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LEMBAGA INSPEKSI TEKNIK

PT. INDO KARYA SENIOR

Jl.Sunan Ampel No.1
Gedung I Lantai 4 Ru IKPLN
Jakarta Selatan
 PREPARASI AUDIT PLTU 1 x 600
HEAT RATEMW
ASESSMENT

ITEM REMARK WEEK 1 WEEK 2 WEEK 3 WEEK 4 WEEK 5 WEEK 6 WEEK 7 WEEK 8

1 DATA COLLECTING 4 DAYS

2 DISCUSSION ON DATA & 3 DAYS
PROGRAMMING
3 PRELIMINARY INSPECTION 3 DAYS
& FIELD SURVEY
4 DETAIL IMPLEMENTATION 4 DAYS
PROGRAM
5 TESTING & INSPECTION 5 DAYS
6 DISCUSSION ON THE RESULT 3 DAYS
7 RE-CHECKING MONITORING 4 DAYS
& FINAL ASSESSMENT
8 FINAL REPORT 5 DAYS
TOTAL 31 DAYS

PERALATAN YANG DIBUTUHKAN

1. MEKANIK SUHU
PADAT - CAIR - GAS TEKANAN
FLOW METER

2. ELEKTRIK KWH METER

AVO METER

3. CHEMIS PERALATAN LAB

 LIST OF DATA YANG DIBUTUHKAN UNTUK NET PLANT HEAT RATE
PLTU 1 x 600 MW COAL FIRED
NO. ITEM PENJELASAN KETERANGAN KECUKUPAN

1 ONE LINE DIAGRAM Mekanikal dan Elektrikal Lengkap/Kurang

Termasuk Water Cooling system
Coal and Firing System

2 DATA TEKNIK & SPESIFIKASI PERALATAN Termasuk data design bila ada
UTAMA Data hasil individual test peralatan utama

3 FACTORY TEST

4 DATA COMMISSIONING Performance Test Certificate

5 LOGIC DIAGRAM

6 LOG SHEET 3 BLN TERAKHIR

7 DATA KALIBRASI PERALATAN UKUR Mekanikal dan Elektrikal

MUTAKHIR

8 DATA GANGGUAN 3 BLN MUTAKHIR

9 COPY PPA - DEFINED PPA

10 DATA MUTU COAL 3 BLN MUTAKHIR

11 DATA LAB.UAP BULAN MUTAKHIR

12 PERSONIL PLTU YANG BERTANGGUNG

JAWAB
PERSONIL PLTU PENDAMPING TEAM
 TEAM ASSESSMENT PLANT HEAT RATE PLTU - COAL FIRED
1 x 600 MW
NO. NAMA PENGALAMAN KERJA
A TIM IKS
1 PEMBINA SOETRISNO OERIP Mantan Deputy Direktur Operasi
Koordinator IKS
2 KETUA TEAM 1 DARYONO Mantan Kepala PLTU Ujung Pandang
Mantan Kep.Dinas Pemeliharaan PLTU
Analisa & Evaluasi NPHR
3 KETUA TEAM 2 PONIJAN Mantan Kepala Pemeliharaan Thermal
Analisa & Evaluasi NPHR
4 ANGGOTA 1 ROSID SUDIBYO AHLI BOILER
Analisa & Evaluasi NPHR
5 ANGGOTA 2 MAX KARAMOY TURBIN & CONDENSOR
6 ANGGOTA 3 HOTMAN TURBIN & CONDENSOR
7 ANGGOTA 4 SUDIRMAN TURBIN
8 ANGGOTA 5 PRABOWO ELEKTRIKAL
9 ANGGOTA 6 DULLAH ELEKTRIKAL
10 ANGGOTA 7 SALIM RECORDING – LAB
11 ANGGOTA 8 SYARIF RECORDING – LAB

B TEAM LAPI NN - 3 ORANG

C TIM OWNER NN
 HEAT RATE POINTERS

NO URAIAN

1 PADA DASARNYA MONITOR HEAT BALANCE PADA SETIAP SUB SYSTEM SEMUA ENERGI MASUK HARUS DAPAT

DIBANDINGKAN ENERGIE KELUAR - ENERGY BALANCE

2 PENGUKURAN DILAKAN SETIAP 15 MENIT PERIODE , DILAKUKAN 9 X UNTUK SETIAP GENERATOR OUTPUT

UNTUK MENDAPATKAN ACCURACY PENGUKURAN CUKUP .

3 TEST BEBAN 50 % - 75 % DAN 100 % CAPACITY TERPASANG

4 PERIODE TEST 15 MENIT - MINIMUM 3 KALI UNTUK MENDAPATKAN KETELITIAN CUKUP

A BOILER HEAT RATE
1 ENERGY INPUT (Ein)
2 LOSSES ( El )
3 FORMULA EFFICEIENCY BOILER
4 CONDENSOR
5 DEFINISI CONDENSOR
B TURBIN HEAT RATE
1 FORMULA EFFICEIENCY turbin
2 PLTU EFFICIENCY/HEAT RATE
1 .FUEL /COAL KABUT CALORIC VALUE
KANDUNGAN CARBON
KANDUNGAN LAINNYA
PULVERIZER – PENGABUTAN
2. AIR SYSTEM/UDARA KANDUNGAN OKSIGEN O2
KEBASAHAN H2O
3. Feed water Nilai pH
LOSSES BOILER Kalor gas buang/flue gas
Kalor hidrogen
Kalor asap/Steam
Kalor Moister Uap
Kalor moister udara
Kalor radiasi – Konduksi
Unburned Carbon
Kalor margin
(Ein - El)/El * 100 %
1. CONDENSOR
2. AIR HEATER
3.FEED WATER HEATER
SUHU RATA2 = SUHU ASAP MASUK - COOLING WATER OUT
ENERGY MASUK TURBIN / GENERATOR OUT PUT
 HAL HAL YANG MEMPENGARUHI HEAT RATE
A Material Supply
1 MUTU COAL/BATU BARA Jenis coal
Coal content
Caloric value
Pengabutan sebelum masuk boiler
Bandingkan dengan design
2 MUTU UDARA MASUK Kandungan oksigen , HIDROGEN
3 MUTU FEED WATER Kandungan pH
Bandingkan dengan design
B Pengatur coal /Damper Kesesuaian dengan beban
C Tungku pembakaran Nyala Api / Flame Unburned Carbon
Flue Gas Karakter flue gas menentukan
efficiency pembakaran
Mutu/ Hasil Superheater
Kerak - kerak pada pada pipa superheater & feed water
D ANTARA BOILER – TURBINE Losses dalam pipa
Besaran PVT masuk turbin
E TURBIN Pengaturan blade
TURBINE INLET
TURBINE OUT LET
F CONDENSOR Temperatur
Cooling water tempereture
G COOLING WATER SYSTEM
H GENERATOR OUTPUT
I AUXLIARY Auxliary / Own use
J EXCITATION SYSTEM Battery - Catu daya
 FORM C2.232
HASIL HITUNG TURBINE HEAT RATE
DAN
GENERATOR POWER OUTPUT

Performance test Tanggal

Beban Jam pelaksanaan

1. Main Steam Flow Calculation (Gms)

Uraian Symbol Data Unit Sample

1 Boiler steam drum water drop level equivalent flow Gbl Data Ton/hr 0,000
2 Deaerator tank water drop level equivalent flow G dl Data (0,258)
3 Hot well water drop level equivalent flow G cl Data -3,823
4 System measurable leakage G ml Data 1,570
5 System unaccounted for leakage dG Eq.(1) -5,651
6 Rear shaft gland leakoff of HP turbine Ggn1 Data 4,161
7 HP Heater #1, #2, #3 & deaer steam flow G he Data 187,270
8 Feed pump leakge G fpl Data 0,000
9 Deaerator discharge flow G dv Data 0,000
10 Reheat spray water flow G rhs Data 0,589

11 Boiler side viewable escape flow Gs Data 0,000

12 Condensate flow Gcw Data 745,947
13 Main steam flow G ms Eq.(2) 794,235

(Eq-1) dG = Gcl + Gbl + Gdl - Gml

(Eq-1) Gms = Gcw + Ghe + Gbl - Gdl - Gfpl - Gdv - Grhs - Gs - dG +Ggn1
 2. Cold reheat steam flow calculation (Gcrh)
Uraian Symbol Data Unit Sample
Data
1 Main steam flow Gms 1.3 Ton/hr 941,320

2 High pressure valve leakage steam flow Gvl Data 3,192

3 Packing leakage from high pressure side of HP turbine Ggl Data 10,224

4 Packing leakage from low pressure side of HP turbine Ggn Data 4,161
5 #1, #2 quantity steam extraction Gex Data 129,930

6 Steam from cold reheat steam to the packing Ggh Data 0,000
steam header
7 Cold reheat Steam Flow Grch Eq.(3) 794,235

dilanjutkan

(Eq-3) Gcrh = Gms - Gvl - Ggl - Ggn - Gex - Ggh

Catatan
Justifikasi

Diuji oleh Disaksikan oleh Diperiksa oleh

 HASIL HITUNG TURBINE HEAT RATE
DAN
GENERATOR POWER OUTPUT

Performance test
Beban
Tanggal
Jam pelaksanaan

3. Hot Reheat Steam Flow Calculation (G hrh)

No. Uraian Symbol Ref No Unit Hasil Uji

1 Cold reheat steam flow G crh Data Ton/hr 7,942,350

2 Reheat spray water flow G rhs Data
3 Hot reheat steam flow G hrh Eq. (4)

(Eq-4) G hrh = G crh + G rhs

 FORM C2.15.233. Lanjutan
HASIL HITUNG TURBINE HEAT RATE
DAN
GENERATOR POWER OUTPUT

Performance test Tanggal

Beban MW - 100 % Jam pelaksanaan

3. Hot Reheat Steam Flow Calculation (G hrh)

No. Uraian Symbol Ref No Unit Hasil Uji

1 Cold reheat steam flow G crh Data Ton/hr 794,235

2 Reheat spray water flow G rhs Data 0,589
3 Hot reheat steam flow G hrh Eq.(4) 794,235

(Eq-4) G hrh = G crh + G rhs

 FORM C2.15.234. Lanjutan
HASIL HITUNG TURBINE HEAT RATE DAN GENERATOR POWER OUTPUT

Performance test Tanggal

Beban MW - 100 % Jam pelaksanaan

5. Corected Heat Rate Calculation (HR corr)

No. Uraian Symbol Ref No Unit Sample

1Corrected to throttle pressure Thp Corr Curve 1,000

2Corrected to throttle Temperature Tht Corr.Curve 1,001
3Corrected to Reheat Temperature R ht Corr.Curve 1,002
4Corrected to Reheat Press % drop R hp Corr.Curve 0,998
5Corrected to Exhaust Pressure E xp Corr.Curve 0,998
6Corrected to Throttle filter gauze pres drop F gtp Corr.Curve 1,003
7Corrected to Reheat filter gauze pres drop F grp Corr.Curve 1,003
8Corrected to Superheater spray water flow S hs Corr.Curve 1,001
9Corrected to reheater spray water flow R hs Corr.Curve 1,000
10Corrected to change in HP Heater TD HPTD
HP Heater 1 Corr.Curve 1,000
HP Heater 2 Corr.Curve 0,999
HP Heater 3 Corr.Curve 1,000
11 Corrected to change in HP Heater DC HPDC Corr.Curve
HP Heater 1 Corr.Curve 1,000
HP Heater 2 Corr.Curve 1,000
HP Heater 3 Corr.Curve 1,000
12Corrected to Change in Exctr Press Drop E xpd
Extraction 1 Corr.Curve 0,999
Extraction 2 Corr.Curve 1,000
Extraction 3 Corr.Curve 0,999
Extraction 4 Corr.Curve 0,999
13Corected to HPGV #3 Position HPGV#3 Corr.Curve 1,004
14Corected to HPGV #4 Position HPGV#4 Corr.Curve 1,000
15Corr to in Final FeedcWater temperature F wt Corr.Curve 1,000
16Corrected to Condenser depression Cd Corr.Curve 0,999
17 Aging factor Ag Corr.Curve 1,000
18Total Corection factor TCF 1,015
19Uncorrected Heat Rate HR uncorr Data 4.3. kJ/kWh 8,173,761
20Corrected Heat Rate HR corr (Eq.7) kJ/kWh 8,049,791

(Eq-7) HR corr = HR uncorr / TCF

 FORM C2.15.235.
HASIL HITUNG TURBINE HEAT RATE DAN GENERATOR POWER OUTPUT

Performance test Power Output Tanggal

Beban MW - 100 % Jam pelaksanaan

5. Corected Heat Rate Calculation (HR corr)

No. Uraian Symbol Ref No Unit Hasil Uji

1Corrected to throttle pressure Thp Corr Curve 0,9921

2Corrected to throttle Temperature Tht Corr.Curve 1,000
3Corrected to Reheat Temperature R ht Corr.Curve 0,9919
4Corrected to Reheat Press % drop R hp Corr.Curve 1,003
5Corrected to Exhaust Pressure E xp Corr.Curve 0.9947
6Corrected to Throttle filter gauze pres drop F gtp Corr.Curve 0,9970
7Corrected to Reheat filter gauze pres drop F grp Corr.Curve 0,9950
8Corrected to Superheater spray water flow S hs Corr.Curve 1,006
9Corrected to reheater spray water flow R hs Corr.Curve 1,000
10Corrected to change in HP Heater TD HPTD
HP Heater 1 Corr.Curve 0,9988
HP Heater 2 Corr.Curve 1,001
HP Heater 3 Corr.Curve 1,000
11 Corrected to change in HP Heater DC HPDC Corr.Curve
HP Heater 1 Corr.Curve 1,000
HP Heater 2 Corr.Curve 0,999
HP Heater 3 Corr.Curve 0,999
12Corrected to Change in Exctr Press Drop E xpd
Extraction 1 Corr.Curve 0.9973
Extraction 2 Corr.Curve 1,000
Extraction 3 Corr.Curve 1,000
Extraction 4 Corr.Curve 1,000
13Corected to HPGV #3 Position HPGV#3 Corr.Curve -
14Corected to HPGV #4 Position HPGV#4 Corr.Curve -
15Corr to in Final FeedcWater temperature F wt Corr.Curve 1,004
16Corrected to Condenser depression Cd Corr.Curve 1,000
17 Aging factor Ag Corr.Curve -
18Total Corection factor TCF 0,9824
19Uncorrected Heat Rate HR uncorr Data 4.3. kW 298,749,787
20Corrected Heat Rate HR corr (Eq.8) kW 304,090,002

(Eq-8) PR corr = PR uncorr / TCF

 4. Heat Rate Calculation (HR) Symbol Ref No Unit Hasil Uji
1 Condensate flowHP heater & G cw Data 1.6 Ton/hr 745,947
2 Deaer Steam flow Ghe Data 187,270
3 Deaerator tank water drop level equi.flow G dl Data (0,258)
4 Feed pump leakage Gfpl Data 0,000
5 Deaerator discharge flow Gdv Data 0,000
6 Rehead spray water flow Grhs Data 0,589
7 Feed water flow Gfw (Eq.5) 931,732
8 Main steam flow Gms Data 2.11 941,732
9 Hot reheat steam flow Ghrh Data 4.3 794,824
10 Cold reheat steam flow Gcrh Data 3.7 794,235
11 Superheater spray flow Gshs Data 41,406
12 Reheat spray water flow Grhs Data 0,589
13 Main steam pressure Pms Data bar 165,330
14 Main steam temperature Tms Data *C 532,172
15 Main steam enthalpy Ims Steam Table kJ/kG 3,381,364
16 Feed water pressure Pfw Data bar 182,300
17 Feed water temperature Tfw Data *C 272,235
18 Final feed water enthalpy Ifw Steam Table kJ/kG 1,193,326
19 Hot reheat pressure P hrh Data bar 32,140
20 Hot reheat temperature T hrh Data *C 527,907
21 Hot reheat steam enthalpy I hrh Steam Table kJ/kG 3,515,382
22 Cold reheat pressure Pcrh Data bar 35,090
23 Cold reheat steam temperature T crh Data *C 314,099
24 Cold reheat steam enthalpy I crh Steam Table kJ/kG 3,013,251
25 Superheater spray water pessure P shs Data bar 182,300
26 Superheater spray water temperature T shs Data *C 173,408
27 Super heater spray water enthalpy I shs Steam Table kJ/kG 743,743
28 Reheat spray water pressure P rhs Data bar 37,520
29 Reheat spray water temperature T rhs Data *C 172,122
30 Reheat spray water enthalpy I rhs Steam Table kJ/kG 730,103
31 Generator output power P Data kW 298,749,787
32 Uncorrected heat rate HR uncorr ( Eq. 6) kJ/kG 8,173,761

Dilanjutkan
(Eq-5) G fw = Gcw + Ghe + Gdl - Gfpl - Gdv - Grhs

(Eq-6) HR = (Gmsxlms + Ghrhxlhrh - Gfwxlfw - Gcrhxlcrh - Gshsxlshs - Grhsxlrhs) / P

 FORM C2.15.236. Lanjutan
HASIL HITUNG TURBINE HEAT RATE

Performance test Turbine Heat Rate Tanggal

Beban kW 100% Jam pelaksanaan

1. Main Steam Flow Calculation (Gms)

Uraian Symbol Data Ton/hr 0,0000

1 Boiler steam drum water drop level G bl Data Ton/hr 0,000

equivalent flow

2 Deaerator tank water drop level equivalent flow G dl Data 0,107

3 Hot well water drop level equivalent flow G cl Data -5,512
4 System measurable leakage G ml Data 1,572
5 System unaccounted for leakage dG (Eq.1) -6,977
6 Rear shaft gland leakoff of HP turbine G gn1 Data 4,182
7 HP Heater #1, #2, #3 & Deaer steam flow G he Data 190,482
8 Feed pump leakge G fpl Data 0,000
9 Deaerator discharge flow G dv Data 0,000
10 Reheat spray water flow+C17 G rhs Data 0,589
11 Boiler side viewable escape flow Gs Data 0,000
12 Condensate flow G cw Data 748,781
13 Main steam flow G ms (Eq.2) 949,942

(Eq-1) dG = Gcl + Gbl + Gdl - Gml

(Eq-2) Gms = Gcw + Ghe + Gbl - Gdl - Gfpl - Gdv - Grhs - Gs - dG +Ggn1
2. Cold reheat steam flow calculation (Gcrh)

Uraian Symbol Data Unit Hasil

1 Main steam flow Gms Data 1,13 Ton/hr 949,942

2 High pressure valve leakage steam flow G vl Data 3,182

3 Packing leakage from high pressure side G gl Data 10,224

of HP turbine

4 Packing leakage from low pressure side G gn Data 4,182

of HP turbine

5 #1, #2 quantity steam extraction G ex Data 132,011

6 Steam from cold reheat steam to the G gh Data 0,000

packing steam header Data

7 Cold reheat Steam flow G crh (Eq.3) 800,343

(Eq-3) Gcrh = Gms - Gvl - Ggl - Ggn - Gex - Ggh

 PENUTUP
SEKIAN DAN TERIMA KASIH

PT.INDO KARYA SENIOR