LEMBAGA INSPEKSI TEKNIKLEMBAGA INSPEKSI TEKNIK

PT. INDO KARYA SENIORPT. INDO KARYA SENIORJl.Sunan Ampel No.1Jl.Sunan Ampel No.1

Gedung I Lantai 4 Ru IKPLNGedung I Lantai 4 Ru IKPLNJakarta SelatanJakarta Selatan

Selamat SiangKami Perkenalkan dari

PREPARASI AUDIT PLTU 1 x 600 MWHEAT RATE 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 SUHUPADAT - CAIR - GAS TEKANAN

FLOW METER

2. ELEKTRIK KWH METER AVO METER

3. CHEMIS PERALATAN LAB

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           

LIST OF DATA YANG DIBUTUHKAN UNTUK NET PLANT HEAT RATEPLTU 1 x 600 MW COAL FIRED

TEAM ASSESSMENT PLANT HEAT RATE PLTU - COAL FIRED1 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) 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

2 LOSSES ( El ) 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

3 FORMULA EFFICEIENCY BOILER (Ein - El)/El * 100 %   4 CONDENSOR 1. CONDENSOR  

  2. AIR HEATER      3.FEED WATER HEATER  

5 DEFINISI CONDENSOR SUHU RATA2 = SUHU ASAP MASUK - COOLING WATER OUT        

B TURBIN HEAT RATE

1 FORMULA EFFICEIENCY turbin ENERGY MASUK TURBIN / GENERATOR OUT PUT

2 PLTU EFFICIENCY/HEAT RATE  

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 , HIDROGEN3 MUTU FEED WATER Kandungan pH

    Bandingkan dengan design

B Pengatur coal /Damper Kesesuaian dengan bebanC 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 turbinE TURBIN Pengaturan blade

  TURBINE INLET   TURBINE OUT LET  

F CONDENSOR Temperatur    Cooling water temperetureG 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  

  1 Main steam flow       Gms Data 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 RATEDAN

GENERATOR POWER OUTPUT

Performance test

BebanTanggalJam 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 7,942,3502 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. LanjutanHASIL HITUNG TURBINE HEAT RATE DAN GENERATOR POWER OUTPUT

Performance test TanggalBeban 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   1,0002Corrected to throttle Temperature Tht Corr.Curve   1,0013Corrected to Reheat Temperature R ht Corr.Curve   1,0024Corrected to Reheat Press % drop R hp Corr.Curve   0,9985Corrected to Exhaust Pressure   E xp Corr.Curve   0,9986Corrected to Throttle filter gauze pres drop F gtp Corr.Curve   1,0037Corrected to Reheat filter gauze pres drop F grp Corr.Curve   1,0038Corrected to Superheater spray water flow S hs Corr.Curve   1,0019Corrected 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   1,00414Corected to HPGV #4 Position   HPGV#4 Corr.Curve   1,00015Corr to in Final FeedcWater temperature F wt Corr.Curve   1,00016Corrected to Condenser depression Cd Corr.Curve   0,99917 Aging factor     Ag Corr.Curve   1,00018Total Corection factor     TCF     1,01519Uncorrected Heat Rate   HR uncorr Data 4.3. kJ/kWh 8,173,76120Corrected 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 TanggalBeban 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   0,99212Corrected to throttle Temperature Tht Corr.Curve   1,0003Corrected to Reheat Temperature R ht Corr.Curve   0,99194Corrected to Reheat Press % drop R hp Corr.Curve   1,0035Corrected to Exhaust Pressure   E xp Corr.Curve   0.99476Corrected to Throttle filter gauze pres drop F gtp Corr.Curve   0,99707Corrected to Reheat filter gauze pres drop F grp Corr.Curve   0,99508Corrected to Superheater spray water flow S hs Corr.Curve   1,0069Corrected 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   1,00416Corrected to Condenser depression Cd Corr.Curve   1,00017 Aging factor     Ag Corr.Curve   -18Total Corection factor     TCF     0,982419Uncorrected Heat Rate   HR uncorr Data 4.3. kW 298,749,78720Corrected 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. LanjutanHASIL HITUNG TURBINE HEAT RATE

Performance test Turbine Heat Rate TanggalBeban kW 100% Jam pelaksanaan

1. Main Steam Flow Calculation (Gms)      

  Uraian Symbol Data Ton/hr 0,0000                 

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

2Deaerator tank water drop level equivalent flow G dl Data   0,1073Hot well water drop level equivalent flow G cl Data   -5,5124System measurable leakage   G ml Data   1,5725System unaccounted for leakage dG (Eq.1)   -6,9776Rear shaft gland leakoff of HP turbine G gn1 Data   4,1827HP Heater #1, #2, #3 & Deaer steam flow G he Data   190,4828Feed pump leakge     G fpl Data   0,0009Deaerator discharge flow   G dv Data   0,000

10Reheat spray water flow+C17   G rhs Data   0,58911Boiler side viewable escape flow G s Data   0,00012Condensate flow   G cw Data   748,78113Main 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

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

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

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

  of HP turbine        

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

  of HP turbine        

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

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

  packing steam header     Data  

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

                 

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

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PT.INDO KARYA SENIOR