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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
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