PERFORMANCE TESTING

STEAM POWER PLANT

 Tujuan Performance Test

• Sebagai acuan yang digunakan untuk menilai kemampuan pembangkit apakah

sesuai dengan kontrak yang telah disepakati oleh pihak kontraktor dan PLN
Performance Guarantees)
• Sebagai baseline pembangkit dalam pengoperasian
• Sebagai ukuran kinerja peralatan utama dan alat bantu dalam upaya monitoring
performance
 Requirement & Test Method
Requirement:
• Seluruh instrument yang akan digunakan untuk pengambilan data performance test harus
sudah dikalibrasi dan harus sudah di submit ke pihak PLN berupa Sertifikat kalibrasi satu
minggu sebelum pelaksanaan performance test
Test method:

1. Preliminary test,

Test awal yang dilakukan dengan tujuan untuk mengecek apakah unit pembangkit telah
memenuhi kondisi yang sesuai untuk dilakukannya pengetesan, serta untuk memeriksa
kondisi seluruh instrument yang digunakan.

2. Acceptance test,

Pengujian yang dilakukan untuk mengukur performance unit apakah memenuhi kondisi
kontrak atau tidak

3. Performance Monitoring

Pengujian untuk melihat kondisi unit, terhadap kemungkinan terjadinya penurunan

performance atau degradasi peralatan dan effisiensi pembangkit.
 Acceptance Test

Item/Load TMCR BMCR 75% TMCR 50% 35% HP Heater

(VWO) TMCR TMCR Cut
Generator Output
Boiler Efficiency
Turbine Heat rate
GPHR
Aux Power
Consumption
Net plant output
NPHR
Boiler Capability
Environtmental
control
ESP Efisiensi
 Test Item

Boiler Turbine Generator

Temperature Flue gas dan Udara Pressure Gross output
Flue gas analysis Temperature Aux power
consumption
Flow primary dan secondary air Flow
Sample ash dan residu Water level
Sample coal
Feed coal temperature measurement
ESP efisiensi
Ambient air dan barometric pressure
Emisi gas buang
 Performance Testing & Monitoring Process

Persiapan Pengambilan Data

Koordinasi Bidang – bidang

Pengecekan kondisi
( Har,Lab , Bahan bakar,
kesiapan peralatan
Operasi)

Pengambilan
Data

Pengolahan
Data

Analisis
Data

Rekomendasi

Evaluasi
Action Plant
 Instrument
Peralatan Instrument Gambar

FDF 1. Thermocouple at site

Indikator Outlet
Temperature in DCS
2. Portable Thermal
Environment Indikator
for measure ambien
condition.

PAF 1. Thermocople at site

Indikator Outlet
Temperature in DCS
2. Portable Thermal
Environment Indikator
for measure ambien
condition.
 Instrument

Peralatan Instrument Gambar

APH FLUEGAS ThermoCouple

Posisi : Outlet APH sisi Flue Gas

Cubicle Kwh mettering , Tang meter for

measure ampere, voltage per
phase.
 Instrument

Peralatan Instrument Gambar

Coal Feeder Counter coal feeder for

measure total coal flow

Kwh mettering Counter Kwh production

Production gross , Auxiliary power ,
Incoming.
 Instrument

Peralatan Instrument Gambar

Emision Emision monitoring at CEMS

monitoring

DCS Screen Capture HMI data

parameter Operasi.
 Coal & Ash Analysis Sample

Peralatan Sample Gambar

Coal Feeder Take sample coal for coal

analysis in Laboratorium.
(Proximate & Ultimate
Analysis)

Bottom & Fly Take sample bottom & fly ash

ash sample for unburned carbon
Analysis from combustion.
 Reference

Reference:
 ASME PTC 6 – 2004 Steam Turbine
 ASME PTC 6a – 2000 Appendix PTC 6 Steam Turbine
 ASME PTC 12.2 – 1998 Steam Surface Condenser
 ASME PTC 4 – 1998 Fired Steam Generator
 Heat Rate Handbook 4th Edition Southern Company Generating Plant Performance
 Heat Rate Improvement Reference Manual (EPRI)
 Power Plant Performance & Efficiency
 ASME PTC 4.1 – 1964 Steam Generating Units
 Test Condition

• Kondisi unit normal operasi dan dalam kondisi steady

• Soot blower dan blowdown posisi close/stop

• Terminal voltage, power factor, frekuensi sesuai rated value

• Bypass system closed

• HP dan LP Heater bypass pipeline closed

• Feedwater heater vents dan emergency drain closed

• Steam dan water pipeline drain valve closed

• Steam dan water pipeline yang terhubung antar unit closed

 Steady State Condition

Variable Permissible Deviation Permissible Rapid

Fluctuation
Main steam pressure ± 3% ±0.25% (abs)
Main steam temperature ±8C ±4C
Reheat steam temperature ±8C ±4C
Feedwater temperature ±6C
Turbine exhaust pressure ±2.5% (abs) ±1% (abs)
Power ±5% ±0.25%
Power factor ±1%
Voltage Output terminal ±5%
Steady State Condition
 Durasi test
Test Load Durasi Test
Contancy Reading
MCR (TMCR) Pulverized Coal 1 jam 2 jam
VWO (BMCR) 0.5 Jam 15 menit
HP Heater Cut 0.5 Jam 15 menit
Minimum Load (35% TMCR) 0.5 Jam 1 jam
75% MCR/TMCR 0.5 Jam 1 jam
50% MCR/TMCR 0.5 Jam 30 menit

Reff: ASME PTC 4 1998

 Frekuensi Observasi Data

Item waktu
Temperature/pressure 5 menit
Condensate flow diff. pressure 1 menit
Analysis of flue gas 15 menit
Sampling coal 60 menit
Sampling residu dan ash Akhir test
Gen output/ aux power/ power factor 60 menit
Ambient parameter 15 menit
Water level, air flow, coal flow 1 menit
Counter Coal feeder 15 menit
 Pengukuran Data Untuk Eff Boiler (Heat Loss Method)

1. Coal Analysis 3. Atmosphere Conditions

No Item Symbol Unit Remark No Item Symbol Unit Remark
1 Carbon Car % Lab 1 Dry-Bulb Temperature TRA
o
C Test Data
2 Hydrogen Har % Lab o
2 Wet-Bulb Temperature TRAW C Test Data
3 Oxygen Oar % Lab
4 Nitrogen Nar % Lab 3 Relative Humidity Φ % Test Data
5 Sulfur Sar % Lab 4 Atmospheric Pressure PA Mpa Test Data
6 Ash Aar % Lab PS
5 Partial Press. Of Saturated Vapor at Tdr Mpa Water & Steam Chart
7 Moisture in Air-Dried Wad % Lab
8 Total Moisture War % Lab
9 High Heating Value HHVF KJ/Kg Lab 4. Carbon Refuse (Unburned Carbon)
10 Low Heating Value LHVF KJ/Kg Lab No Item Symbol Unit Remark
11 Coal Mass flow Wfe t/h Coal Totalizer 1 Carbon Content of Refuse (Bottom Ash) CS % Lab
2 Carbon Content of Fly Ash (Fly Ash) Cf % Lab
2. Flue Gas Analysis 3 Carbon of AH Refuse (Fly Ash) Cah % Lab
No Item Symbol Unit Remark
1 Carbon dioxide Leaving AH CO2 % Test Data
2 Oxygen Leaving AH O2 % Test Data 5. Air & Gas Data
3 Carbon monoxide Leaving AH CO % Test Data
No Item Symbol Unit Remark
4 Nitrogen Leaving AH N2 % 100-CO2-O2-CO
1 PA Flow Wpa NM3/H Test Data
5 Carbon Dioxide Entering AH CO2' % Test Data 2 SA Flow Wfa NM3/H Test Data
6 Oxygen Entering AH O2 % Test Data o
3 PA Temperature Tpa C Test Data
o
4 SA Temperature Tfa C Test Data
o
5 Exhaust Gas Temperature TG C Test Data
 Perhitungan Effisiensi Boiler (Heat Loss Method)

Total Loss (L) = Luc+ LG + Lmf+ LH + LmA + LCO + Lβ + Ld’

Total Credit (B) = Bfe + Bmae

Dimana:
•Heat Loss due to Unburned Carbon (Luc)
Credit yang masuk dalam perhitungan ini
•Heat Loss due to exhaust gas (LG)
adalah :
•Heat Loss due to Fuel Moisture (Lmf)
•Heat supplied by sensible heat in fuel (Bfe)
•Heat Loss due to Hydrogen (LH)
•Heat supplied from moisture in fuel (Bmae)
•Heat Loss due to Moisture in Air (LmA)

•Heat Loss due to CO (LCO)

•Heat Loss due to surface Radiation (Lβ)

•Heat Loss due to Fly Ash sensible (Ld’)

 Perhitungan Effisiensi Boiler (Heat Loss Method)

Faktor Koreksi:
•Koreksi LHVf of fuel as fired (A1)
•Koreksi ambient temperature (A7)
•Koreksi feedwater temperature (A11)
•Koreksi Main steam pressure (A13)
 Perhitungan Heat Rate (Heat Loss Method)

Gms.Hms  Gshs.Hshs  Gfw.Hfw

THR 
Pgross

Note :
THR= Turbine Heatrate
Gms = Main Steam Flow
Hms = Main steam Enthalpy
Gshs = Superheater spray flow
Hshs = Superheater spray Enthalpy
Gfw = Feedwater flow
Hfw = Feedwater Enthalpy
Pgross = Generator Output
 Perhitungan Heat Rate (Heat Loss Method)

Gen Net Output Corrected = Pgroc – Paux – Ptl – Pexct

Dimana :
Pgroc = P gross Corrected
Ptl = P transformer losses
P exct = P excitasi
Dimana untuk Perhitungan P gross :

P gross = (Wa1+Wb1+Wc1).Kpt.Kct / 1000 (kW)

Pgross
Pgross Corrected
Terima Kasih

APPENDIX