lr-pk-un-003 sop hot start up unit (rev01)

PT PEMBANGKITAN JAWA BALI No.Dokumen : LR-PK-UN-003

UBJ O&M REMBANG MANAGEMEN SYSTEM Tanggal Terbit : 24 - 04 - 2011

STANDAR OPERATION PROCEDURE (SOP) HOT START UP UNIT Revisi : 01

PEMILIK PROSES : M. OPERASI Halaman : 1 dari 9

• Dokumen terkendali adalah dokumen on line & dokumen yang tercetak dengan stampel • Dokumen tidak terkendali adalah dokumen yang tercetak tanpa stampel

1. Fungsi

1.1. Fungsi System/Equipment:

Hot Start adalah kegiatan start Up Unit yang dilakukan setelah Unit shutdown selama

kurang dari 10 jam sampai Unit berbeban dan paralel dengan jaringan 150 KV yang

berpatokan utama pada parameter tekanan uap utama (main steam pressure), temperatur

uap utama (main steam temperature) dan temperatur sudu pertama Turbin.

1.2. Fungsi SOP:

Sebagai panduan bagi operator dalam melaksanakan kegiatan hot start up unit agar

terlaksana dengan aman dan efisien.

2. APD Yang Digunakan

2.1. Helm pengaman

2.2. Sepatu safety

2.3. Sarung tangan

2.4. Majun

2.5. Masker

3. Alat Kerja

3.1. Kunci F

3.2. Kunci Inggris

3.3. Kunci Pipa






4. Spesifikasi Teknik

4.1. Boiler

1) Model : DG1025/18.2-π13

2) Max. continous rating : 1025 t/h (max. evaporation capacity: 1055,75 t/h)

3) SH out steam press/temp : 17,5 MPa / 541°C (BMCR condition)

4) RH steam flow : 840,8 t/h (BMCR condition)

5) RH in/out steam temp. : 3,90 MPa / 3,73 MPa (BMCR condition)

6) RH in/out steam press. : 330°C / 541°C (BMCR condition)

7) Feedwater temp : 280°C (BMCR condition)

8) Guaranteed efficiency : 92,71%

4.2. Turbin

1) Model : N300-16.7/537/537, subcritical pressure, impulse type,

tandem compound two cylinders, double casing with 2

line flow exhaust, reheat condenseing turbine.

2) Guaranteed / Max. pwr : 315,846 MW / 325,8 MW

3) MSV inlet press./temp. : 16,67 MPa / 538°C

4) IP inlet temp : 538°C, 1025 t/h (VWO condition)

5) Condenser back press : 8,7 kPa






5. Batasan Operasi

5.1. Unit telah shutdown selama ≤ 10 jam

5.2. Parameter-parameter Hot Start :

1) Tekanan uap utama : ≥ 7.5 Mpa

2) Temperatur uap utama : ≥ 400 oC

3) Tekanan Reheater : ≥ 0.1 MPa

4) Temperatur Reheater : ≥ 400 oC

5) Temperatur Metal Boiler : ≥ 370 oC

6) Temperatur sudu pertama turbin : ≥ 380 oC

5.3. Parameter rolling turbin :

1) Tekanan uap utama : 7.85 MPa

2) Temperatur uap utama : ≥ 450 oC

3) Tekanan uap reheat : 0,883 MPa

4) Temparatur uap reheat : ≥ 417oC

5) Temperatur sudu pertama turbin : ≥ 400oC

6) Temperatur HP Inner Casing In Up : ≥ 400 oC

Temperatur HP Inner Casing In Down : ≥ 400 oC

Temperatur HP Inner Casing Out Up : ≥ 400 oC

Temperature HP Inner Casing Out Down : ≥ 400 oC

7) Target : 500 rpm ; Accelerating rate : 200 rpm/menit

Target : 3000 rpm ; Accelerating rate : 200 rpm/menit.

8) Load up rate : 4.8 MW/menit

9) Initial load applied : 6 - 9 MW






6. Peralatan Yang Tetap Beroperasi Selama Shutdown < 10 Jam

6.1. Circulating water system.

6.2. Sea water booster system

6.3. Closed coling water system

6.4. Service dan instrument air compressor

6.5. Auxiliary steam

6.6. AC Lube Oil Turbine, Jacking Oil Pump, dan turning gear

6.7. Vacuum pump condenser~ -87 kPa, dan Gland sealing turbine

6.8. EH System

6.9. Generator Cooling system

6.10. level steam drum, deaerator, dan Condenser hotwell normal

6.11. Condensate Extruction pump

6.12. MBFP

6.13. Air Heater

6.14. All Venting dan drainage Posisi Close






7. Pelaksanaan Hot Start Unit

7.1. Start draft system

1) Start Air Heater (AH) system

2) Start ID Fan system ; (furnace press : - 50 Pa – (-100 Pa))

3) Start FD fan system ; (air flow : > 30 % ~ 400 t/h), setelah purging naikkan Air

flow sampai > 700 t/h

7.2. Firing Boiler

1) Purging boiler, reset MFT (300 detik).

2) Insert thermoprobe.

3) Insert FTV.

4) Aktivasi soot blower AH continuously.

5) Start oil gun, layer AB boosting up boiler rate: 1.45˚C/min, 0.43MPa/min.

6) Pressurize Main steam.

7) Rising temperature Main steam.

a. Coal firing 1st Mill (Mill A)

b. Temp. outlet primary air > 265 ˚C

c. Start PA Fan system (out press: 8 KPa)

d. Start seal air fan (press : 10 KPa)

e. Start Mill system

f. Start coal feeder (flow rate 6 – 45 t/h)

Range Press. (MPa) Temp. Rate (°C/min) Press.Rate (MPa/min)

7.85 ~ 16.7 1.45 0.43

7.3. Bypass Operation

1) Maintain pressure & temp. Main Steam. P: 7.85 MPa, T: ≥ 450 ˚C.

7.4. Rolling-up Turbine.

1) Tutup HP & LP Bypass.

2) Turbine reset at DCS panel, LATCH.

3) Set Target: 500 rpm ; Acc: 200 rpm/min (Lakukan friction/rub check di local).

4) Set Target: 3000 rpm, Acc: 200 rpm/min.






a. Hold di 3000 rpm. Lakukan heat soak selama 15 menit.

Target:

Amati vacuum condenser: 87kPa – 92kPa.

Temp. LP Exhaust: 45 - 50˚C (≥80˚C LP spray auto open)

Stop AC lube oil, MOP in-service pada putaran 3000Rpm, disch. Press:

1.75 – 1.85 MPa. Lubricating pressure di bearing turbine: 0.07 – 0.12

MPa. Temp. lube oil: 40 – 45 ˚C.

HP & LP Bypass switch to “Auto” mode. Ketika pressure main steam

7.85 MPa dan Temperature Main steam 450 ˚C

5) In service Low Pressure Heater (LPH) steam side

8. Unit Synchronizing

8.1. Langkah synchronizing

1) DS GCB close (pastikan grounding open)

2) FCB close (reset panel di relay room)

3) Excitation ON

4) GCB Syn

5) Engage auto syn

6) Auto synchron “IN” (DEH menu)

8.2. Initial load at 6 MW dan Increase Load 1 MW/Min

8.3. Ketika Load > 8 MW Load Control “IN”

9. Proses Increasing Load dengan Fixed Pressure

9.1. Pada beban ± 45 MW

1) di tahan selama ± 15 menit

9.2. Pada beban ≥ 45 MW

1) Change Over Supply Steam Deaerator From Aux. Steam to IP Extraction Steam

No. 4 saat Pressure > 0.1MPa

2) Deaerator level control kondisi three element

3) Change over bypass feedwater line to main feed water line (pada saat 60 MW).






Prosedur:

a. Posisikan MBFP manual pada Scoop tube dan CV (posisi terakhir)

b. Buka control valve pada bypass feed water line sampai >70% , DP Set Point

turun sampai 1 MPa. (Pastikan Feedwater flow tetap stabil saat kondisi ini).

Jika berubah tambah scoop tube.

c. Buka front MOV pada main feed water line

d. Setelah feedwater flow dan level drum normal, posisikan out service bypass

feed water line.


1) Pastikan Drain Valve pada Cold Reheat, Hot Reheat, ICV, IP Casing, & semua IP

Casing Extraction pipe dalam kondisi Close

2) Aktifasi Spray De-Superheater dan Reheater

3) Aktifasi 1st Turbine boiler feed pump (BFPT)

a. Warming line BFPT (T = Temp. auxiliary steam header ~ ≥300 ˚C)

b. Start vacuum BFPT (± 87kPa)

c. Start booster pump BFPT (Press : 1,2 MPa)

d. Rolling BFPT

e. Balancing Header Pressure Feedwater Naikkan rpm BFPT melalui set target

pada MEH.

f. Buka Outlet Valve BFPT

g. Remote CCS IN Auto LCV pada BFPT

h. Stand By MBFP

4) Coal firing 2nd Mill (Mill B)

9.4. Pada beban ≥ 90 MW, Aktivitas :

1) Pastikan Drain valve pada semua LP casing extraction steam pipe dalam kondisi

close

2) In service HPH steam side

HP Heater #1 #2 #3

Pressure Ext. Steam ≥ 0.6 MPa ≥ 1.2 MPa ≥ 2.0 MPa






10. Proses Increasing Load dengan Sliding Pressure


1) Coal firing 3rd Mill (Mill C)


1) Aktifasi 2nd Turbine boiler feed pump (BFPT)

2) Aktifkan CCS IN pada Unit Master

3) Aktifkan Turbine Following Mode Auto

4) Aktifkan Self Sealing pada gland seal turbin


1) Pastikan pada kondisi ini MSP ≥ 13 MPa dan MST ≥ 515 ˚C


1) Coal Firing 4th Mill (Mill D)

2) Aktifkan Soot Blower pada Boiler jika diperlukan

3) Lakukan Vacuum leakage test pada 225 MW jika diperlukan

4) Change over Single Valve to Sequence Valve jika diperlukan


1) Retract All Oil Gun

2) Aktifkan ESP

3) Aktifkan Boiler Following Mode Auto

4) Unit pada kondisi CCS Mode

10.6. Full Load pada 300 MW

Catatan :

Saat Cold Start amati dari lokal maupun CCR dan jika ada kelainan, segera buat SR (Service

Request) untuk perbaikan






11. Lampiran

Lampiran 1. Hot Start Up Curve with HIP Casing

Lampiran 2. Hot Start Up Curve with IP Casing

Lampiran 3. Relation Curve of Steam Temperature Under Steam Pressure During

Initial Turbine Rolling and Steam Temperature After Control Stage

Lampiran 4. Relation Curve of Main Steam Flow And Power

Lampiran 5. Temperature Change Over Curve of the Control Stage on HP Casing

Lampiran 6. Temperature Change Over Curve of the Control Stage on IP Casing

Lampiran 7. Life-loss Curve of HP Rotor

Lampiran 8. Life-loss Curve of IP Rotor

Lampiran 9. Turbine IP Cylinder Startup System

Lampiran 1. Hot Start Up Curve With HIP Casing

Lampiran 2. Hot Start Up Curve With IP Casing

Lampiran 3. Relation Curve of Steam Temperature Under Steam Pressure During Initial Turbine Rolling and Steam Temperature After Control Stage

Lampiran 4. Relation Curve of Main Steam Flow And Power

100%

300 100%

Lampiran 5. Temperature Change Over Curve of the Control Stage on HP Casing

Lampiran 6. Temperature Change Over Curve of the Control Stage on IP Casing

Lampiran 7. Life-losse Curve of HP Rotor

Lampiran 8. Life-losse Curve of IP Rotor

Lampiran 9. Turbine IP Cylinder Startup System

lr-pk-un-003 sop hot start up unit (rev01)

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