Commissioning & Start Up P-IIB, STG - BB

STG-BB BLOCK DIAGRAM

COAL JETTY
COAL FIXED GRAB
COAL COAL
UNITCOAL COAL BUNKER
5000 JETTY & FIXED CONVEYOR
STORAGE
CONVEYOR
CRUSHER
CONVEYOR
Kcal/kg GRAB 4 x 640 MT
30.000 MT 2 x 600 T/H
ARB
600 TPH

COAL FEEDER
DEMIN IMPORT

environmental protection

WATER BOILER
DEAERATOR FLY ASH HANDLING
RIVER TREATMENT DEMINERALIZED UNIT – 1 & 2
BOILER FEED 2x40 TPD
PLANT WATER PLANT
WATER (WTP)
WATER (BFW)
2x240 TPH
BOTTOM ASH HANDLING
INTAKE 130 TPH 53 kg/cm2
480 TPH 2x10 TPD
523TPH 485 oC

COOLING WATER M/U

SERVICES WATER STEAM TURBINE
SURFACE 170 TPH
CONDENSER
POWER
PA/IA/DA 80 TPH GENERATOR
38 MW

POWER EXPORT STEAM EXPORT

23 MW 310 TPH Q&A
 WATER TREATMENT PLANT
Pressure Sand Filter (6P-4011-
FA/FB/FC/FD) C Filtered Water Tank (6P-4002-F)
RWI Clarifier (6P-4021-F) A Clear Well (6P-4002-BA) B Dia x P : 3200 mm x 6500 mm
Material : CS / Epoxy
Tipe : Rectangular
Material : Carbon steel
Material : Reinforced Concrete Tipe : Rectangular Kapasitas : 170 m3/jam
Kapasitas : 523 m3/jam Material : Reinforced Concrete Tipe : Horizontal Pressurized
Dia x T : 18.2 m x 17.9 m
Kapasitas: 4579 m3 D
Dia x T : 16 m x 5.7 m P x L x T : 11.750 m x 9 m x 5 m Backwash flow rate : 30 m3/jam/m2
Kapasitas : 508 m3 (≈624 m3/jam
selama 10 menit)
Backwash air rate : 60 Nm3/jam/m2
(≈20,8 Nm3/menit)
Demin Plant
& Distribution
Sludge Pond (6P-4003-BA)
Tipe : Rectangular Underground Backwash Recovery Pond (6P-4004-BA)
Material : Reinforced Concrete Tipe : Rectangular underground
P x L x T : 7.5 m x 8 m x 3.5 m Material : Reinforced Concrete
Kapasitas : 223 m3 P x L x T : 9 m x 6.9 m x 3.5 m
E Kapasitas: 217 m3 F
D

B
A C

E
 WATER TREATMENT PLANT

Filtered water Quality

Water Treatment Plant (WTP)

No Parameter Unit Nilai
Capacity : 523 m3/H
1 Temperatur ºC 28 – 32
Usage : 2 M Alkalinity as CaCO3 ppm 12 – 25
1. Demin Water Plant : 130 m3/H 3 Chloride as Cl ppm 1 – 10
2. Make Up CW : 120 m3/H
4 Sulfate as SO4 ppm 15 – 40
3. Service Water : 85 m3/H
4. Deluge Fire Water 5 Calcium as Ca ppm 3 – 10

5. Dust Suppression System 6 Magnesium as Mg ppm 1–5

7 Total Hardness as CaCO3 ppm 10 – 30

8 Chloride as Cl2 ppm 0,0 – 0,2

9 Silica as SiO2 ppm 10 – 30

10 pH - 6,5 – 7,5
11 Conductivity µS/cm 90 – 160

12 Iron as Fe ppm 0,01 – 0,15

13 Turbidity NTU 2–5

14 Nitrate as NO3 ppm 1–8

BACK
 DEMINERALIZED WATER PLANT
RO Unit (6P-4005-FRA/B/C) RO Product Tank (6P-4003-F)
Filtered
Water
Activated Carbon Filter
(6P-4013-FA/B/C) A Mode Operasi
Inlet flowrate
: 2 Run + 1 Standby
: 125,3 m3/jam
Type : Cone Roof
Mixed Bed Polisher (6P-4018-
FA/B/C)
D
Kapasitas : 62,5 m3/jam Kapasitas : 54 m3/jam
Permeate flowrate : 100,3 m3/jam Mode Operasi : 2 Run + 1 Standby
Dia x T : 2300 x 2440 mm Dia x T : 4.18 m x 4.25 m
Concentrate flowrate : 25 m3/jam Dia x T : 1,2 m x 3,05 m
Des. Press : 8 kg/cm2G RO Vessel
Des. Press
Material
: Full Water
: Stainless Steel
C Kapasitas : 2 x 50,15 m3/jam
Running time : 23,5 jam/cycle Brand / Model : Pentair Codeline / 80S30 Des./Opr Press: 5,6 / 3,5 kg/cm2G
Size : 8” dia x 6600mm Length Cation/Anion Resin 500/500 lt/vessel
: 6 element/vessel
Design Pressure: 300 psi
Jumlah : 24 pcs (3 skid) B
RO Membrane
Brand / Model: Dow Filmtec / BW30-400
Jumlah : 144 pcs Demin Water Tank (6P-4001-F)
Make Up Type : Cone Roof
Deaerator Kapasitas : 2347 m3
Dia x T : 14.02 m x 15.5 m
Des. Press
Material
: Full Water
: Stainless Steel E

E
A D
C
B
 DEMINERALIZED WATER PLANT

RO Product Water Quality

Parameter Unit Nilai Demineralized Water Quality
pH - 6,5 - 7
Parameter Unit Nilai
Turbidity NTU < 0,5
pH - 6,5 - 7,5
P Alkalinity (as CaCO3) ppm Nil Conductivity µS/cm < 0,25
M Alkalinity (as CaCO3) ppm <1 Silica ppm < 0,005
Chloride (as Cl-) ppm <1 Total Fe (as Fe) ppm < 0,02
Sulfate (as SO4) ppm <1 Total Cu (as Cu) ppm < 0,003
Ammonia (as NH3) ppm <1 Chloride (as Cl) ppm < 0,02
Calcium Hardness (as CaCO3) ppm <1 Na + K (as Ion) ppm < 0,01
Magnesium Hardness (as
CaCO3) ppm <1
Iron (as Fe) ppm < 0,3 Demineralized Water Plant (Demin Plant)
Silica (as SiO2) ppm < 0,5 Capacity : 120 M3/H
Total Suspended Solid ppm <1
Total Dissolved Solid ppm <5
Conductivity µS/cm < 10
Usage :
1. Condenser water filling line
2. Steam turbine bypass spray water
line
3. Separator tank di vacuum pump
water filling line
4. Inert steam spray water line
5. Boiler filling lineDemin Water
Plant BACK
Terdiri atas 2 Line :
• Line 4004 : CWS untuk Steam Condenser STG (3 pompa, 2 running 1 stand by)
• Line 4005 : CWS untuk Boiler & seluruh Rotating Equipment (2 pompa, 1 run 1 stand by)
• Cooling Tower Fan 4 unit, 3 running 1 stand by
• Plant Air (Service Air) disediakan sebagai atomizing air ke LFO Burner dan
untuk keperluan flushing dan cleaning area tertentu yang membutuhkan
udara bertekanan tanpa memerlukan persyaratan moisture free.
• Instrument Air disediakan untuk menggerakkan actuator di Control Valve
dan Pneumatic On-Off Valve dan untuk membantu proses cleaning di Bag
Filter
• Dry Air disiapkan untuk proses pneumatic transporting di fly ash

NO PARAMETER PLANT AIR INST AIR DRY AIR

1 Tekanan 10 kg/cm2 9,5 kg/cm2 6,5 kg/cm2
2 Temperature 40ºC 40ºC 40ºC
3 Max Oil Content < 3 mg/m3 - -
4 Dew Point - -40ºC 3ºC
 LP Heater -2 (6P-4004-EA)
Type : Shell and Tube
BOILER FEED WATER (BFW)
Shell side Tube side Boiler Feed Water Pump
Deaerator (6P-4005-F)
Des. Temp 194 194 oC
Tipe : Spray / Tray (6P-4001-J A/B/C)
Type : Centrifugal Pump
BFW
Des. Press 3,7 11,9 kg/cm2 OD x H Deaerator: 2,286 m x 4,572 m
OD x H Storage : 3,7 m x 13,5 m Kapasitas : 280,56 m3/jam
Oper. Temp 146,1 125,7 oC
Temp/press des : 217ºC / 7 kg/cm2 Disch. Press : 79,5 kg/cm2 Desuperheat
Oper. Press 1,8 9,1 kg/cm2 Temp/press oper: 187ºC / 3,3 kg/cm2 Head : 825,6 m
Heat Trans. Area : 537,04 m2 Rated Pow : 798,8 kW

LP Heater -1 (6P-4003-EA)
Type : Shell and Tube
Shell side Tube side
Des. Temp 142 142 oC

Des. Press 3.7 11.9 kg/cm2

Oper. Temp 101.7 95.1 oC

Oper. Press 0,07 9,5 kg/cm2

Heat Trans. Area : 637.79 m2

Demin Water Pump

(6P-4011-J A/B)
Type : Centrifugal Pump
Kapasitas : 582 m3/jam
Disch. Press : 9,49 kg/cm2
Head : 97,2 m
Rated Pow : 200 kW

Demin Water Tank (6P-4001-F)

Type : Cone Roof
Kapasitas : 2347 m3
Dia x T : 14.02 m x 15.5 m
Des. Press : Full Water
Material : Stainless Steel

•Demin Plant
•SC fr STG
•Import P2B
•Import Existing Plant
 BOILER FEED WATER (BFW)
Boiler Feed Water Quality

pH - 8.5 - 9.7
Conductivity mS/m -
Dissolved Oxygen ppb Max. 7
Oxygen Scavenger (Hydrazine) ppb Min. 10

Dissolved Oxygen Control

Dissolved Oxygen dalam BFW sangat berbahaya bagi operasional boiler, karena merupakan salah satu penyebab paling utama
terjadinya korosi di boiler.
Semakin tinggi tekanan dan temperatur operasi boiler maka semakin kecil angka Dissolved Oxygen yang diijinkan .

Oksigen dihilangkan di Daerator dengan 2 tahap, yaitu :

1. Secara Mekanis, yaitu dengan proses stripping menggunakan Low pressure Steam yang terjadi Stripping section deaerator.
Proses deaerasi secara mekanis dapat menghilangkan kandungan Oksigen dalam air sampai 90%.

2. Secara Kimia, yaitu dengan menggunakan bahan kimia yang dikenal dengan nama oxygen scavenger. Oxygen Scavenger akan
melanjutkan proses penghilangan oksigen sisa sampai spesifikasi yang diijinkan. Reaksi kimia yang terjadi adalah :
N2H4 + O2 → N2 + H2O

Selain itu Deaerator mempunyai fungsi improve operasional dan penghematan energy dengan naik nya temperatur BFW akibat
stripping, sehingga menurunkan kebutuhan energy pemanasan di Boiler
 pH Control
BOILER FEED WATER (BFW)

Relation between pH and the rate of corrosion of iron by Berl & Van Taack

pH Boiler Feed Water dijaga pada 8,5—9,7 menggunakan Ammonia (NH3)

Tidak digunakan NaOH , karena NaOH akan mengikat CO2 yang terkandung dalam air menjadi Sodium Karbonat dan Sodium Bikarbonat
2NaOH + CO2 ↔ Na2CO3 + H2O + Heat
Na2CO3 + CO2 + H2O ↔ 2NaHCO3 + Heat

Pada proses pemanasan air dalam boiler, Sodium Karbonat dan Sodium Bikarbonat akan terpecah kembali menjadi NaOH dan CO 2
2NaHCO3 + Heat ↔ Na2CO3 + CO2 + H2O
Na2CO3 + H2O + Heat ↔ 2NaOH + CO2

CO2 terlarut dalam BFW juga merupakan salah satu penyebab Korosi di perpipaan dan Tube Boiler

Jika karbon dioksida hadir dengan oksigen, kedua gas yang bekerja secara simultan hingga 40% lebih korosif BACK
daripada dalam jumlah yang sama dari dua gas bertindak secara individual
 PULVERIZED COAL BOILER

Quantity : Two (2) Units

Type of Boiler : Kawasaki SR-240 type PCB
Mono Drum Radiant Type Natural Circulation Boiler
Boiler Maximum Continuous Rating : 240 T/H per one (1) Unit Boiler

Steam Pressure (SH Outlet) : 56.0 kg/cm2G

Steam Temperature (SH Outlet) : 487 oC

Feed Water temperature (ECO inlet) : 145 oC

Ambient air temperature : 35 oC

Relative humidity : 80%
Boiler Operation system : Constant pressure operation
Steam control system : Spray water attemperator system
Draft system : Balanced draft
Combustion system : Direct Combustion system with pulverized coal
Main Fuel : Coal
Start-up Fuel : High speed diesel oil (HSD Oil)
Coal Consumption : 40.6 T/H per 1 unit boiler (4650 kcal/kg coal)
 COAL SPECIFICATION
Design Coal data
 COAL SPECIFICATION
Actual Coal data
 PULVERIZED COAL BOILER
Steam Superheated
steam generation (product)
Press : 56 kg/cm2
Temp : 487 oC
Qsensible-2
QLatent

Feed Water
Press : 63 kg/cm2
Temp : 278 oC

Evaporator Saturated Steam

Qsensible-1 Press : 63 kg/cm2
Temp : 278 oC

Feed Water (inlet)

Press : 65 kg/cm2
Temp : 145 oC

Heat Required = Qsensible-1 + QLatent + Qsensible-2

PULVERIZED COAL BOILER
PULVERIZED COAL (PC) FIRED

FLOW COAL FUEL

 PULVERIZED COAL BOILER

Operator Training for PC Boiler

PULVERIZED COAL BOILER

BACK
 Coal Bunker
Fungsi : Sebagai wadah untuk menampung sekaligus menakar batubara
sebelum dimasukkan ke Coal Feeder

Kapasitas :
4 X 640 Ton
 Coal Feeder
Coal Feeder memiliki 2 fungsi
1. Memberikan pasokan batubara secara kontinyu ke coal mill
2. Mengatur aliran batubara sebagai feeding boiler sesuai dengan rate boiler yang
ditentukan.

• Terdapat 2 buah Coal feeder untuk tiap Unit boiler, yang mana satu coal feeder
menyuplai batubara pada satu coal mill.
• Kapasitas maksimal 1 coal feeder 27 ton/h
Coal Feeder
 Coal Mill
Coal Mill berfungsi sebagai tempat penggilingan
batubara, type yang digunakan roller ball dimana
terdapat 3 roller ball sebagai penghancur batubara dan
sebuah grinding table sebagai alasnya.
Outlet Coal Mill adalah batubara yang berbentuk serbuk
(pulverized coal ) > 80% dengan mesh 200.
Setelah batubara hancur menjadi serbuk kemudian
dihantarkan masuk ke dalam ruang pembakaran
(furnace) dengan udara PAF (Primary Air Fan).
Tipe coal mill ini menggunakan sistem oli hydraulik
sebagai tenaga penggerak roller ball.
Terdapat 2 buah Coal mill untuk tiap-tiap Unit
Pembangkit pada STG BB
Yaitu:
1. Boiler Unit 1 :
1. Coal mill 1A
2. Coal mill 1B
2. Boiler Unit 2 :
1. Coal mill 2A
2. Coal mill 2B

Grinding roller
FLY ASH & BOTTOM ASH HANDLING
Fly Ash Silo Cap : @ 500 m3
263 Ton

Fly Ash Transported from

ESP Bin to Silo by
pneumatic transporting
line
FLY ASH SILO
 FLY ASH & BOTTOM ASH HANDLING
ASH PRODUCTION
Coal Flow (100% BMCR) : 40.6 TPH
Ash Content : 4.4 %
Ash Production : 90% Fly Ash ; 10% Bottom Ash
• Fly Ash Production : 4.4 % x 40.6 TPH x 90 % = 1.61 TPH 38.6 TPD
• Bottom Ash Production : 4.4 % x 40.6 TPH x 10 % = 0.18 TPH 4.29 TPD

FLY ASH COMPOSITION

ASTM C-618 –
“coal fly ash and raw or calcined natural pozzolan for use in concrete where cementitious or
pozzolanic action, or both, is desired, or where other properties normally attributed to fly
ash or pozzolans may be desired, or where both objectives are to be achieved”

BACK

Steam Turbine (6P-3001-ST)
Tipe
Steam Rate
Flow Steam Inlet (Normal / Max.)
Temperature (Design / Operating)
STEAM TURBINE GENERATOR (STG)
: Condensing
: 4.52 kg/kWh
: 171.56 / 178.43 TPH
: 495 / 482 oC

Pressure (Design / Operating) : 67.3 / 51 kg/cm2G

Max Continuous Speed : 5338 rpm
1st Critical : 2640 rpm
Gearbox (6P-3250-GX)
2nd Critical : 6000 rpm
OST (Electrical) : 5972 rpm Model : N3491C
Single Stage, Double
Tipe : Helical
Input Power : 41395 kW
Electric Generator (6P-6006-GT) Input Speed : 5338 rpm
CACW Totally Enclosed Water Output Speed : 1500 rpm
Enclosure : Cooled Gear Ratio : 3.5587
Stator Winding Connection : STAR Full Load Power Loss : 620.9 kW
Rating : 44706 kVA Mechanical Efficiency : 98.5 %
Voltage : 13800 V
Lube Oil Flow (1.8-2.0 kg/cm2G) : 800 LPM
Frequency : 50 Hz
Rated Power Factor (Lag/Lead) : 0.8 / 0.95
Rated Line Current : 1870 A
Phase : 3
Pole : 4 (Salient Pole Rotor)
Speeed : 1500 rpm
Overspeed : 1800 rpm
Air Gap : 20 mm

Excitation Ampere
1. Rated Full Load on the Machine : 8.2 A
2. Rated Voltage on No Load : 2.8 A

PMG for AVR Power Supply

Output Voltage : 240 V
Full Load Current : 1.5 A
Frequency : 275 Hz
STEAM TURBINE GENERATOR (STG)
STEAM TURBINE GENERATOR (STG)
STEAM TURBINE GENERATOR (STG)
 STEAM TURBINE GENERATOR (STG)
Overall Rotor Lengths : 7090 mm
Rotor Diameter : 860 mm
Overall Stator Diameter : 1300 mm

Segmental Laminations
Stator
4-Pole Salient Rotor
STEAM TURBINE GENERATOR (STG)
STEAM TURBINE GENERATOR (STG)

BACK
COAL JETTY & FIXED GRAB UNIT
TT-2 Coal Bunker
Coal
Storage TT-5
TT-4
TT-3

BACK
COAL STORAGE

BACK
 COAL CONVEYOR
Main Equipment
1. Belt Conveyor
2. Tripper Car
3. Crusher
4. Vibrating Screen
5. Vibrating Feeder
6. Coal Sampler

Auxiliary Equipment
1. Diverter Gate
2. Bag Filter
3. Dust Suppression
4. Belt Weigher
5. Metal Detector
6. Magnetic Separator

Coal Conveyor Capacity :

2 x 600 TPH
1 running & 1 Standby
COAL CONVEYOR

BACK
 COAL CRUSHER

Main Design Data

BACK
 ENVIRONMENTAL PROTECTION

 Electrostatic Precipitator (ESP) (6P-1453/2453-EP) dipasang di flue gas outlet Gas

Air Heater (GAH) (6P-1434/2434-EA) untuk menangkap debu atau fly ash yang
terpisah dari flue gas sebelum dibuang ke atmosfer melalui Stack (6P-1490/2490-
SK)

 Tersedia juga CEMS (Continuous Emission Monitoring System) di masing-masing

Stack untuk memonitor flue gas.
Parameter monitoring CEMS adalah air (H2O), carbondioksida (CO2), sulfur
dioksida (SO2), nitrogen monoksida dan nitrogen dioksida (NOx), carbon
monoksida (CO), oksigen (O2), opacity (sifat tak tembus cahaya) dan debu

 Waste Water treatment Plant tersedia untuk mengolah seluruh air buangan di
Plant STG-BB sebelum dibuang ke sungai sebagai air buangan yang bersih (purified
waste water), sehingga memenuhi bakumutu lingkungan yang diijinkan
 ENVIRONMENTAL PROTECTION
Batasan kualitas emisi gas mengacu kepada Peraturan Menteri Lingkungan Hidup No. Permen LH No.21 tahun 2008
dengan parameter sebagai berikut:

Parameter Batasan
Total Partikel 150 mg/m3
Sulfur dioksida (SO2) 750 mg/m3
Nitrogen dioksida (NO2) 850 mg/m3
Opacity 20%

Batasan kualitas udara ambient mengacu kepada Peraturan Pemerintah No.41, 26 Mei 1999 berkenaan dengan National
Ambient Level Standard of Air Pollutant dengan paramater sebagai berikut:

Parameter Durasi Pengukuran Standar

2 jam 900 µg/Nm3
Sulfur dioksida (SO2) 24 jam 365 µg/Nm3
1 tahun 60 µg/Nm3
1 jam 30.000 µg/Nm3
Carbon Monoksida (CO)
24 jam 10.000 µg/Nm3
1 jam 400 µg/Nm3
Nitrogen dioksida (NO2) 24 jam 150 µg/Nm3
1 tahun 100 µg/Nm3
PM10 (Partikel < 10 µm) 24 jam 150 µg/Nm3
24 jam 65 µg/Nm3
PM2,5 (Partikel < 2,5 µm)
1 tahun 15 µg/Nm3
24 jam 230 µg/Nm3
TSP (debu) 1 tahun 90 µg/Nm3
1 tahun 1 µg/Nm3
10 t/km2/bulan (dwelling area)
Debu yang jatuh 30 hari
20 /t/km2/bulan (Industri)
Sulfate Index 30 hari 1 mg SO2/100 cm3 dari lead peroksida
 ENVIRONMENTAL PROTECTION
Electrostatic Precipitator (ESP) (6P-1453/2453-EP)
Tipe : Dry Horizontal
Temp/Press Design : 190ºC / 1,75 kg/cm2G
Temp/Press Operating : 132ºC / -0,0307 kg/cm2G
Capacity (Des.) : 348.200 Nm3/H flue gas
Dust content Reduction : 12,5 g/Nm3 to Max. 150 mg/Nm3 (dry).

ESP Process
ELECTROSTATIC PRECIPITATOR (ESP)
ELECTROSTATIC PRECIPITATOR (ESP)
 ENVIRONMENTAL PROTECTION
Waste Water Treatment Plant
 Capacity : 48,6 M3/Jam.
 Suspended Solid < 200 mg/Liter.
 Dissolved Solid < 2.000 mg/liter.
 Fe < 5 mg/liter.
 COD < 100. mg/liter
 BOD < 50 mg/liter.
 ENVIRONMENTAL PROTECTION
Kualitas purified waste water dengan mengacu kepada SK Menteri LH No.51/1995
No Parameter Unit Standar
1 Temperatur ºC 38
2 Suspended solid mg/l 100
3 Dissolved solid mg/l 2000
4 pH - 6–9
5 Fe mg/l 2
6 Mn mg/l 2
7 Ba mg/l 2
8 Cu mg/l 1
9 Zn mg/l 1
10 Cr+6 mg/l 0,1
11 Cr mg/l 0,5
12 Cd mg/l 0,05
13 Hg mg/l 0,002
14 Pb mg/l 0,1
15 Sn mg/l 2
16 As mg/l 0,1
17 Se mg/l 0,05
18 Ni mg/l 0,2
19 Co mg/l 0,4
20 CN mg/l 0,05
21 H2S mg/l 0,05
22 F mg/l 2
23 Cl2 mg/l 0,5
24 NH3-N mg/l 1
25 NO3-N mg/l 20
26 NO2-N mg/l 1
27 BOD5 mg/l 50
28 COD mg/l 100
29 Active Methylene Blue mg/l 5
30 Phenol mg/l 0,5
31 Vegetable oil mg/l 5
32 Mineral oil mg/l 10
33 Radioactivity - - BACK
34 Phosphate (PO4-) mg/l 10
 ありがとう
谢谢

Click to edit Master title style

merci