda di DCS STOP (untuk
POMPA / FANS)
WarnaMERAH di DCS tanda OPEN &WarnaHIJAU tanda di DCS CLOSE ( untuk VALVE /
DAMPER )
REFERENSI:
1. Manual OPERATION INSTRUCTION for 2 x 135MW Superhigh Pressure CFB Boilers, DONGFANG
BOILER GROUP CO. ,LTD.
2. TURBINE OPERATION MANUAL for 2 x 135MW Volumn I, CHINA NATIONAL ELECTRIC
ENGINEERING CO. ,LTD.
LEMBAR PENGESAHAN
I. DISUSUN
No Nama Jabatan Tanda Tangan
1 INDRA HIMAWAN SPV PRODUKSI A
2 FATHONI SPV PRODUKSI B
3 HENDRY SPV PRODUKSI C
4 RESWANDA YUDHISTIRA SPV PRODUKSI D
II. DIPERIKSA
1 ERICK YUDIAWAN DM OPERASI
III. DISAHKAN
1 HEDEN SIAHAAN MANAGER UNIT

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PT PEMBANGKITAN JAWA BALI SERVICES No.Dokumen : IK-BJ-5.1.3.

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 0 dari 21

SIAP INTEGRATED MANAGEMENT SYSTEM

NOMOR DOKUMEN : IK-BJ-5.1.3.01

PT PEMBANGKITAN JAWA BALI SERVICES

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 1 dari 21

II. APD YANG DIGUNAKAN :

III. PERALATAN YANG DIGUNAKAN :

IV. PELAKSANACOLD START-UP :

VI. SPESIFIKASI PERALATAN :

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 2 dari 21

c. Start-up state classification of steam turbin

Start up classification berdasarkan inner wall metal temperature of governing stage of HP

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 3 dari 21

VII. BATASAN OPERASI :

a. Parameter Cold Start-Up Unit

b. Boiler MFT Operation Condition

c. Normal Operation Regulation Boiler

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 4 dari 21

d. Speed Increasing Rate

e. Jangka Waktu Start

Super Hot state 20 25 45

VIII. Persiapan Cold Start-Up Unit

No Item Aktifitas Foto

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 5 dari 21

5 Pastikan Power Close 6.3 KV incoming line (6.3 KV

6 Pastikan Lube oil AC oil pump start

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 6 dari 21

7 Pastikan Turning Turning Gear motor start

8 MBFP dan Lubrication auxiliary pump start

9 Pastikan system W Pump start

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 7 dari 21

10 Pastikan Air Air instrument air compresor start

11 Pastikan Conveying air compresor start

12 Filling Steam Check dan Tutup :

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 8 dari 21

13 Filling Dearator Pastikan level condensate storage tank

(Note : hindari filling dearator dari

14 Pengisian Hot Pastikan level condensate storage tank

15 Condensate A/B Condensate pump A/B Start

SIAP INTEGRATED MANAGEMENT SYSTEM Tanggal Terbit : 2 Februari 2016

INSTRUKSI KERJA Revisi : 00

COLD START UP Halaman : 9 dari 21

IX. PELAKSANAAN START :