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Fathia 2018
Fathia 2018
ICPERE 2018
Abstract—Admission control valve (ACV), as one of the crucial Pembangkit Jawa-Bali (PJB), Muara Karang owns two steam
component in steam generator, requires reliable control and high power plants and a combined-cycle plant consisting of 5 gas
efficiency to assure system’s production operation in a combined- turbines and 4 steam turbines with total capacity of 1200
cycle power plant. Muara Karang power plant utilizes such device
MW[1].
to control steam supply to the steam turbine generator (STG).
Field data have shown that the performance of the existing ACV The operation of the CCPP is inseparable to the use of the
device is unsatisfactory and uses up too much hydraulic oil for its admission control valve (ACV), which functions to control
operation caused by oil leakeage from one of the broken seal steam flow produced in the Heat Recovery Steam Generator
component. Doing corrective maintenace for this device will cause (HRSG) to the LP steam turbine in PLTGU Blok 1 Muara
steam turbine derating up to 25 MW. Thus, studies on increasing Karang. The ACV itself is a throttling valve that is required to
valve’s reliability and eliminating unwanted products affecting the
operate and maneuver continuously to increase or decrease load
environment due to oil leakage is required. This paper presents a
modified ACV design, considering the valve’s structure and its for as long as the steam generator unit is online.
component’s material. Discussions in this paper are based on the With the rapid development of technology and industries, the
impact towards operation’s financial benefit, or decreasing demand for electricity is inevitably increasing, thus, reliability
spending in oil supply, and the environmental benefit. The impact from generation units as the main electricity producers and
of the new design was studied to gradually get the optimal design, suppliers is needed. One problem found in the Muara Karang
hence was tested and proven more robust, reliable and suited for
Plant is the ACV operation, resulting decrement of electricity
Muara Karang combined-cycle plant.
supply, are caused by: (1) breakdown in rod seal piston; and (2)
Keywords—admission control valve (ACV), combined-cycle power oil leakage in the rod seal.
plant, valve design, hydraulic valve This paper is organized as follows: in section II and III, a
background on Muara Karang plant and ACV operation is
NOMENCLATURE given. Section IV describes the proposed method and section V
ACV admission control valve gives the obtained results by the applying the proposed method.
CCPP combined cycle power plant The paper is concluded in section VI.
HPU hydraulic power unit
HRSG heat recovery steam generator II. MUARA KARANG COMBINED-CYCLE
MCV main control valve Muara Karang is a combined-cycle power plant consisting of
STG steam turbine generator two main units: gas turbine generator (GTG) and steam turbine
generator (STG). In the Block 1 CCPP, the GTG consists of 3
I. INTRODUCTION units, each having a capacity of 105 MW. The STG have a
capacity of 185 MW, totaling to 500 MW total capacity in the
Muara Karang Power Plant is the most important electricity
Block 1 CPP. Additionally, Muara Karang has a HRSG unit to
supplier to Indonesia’s capital, Jakarta, and its capital buildings maximize the efficiency in a CCPP.
such as Istana Negara, MPR/DPR building and Soekarno Hatta The process begins in the GTG, where the GTG is supplied
Airport. Operated by the Indonesia’s state owned electricity with gas with very high temperature that spins the gas turbine.
company PLN, sub division Jawa-Bali Generation aka The fast-spinning turbine drives the generator that converts the
1B31-1 The 4th IEEE Conference on Power Engineering and Renewable Energy
ICPERE 2018
Field data :
1. Damage in seal rod and seal piston due to heat exposure from
steam that flows through valve’s stem and body.
2. Design of cylinder actuator positions hydraulic supply inside and
near stem valve.
Field study :
Analyze the cylinder actuator design & seal rod and seal
piston material
A. Material Selection
Materials used for the valve components have to withstand
many stress cycles of steam flow, pressure, and temperature
changes. Material used in the existing design consist of
Fluorocarbon type A. With the problem in oil leakage and rod
seal damage, the material chosen as a substitute in the initial
design is Perfluoroelastomer due to its following characteristics
[2]:
• High temperature resistance
(a)
• Excellent chemical resistance
• Low out gassing
• Chlorine wet/dry
• Petroleum oil
• Chlorinated hydrocarbons
B. Actuator Design Analysis
Modification is done by relocating the hydraulic actuator
part, where in the initial design the hydraulic supply manifold
is in the inner position and adjacent to the stem valve. This has
a risk of heat exposure from steam in the event of a gland-
packing leak in the ACV valve. Since the supply position is on (b)
the inner side, piston rod requires a seal so that hydraulic oil Fig. 7. Admission control valve before redesign (a) cross section (b) actual
does not leak through the piston rod.
After modification, the hydraulic supply manifold of the
To avoid rod seal damage, modifications was done by
ACV is located on the outside of the cylinder actuator; therefore
moving the position of the supply manifold on the outer side of
the cylinder actuator. This design has several advantages: the hydraulic oil is in the outboard position of the cylinder and
• Damage to the seal kit due to heat exposure can be away from the body valve and stem. This design is highly
minimized. dependent on the quality of the piston seal to prevent hydraulic
• The rod seal in the new design no longer functions as a oil leakage out of the cylinder. In this modified design, the rod
pressurized hydraulic oil seal but is installed for safety. In seal's role is no longer the main seal for hydraulic oil leakage,
case of leakage in piston seal, hydraulic oil will not flow to but only as a safety in the event of piston seal damage, hydraulic
the drive module but is drained directly to the allocated oil will not flow into the valve body area. The new design of the
drain hole. ACV can be seen in Fig. 8.
(a)
1B31-1 The 4th IEEE Conference on Power Engineering and Renewable Energy
ICPERE 2018
= (1)
×
×
= 25.000 kW × 24 hours × Rp. 830,27
= Rp. 498.162.000,-/ day
= Rp. 498.162.000× 30 days
= Rp14.944.860.000,-/month
ACKNOWLEDGMENT
The research data was provided by PJB PLN Muara Karang.
REFERENCES
[1] “UNIT PEMBANGKITAN.” PT Pembangkitan Jawa Bali,
www.ptpjb.com/unit-pembangkitan/.
[2] “O-Ring Material Quick Reference Guide - Rubber Sealing
Materials.” Marco Rubber, www.marcorubber.com/materialguide.htm.
[3] Sors F, Holm P, Eriksson B, Ölvander J. Development of Steam Turbine
Inlet Control Valve for Supercritical Pressure at Siemens Industrial
Turbomachinery AB. Linköpings Univ, Maskinkonstruktion 2010
[4] Pondini, M., et al. “Steam Turbine Control Valve and Actuation System
Modeling for Dynamics Analysis.” Energy Procedia, vol. 105, 2017, pp.
1651–1656.
[5] General Electric, 1995, “Steam Turbine Operation Training Manual
volume I”, Muara Karang Combine Cycle Power Plant
[6] Mutama KR. Some Aspects of Steam Turbine Valves: Materials,
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Generators; Heat Exchangers and Cooling Systems; Turbines, Generators
and Auxiliaries; Plant Operations and Maintenance ():V001T04A009.
[7] PROPER, proper.menlhk.go.id/portal/.