LAPORAN PRAKTIK INDUSTRI

SISTEM KONTROL TINY OIL PADA BOILER

PLTU PAITON BARU

Oleh:
Mohamad Abdul Shodiq
130534608439

UNIVERSITAS NEGERI MALANG

FAKULTAS TEKNIK
JURUSAN TEKNIK ELEKTRO
OKTOBER 2015

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 KATA PENGANTAR
Puji Syukur kehadirat Allah SWT yang telah memberikan hidayah-Nya
sehingga penulis dapat menyelesaikan Laporan Praktik Industri (PI) yang
dilaksanakan di PLTU Paiton Baru. Dalam laporan ini, penulis mengangkat judul
“Sistem Kontrol Tiny Oil pada Boiler PLTU Paiton Baru”.
Maksud dan tujuan dari pembuatan laporan ini adalah untuk melaporkan
kegiatan-kegiatan yang penulis lakukan selama Praktik Industri, dan untuk
memenuhi tugas matakuliah Praktik Industri. Penulis menyadari bahwa penulisan
Laporan Praktik Industri ini tidak akan tersusun dengan baik tanpa pengarahan,
bimbingan, dan bantuan dari berbagai pihak. Untuk itu penulis mengucapkan terima
kasih kepada:
1. Dr. Hakkun Elmunsyah, S.T., M.T., selaku Ketua Jurusan Teknik Elektro
2. Yuni Rahmawati, S.T., M.T., selaku Koordinator Praktik Industri Program Studi
Pendidikan Teknik Elektronika
3. Mochamad Rodhi Faiz, S.T., M.T., selaku Dosen Pembimbing Praktik Industri
4. Nyugihono selaku Manajer Administrasi PLTU Paiton Baru yang memberikan
kesempatan kepada penulis untuk melakukan praktik industri
5. Joko Purwanto selaku Pembimbing Industri yang memberikan bimbingan serta
arahannya selama penulis melakukan praktik industri
6. Seluruh Staf dan Karyawan PT. PJB UBJ O&M PLTU Paiton Baru yang telah
banyak membantu penulis dalam mengumpulkan data-data serta informasi yang
penulis butuhkan, dan
7. Teman-teman S1 Pendidikan Teknik Elektro 2013 atas dukungannya.
Dalam penyusunan Laporan Praktik Industri ini, penulis menyadari bahwa
masih terdapat kekurangan pada saat pelaksanaan maupun penyusunan laporan
Praktik Industri. Untuk itu penulis menantikan kritik dan saran yang bersifat
membangun dari semua pihak. Semoga laporan ini dapat bermanfaat bagi penulis
pada khususnya dan pembaca pada umumnya.

Malang, 22 Oktober 2015

Penulis

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 DAFTAR ISI

Judul ................................................................................................................. i
Lembar Pengesahan Laporan Praktik Industri ................................................. ii
Lembar Pengesahan ......................................................................................... iii
Kata pengantar ................................................................................................. iv
Daftar Isi........................................................................................................... v-vi
Daftar Gambar ................................................................................................ vii-viii
Daftar Tabel ..................................................................................................... ix

BAB I Pendahuluan ......................................................................................... 1

1.1 Latar belakang ....................................................................................... 1-2
1.2 Tujuan .................................................................................................... 2
1.3 Manfaat .................................................................................................. 2-3
1.3.1 Bagi Mahasiswa ............................................................................. 3
1.3.2 Bagi Perguruan Tinggi ................................................................... 3
1.3.3 Bagi Perusahaan............................................................................. 3
1.4 Sistematika Penyusunan Laporan .......................................................... 3-4
1.5 Jadwal kegiatan ..................................................................................... 4

BAB II Kegiatan Umum PT. PJB UBJ O&M PLTU Paiton Baru .................. 5
2.1 Identitas Perusahaan .............................................................................. 5-8
2.2 Deskripsi Umum Perusahaan Proyek PLTU Paiton Baru ..................... 8-9
2.3 Visi dan Misi Perusahaan ...................................................................... 9
2.3.1 Visi Perusahaan ............................................................................. 9
2.3.2 Misi Perusahaan ............................................................................. 9
2.4 Strategi O&M PJB................................................................................. 9
2.5 Struktur Organisasi ................................................................................ 10
2.6 Debah Lokasi PLTU Paiton Baru .......................................................... 10
2.7 Bentuk dan Badan Hukum Perusahaan ................................................. 11
2.8 Bidang Pekerjaan Perusahaan ............................................................... 11
2.9 Bagian atau Divisi Tempat Praktek Industri ......................................... 11

BAB III Dasar Teori......................................................................................... 12

3.1 Bagian-bagian Utama pada PLTU Paiton Baru .................................... 12
3.1.1 Boiler ............................................................................................. 12-15
3.1.2 Turbin uap ..................................................................................... 16-18
3.1.3 Gernerator ..................................................................................... 18
3.2 Siklus dan Sistem Penanganan pada PLTU Paiton Baru ...................... 18-19
3.2.1 Siklus Penanganan Batubara (Coal Handling) .............................. 19-26
3.2.2 Siklus Air dan Uap ........................................................................ 26-36
3.2.3 Siklus Penanganan Abu Batubara (Ash Handling) ....................... 36-38

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 3.3 Sistem Kontrol PLTU Paiton Baru ........................................................ 38
3.3.1 Distributed Control System (DCS) ................................................ 38-40

BAB IV Kegiatan Khusus ................................................................................ 41

A. Kontrol dan Monitoring ..........................................................................41
B. Pemeliharaan ...........................................................................................44
C. Observasi .................................................................................................49

BAB V Penutup ............................................................................................... 61

4.1 Kesimpulan ............................................................................................ 61
4.2 Saran ...................................................................................................... 61

Daftar Rujukan

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 DAFTAR GAMBAR

2.1 Lokasi Pembangkit PT PJB .................................................................... 5

2.2 Lay-out Kawasan Paiton ......................................................................... 6
2.3 Struktur Organisasi ................................................................................. 10
2.4 Denah lokasi PT. PJB UBJ O&M PLTU Paiton .................................... 10
3.1 Steam Drum ............................................................................................ 13
3.2 Ruang Pulverizer .................................................................................... 15
3.3 Prinsip Kerja dari Turbin ........................................................................ 16
3.4 Siklus PLTU ........................................................................................... 18
3.5 Siklus Batubara ....................................................................................... 19
3.6 Coal Conveyor System ............................................................................ 20
3.7 Jalur Conveyor ........................................................................................ 21
3.8 Ship Unloader ......................................................................................... 22
3.9 Proses Pembongkaran Batubara dengan SU ........................................... 22
3.10 Stacker Reclaimer ................................................................................... 23
3.11 Juction House atau Ttransfer Tower ...................................................... 24
3.12 Crusher ................................................................................................... 25
3.13 Roller Screen .......................................................................................... 25
3.15 Diverter Gate (DG)................................................................................. 26
3.16 Plough Tripper ....................................................................................... 26
3.17 Siklus aliran air dan uap ......................................................................... 28
3.18 Mechanical Clarifier ............................................................................... 30
3.19 Air Scouring Filter .................................................................................. 30
3.20 Self Cleaning Filter ................................................................................. 31
3.21 First High Pressure Pump ...................................................................... 32
3.22 First High Pressure Pump ...................................................................... 32
3.23 Alur Reverse Osmosis WTP ................................................................... 33
3.24 Chlorination Plant ................................................................................... 34
3.25 Hydrogen Plant ....................................................................................... 35
3.26 Sistem Ash Heandling secara umum ...................................................... 36
3.27 Limbah Bottom Ash ................................................................................ 37
3.28 Fly Ash .................................................................................................... 38
3.29 Ilustrasi Central Control Room .............................................................. 39
3.30 Contoh Tampilan HMI ........................................................................... 40
4.1 HMI Jalur Conveyor .................................................................................. 43
4.2 Rangkaian Uji Unjuk Kerja RTD 3 kabel .................................................. 45
4.3 Alat Dead Weight Tester ............................................................................ 46
4.4 Electric Pressure Transmitter ..................................................................... 47
4.5 Pilot Float Ball Valve ................................................................................. 48
4.6 Pull Cord atau Pull Rope Switch................................................................ 49

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4.7 Struktur Grafik dari Tiny-oil Pulverized Coal Burner ............................ 49
4.8 Tiny-Oil Pulverized Coal Burner............................................................ 51
4.9 Api hasil Oil-gun .................................................................................... 51
4.10 Api hasil Tiny-oil .................................................................................... 51
4.11 Single-line Diagram Air System ............................................................. 53
4.12 Manual Valve Utama .............................................................................. 53
4.13 Manual Valve Nozzle Utama Tiny-Oil dan Nozzle Bantu Tiny-oil ........ 54
4.14 Manual Valve Alat Pendeteksi Api dan Kamera .................................... 54
4.15 Aliran Udara Primer ............................................................................... 55
4.16 Single-line Diagram Oil System ............................................................. 55
4.17 Local Cabinet (Local Control Panel) ..................................................... 56
4.18 Single-Line Diagram Local Cabinet (Local Control Panel) .................. 56
4.19 Tampilan HMI dari Tiny-oil ................................................................... 57
4.20 Pembakaran dengan Oil-gun................................................................... 58
4.21 Pembakaran dengan Tiny-oil .................................................................. 58
4.22 Nozzle Utama Tiny-oil ............................................................................ 59
4.23 Tiny-oil dalam burner ............................................................................. 59
4.24 Diagram Logika Basic Tiny-Oil 1........................................................... 60
4.25 Diagram Logika Basic Tiny-Oil 2........................................................... 60
4.26 Flowchart Tiny-oil valve Opened ........................................................... 61
4.27 Flowchart Tiny-oil valve Closed ............................................................ 62
4.28 Perintah Mode Tiny-oil ........................................................................... 62
4.29 Tampilan HMI Tiny-oil Permit ............................................................... 65
4.30 Tampilan HMI MFT Reset...................................................................... 65
4.31 Tampilan HMI OFT Reset ...................................................................... 66
4.32 Tampilan HMI Mill A ............................................................................. 66
4.33 Tampilan HMI Tiny-oil Alarm................................................................ 67

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 DAFTAR TABEL

1.1 Jadwal Kegiatan Praktek Kerja Industri ..................................................... 4

2.1 Perencanaan PLTU Paiton Baru................................................................. 7

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