ANTAMPOMALAA ANTAM POMALAA ESF3GCTCommissioningAssistance ESF3 GCT Commissioning Assistance

Update25th March 7th April2012

HTVTechnologyInc. Totok Risantono Imbran Pabitjcara Bambang Pudji Utomo

HIGHLIGHTS
Explosion vents on the spray chamber mountain side was opened on 17 March 2012 and burn the cable control for ESF#3 electrodes. Some protection was installed on 28 March 2012 to prevent it happens again. GCT restarted up on 30 March 2012 05:00 PM and shut off again on 7 April 2012 due to dust handling problem. Continue th commissioning and t bl shooting on th d t h dli C ti the i i i d trouble h ti the dust handling system (Pulse Jet System, Air Slide Conveyor System and Blow Pot System) Installation screw conveyor as short term solution to handle dust after 100 ton bin operates.

TrendofCombustionChamberTemp
GCTRunning

The combustion chamber temperature range is between 450 600 C Normally to combust all the residual CO need C. temperature min 600 C. Need to consider : Adjust the opening of off take gap Patching the opening on the Furnace Roof

TrendofOutletSprayChamberTemp
GCTRunning

Outlet Spray Chamber Temperature works like we expected by keep the temperature outlet 290 310 C.

DraftControlDamperProblem Draft Control Damper Problem

1. Draft control damper was stuck on 26% opening on the restarting up of the GCT on 30 March 2012 It was 2012. happened when we operate automatically by put the set point of pressure of the Furnace. To accommodate this problem right now we operate semi automatically d ft bl i ht t i t ti ll draft control damper by set the percentage of opening. 2. Another problem there is still off set between setting p g and the actual on the opening higher than 80% even on the 28th March 2012 (2 days before start up can open until 94%) Need to check mechanically mechanically.

Blue line is actual opening. During the test on 28 March 2012 it can be opened until 93,75 %.

GCTRunning g

Blue line is actual opening. Pink line is set point During GCT running there off set between setting and actual especially in the opening higher than 80%.

TrendofInletBagHouseTemp
GCTRunning

Inlet Bag House Temperature is around 180 225 C. The standard 180 240 C.

IDFan
During GCT Running opening scoop tube operates between 25 30 % and manual monitoring for the parameters that the instrumentation devices not installed yet (Fan Vibration, Rpm and Oil Temperature). Another parameters is within standard only the fluid drive vibration on the input bearing on the X axis that almost reach first hi alarm (average about 4.5 mm/s instead of 6 mm/s as a first hi alarm).

DustHandlingFinding
1. BlowPot1: Venting valve mechanically is working well but the limit cannot read accurately now, we jumper the limit. Filling Time Venting Time and Conveying Time need fine tuning consider Time, the compressed air supply and the dusting rate of the ESF3 off gas 2. Blow Pot 2 : Indication blocked line sometimes turn on still on the trouble shooting g Filling Time, Venting Time and Conveying Time need fine tuning consider the compressed air supply and the dusting rate of the ESF3 off gas 3. Hopper Bag House Compartment 1 8 C Compartment h t t hopper was f found f ll of d t H d full f dust Hopper aeration cannot ti t operates together due to limitation of air pressure supply. 4. Air Slide Conveyor Some tools was left and blocked the air line on the cross conveyor (water pass and hammer) Slide Conveyor was found full of dust and some section on the collector air slide conveyor is wet. Wet dust (mud) was found in the inside of slide conveyor One of the possibility where is the water come from is from heavy rain.

DustHandlingFinding(cont d) Dust Handling Finding (contd)

5.Both of the 19 ton bin Air slide as a fluidizer on the 19 ton bin must be operated when we will start to fill the 19 ton bin other wise we will have rat hole even in small amount of dust in the bin. Now air slide inside the 19 ton bin supply by reservoir tank In fact tank. when we operates this air slide 19 ton bin reservoir tank pressure drop until 40 psi and blow pot cannot operates. We need to consider additional supply air to operates pressure air properly (design requirement 5 psi and 228 acfm). 6.100 Ton Bin Screw Conveyor was installed on the outlet of the 100 ton bin but the d cannot fl i N d f h i h dust flowing Need further investigation i i 7.Need to install interface between PLC and DCS to see all the blow pot indication (blowing, filling and venting) in the control room DCS

Compartment condition after clean up the dust

Compartment 1 8 was found full of dust. Adjust the air distribution on the slide conveyor system y y Hopper aeration cannot operates together due to limitation of air pressure supply. Maximum only 2 hopper aeration can operate together

There is water infiltrate to the fabric (kevlar) on the joint section of collector air slide conveyor. Create mud and some wet area in the inside of the air slide conveyor. Action : Need to improve the seal on the joint section of air slide collector conveyor Need to check the clogging on the fabric

There is left tools (water pass and customized hammer) inside of air line on th cross air slide conveyor the i lid

Air Slide Collector Conveyor full of dust

Thedustbecomelump

The dust almost full (1 meter from top) and rat holing was happened (dust only flows on outlet path of the out let bin)