Boster Fan Improvement presentation

7/29/2019 Boster Fan Improvement presentation

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Operation Performance Improvement Initiative

Optimasi Kontrol BoosterFan guna menghindariUnit Derating

Jepara, 4 Oktober 2012

Oleh : Muhammad Arif Susetyo

OPI Local Coach Technical System


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Kontrol Eksisting : Booster Fan Tripmenyebabkan runback atau unit trip

Telah terjadi 2 kali trip booster fan padaperiode Juli-agustus 2012 yangmenyebabkan runback 50%

Kegagalan produksi listrik : 7 jam x330MWh = 2310 MWh

Latar Belakang


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Apakah Booster Fan?

Merupakan MainEquipment pada Unit

3 Phase Motor

Kapasitas Motor : 2 MW

Power Factor : 0.775


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Fan Axial untuk mendorong gas buangmenuju Flue Gas Desulfirizer absorber

Berguna untuk mengatasi head loss padaFGD Absorber

Kapasitas 2 x 50%

Apakah Booster fan?

ESPBoiler

IDFan2 x50%

BoosterFan A

BoosterFan B

FGD

Stack

Bypass

DamperA

BypassDamper

B

Atmosphere


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Memodifikasi DCS logic gunamenghilangkan runback ketika booster fantrip

Ada potensi improvement karena adanyaFGD Bypass Line

Ketika dilakukan FGD bypass, booster fantidak diperlukan

Tujuan modifikasi : Membuka FGD bypass

pada kejadian trip booster fan.

Cakupan Studi


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Dasar Analisa : RunbackUnit 4 pada 16/6/2012

BoosterFan 4B

Trip

Runback Sequencecommenced : ID Fan

4B, PA Fan 4B, FDFan 4B Trip

Unit LoadReduced to 40

% Load

Tripnya Booster Fan 4Bmenyebabkan Runback,dengan mentripkan ID fan4B, PA Fan 4B, dan FD Fan

4B.

sesuai dengan LogicExisting


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Konfigurasi fanboiler adalah2x50%

Kontrol eksiting ;Tripnya salahsatu dari 3 fanutama (IDF , PAF,& FDF & BUF)akan mematikanfan lainnya danmenurunkanbeban unit

Filosofi Proteksi Boiler

B

OILER

FD FAN

2x50%

PA FAN2x50%

ID FAN2x50

%

J ifik i


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JustifikasiModifikasi OLD

16/6/2012

Booster Fan3A Trip

Runback Sequence notPermitted due to ID Fan 3A &3B Damper In manual Mode

(Loss Power)

Furnace Pressure &Booster Fan Inlet

Pressure Increase

FGD BypassDamper 3A Open

Furnace Pressure & Booster FanInlet Pressure Normalized

FGD BypassDamper 3B Open

Booster Fan 3BTrip

Unit Full Load Maintained(684 MW Gross)

Booster Fan Inletpressure high alarm

activated

Pada hari yang sama,Booster Fan 3A Jugamengalami Trip

Karena ada gangguanelectrical pada damper IDfan, maka ID fan tidak bisatrip, sehingga runbackpermit tidak terpenuhi

Hal ini menyebabkan

Tekanan Inlet Booster Fantin i dan FGD b ass

Fil fi K t l


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Unit Full Load

RunbackPermit?

1st layerprotectionTrip

single train of IDFan, PA Fan, FDFan.

Yes

Single Booster

Fan Trip

No

Booster faninlet pressureincrease

2nd layerprotectionFGD Bypass

Open (after 35sintegrationtime)

Unit Runback40% Load

Unit LoadMaintained-PROVED

(Risk of MainFuel Trip due to35s integrationtime)

Both BoosterFans Trip

RunbackPermit?

1st layerprotectionTrip

Both train of ID Fan,PA Fan, FD Fan, &

Main Fuel Trip

Yes

No

Booster faninlet pressureincrease

2nd layerprotectionFGD BypassOpen (after 35sintegrationtime)

Unit TripPOSSIBLITY ofUnit LoadMaintained(Risk of Main Fuel

Trip due to 35sintegration time)

Tripnya 1Booster Fanakanmenyebabkan

Runback Unit(1st LayerProtection)

ApabilaRunback tidakmemungkinkan, Maka FGDBypass damper

Filosofi KontrolBooster Fan & UnitLoad (OLD)

K i l K t l


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Kontrol Eksisting Tidak Optimal dari sisimempertahankan beban Unit

Posisi 1st dan 2nd Layer Protection perludibalik

Dibukanya FGD bypass damper akan

menaikkan emisi SO2, namun regulasi KLHcukup toleran (750 mg/Nm3 24 hoursaverage)

Optimasi Kontrol Booster fan dapat

Kesimpulan KontrolBooster Fan Eksisting

(OLD)

DCS L i


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Trip Boosterfan akanmemicudibukanya

FGD Bypass

Apabila FGDBypass A&Bmasihtertutup 5detik setelahBooster Fantrip, maka

DCS LogicModificatio

n

Unit Full Load

1st layerprotection FGDBypass damper

forced open?

After 5 seconds,FGD Bypasss

damper A&B stillfully closed?

No

Single BoosterFan Trip

2nd layerprotectionBooster FanRunbackOperate1 Train of ID,PA, FD Fan Trip

Unit LoadMaintained

UnitRunback40% Load

Both BoosterFans Trip

Yes

1st layerprotection FGDBypass damper

Open?

After 5 seconds,FGD Bypasss

damper A&B stillfully closed?

Yes

Unit LoadMaintained

Possibility ofUnit Trip

No

2nd layerprotectionBooster FanRunbackOperate1 Train of ID,PA, FD Fan Trip


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Point A to BIF BUF A trip OR BUF B TRIP

THEN Bypass damper Forced Open

DCS Ladder DiagramModification Part 1

A

B


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Point A to BIF after 5 Second from BUF A OR BUF B Trip

AND FGD Bypass A AND FGD Bypass B Closed

THEN Booster Fan Runback Operate

DCS Ladder DiagramModification Part 2


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Implementasi modifikasi dilakukan di Unit 3

Testing dilakukan Pada Beban 361 MW nett@ 14/9/2012

Metode test dengan melakukan trip boosterfan A

Implementation andTesting


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FGD Bypass A&B : Berhasil langsungTerbuka

Boiler Pressure : Vakuum Normal

Generator MW : Normal

SO2 CEMS : Normal

Hasil Test


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Kontrol Eksisting booster fan dititikberatkanuntuk emisi.

Modifikasi DCS efektif untuk optimasikontrol Booster Fan guna menjaga bebanunit di saat booster fan trip

Naiknya emisi dalam batas toleransiperaturan KLH (SO2 750 mg/nm3 2hrsaverage)

Penyebab Booster Fan Trip Harus

Kesimpulan Modifikasi


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There is no knowledge that is not power-Ralph Waldo Emerson

Terima Kasih

Boster Fan Improvement presentation

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