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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) 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 , 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