10 April 2012
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
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
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)
Handling
Pengisian bed meterial lebih Aman dan Terkontrol Mengurangi biaya pengangkatan dan pengisian menuju boiler Mengurangi biaya untuk pengadaan baru Waktu pengisian lebih cepat
Opsi 1
Opsi 2
Opsi 3 Opsi 4
Memanfaatkan sistem limestone dengan modifikasi 1 Memanfaatkan sistem limestone dengan modifikasi 2
19 m To Furnace
92,8 m
From jetpack
From root blower
BED MATERIAL
Amount
25.5 t
2.4 t/h
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
Dense phase
SILICA SAND
GOOD PERMEABILITY
DILUTE PHASE
PENGISIAN SILO
Conveying dari Jetpack truck menuju Silo
50 45 40
1.4
35
30
35
25
30
25 20 15 10 5 0 0.1 0.15 0.2 0.25 0.3 0.35 0.4
Pipe bore 4 in, length 40,4 m P=1.2 Bar, Q=0,308 kg/s, p= 9 t/h
60
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
Opsi 1, Pipe bore 6 in, length 68,77 m P=0.4 Bar, Q=0,374 kg/s, p=19 t/h
Solids loading ratio Conveying line pressure drop (Bar) 1 0.8 10 20 1.4 1.2 15
60
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
Opsi 1, Pipe bore 6 in, length 92,87 m P=0.4 Bar, Q=0,374 kg/s, p=17 t/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
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
Open the vale from service air line to main line immediately to provide pressured air. Restart the trip's root blower
Operator Lumintu
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
High
Low
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
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