demin water facilities for boilers cleaning

TITTLE

Whom, When

by

Hendra Saputra 08 614 007 Chemical Engineering DepartmentPoliteknik Negeri SamarindaPT. Badak NGL Process Engineering Section

Pembimbing : Irmawati Syahrir, ST, MTFany Arfianto, ST

September 2010

Perancangan Fasilitas Demineralizer Water untuk Proses

Cleaning Boiler di Utilities-I

SHE-Q Moment

Use protective equipment

Focus on the job

Know your limitations

Problem

Tinjauan Pustaka

Perancangan

Cost EstimationKesimpulan dan Rekomendasi

Proses Cleaning

Boiler

Fasilitas Cleaning Belum

Tersedia

Menggunakan Demineralizer

Water

Biennial Inspect Boiler

Carbon SteelKeunggulan

Material yang paling umum di gunakan pada industri MigasKetahanan korosi tinggiMemiliki Tensile Strength yang besar ( 70 000 psi)

Kelemahan

Strength pipa akan berkurang apabila suhu lebih tinggi dari 750 oF (398,9 oC)

Material Pipa

Tipe – Tipe Manufaktur dari Pipa Carbon Steel

Pipa Carbon Steel diproduksi dengan berbagai metode berdasarkan karakteristiknya meliputi

Tekanan maksimal

Temperatur maksimalKetahanan korosiWall thickness pipaStrength pipa

Ukuran pipa dinyatakan dengan NPS (Nominal Pipe Size)

yang digunakan untuk menjelaskan struktur pipa.

NPS menyatakan

ketebalan suatu pipa

dinyatakan dalam

schedule number

NPS pipa identik dengan wall thicknessnya

a. Standard (STD) : Schedule 40

b. Extra Strong (XS) : Schedule 80

c. Double Extra Strong (XXS) : Schedule 160

Nominal Pipe Size

NPS ¾”

Schedule Number

80 (XS Pipe)

Wall thickness

0,154”

Metode Penyambungan Pipa

Space 1/16”

Kantung Cairan

Korosi Celah

Socket Welded

Joint

Existing Facilities

31-D-21A 31-D-21B

31- F - 07

31- F - 08Flow sebesar

5-10 m3/h

Flow = 147 m3/hPressure drop = 6,6 kg/cm2

31-D 23

Mud Drum

Superheater

Steam Drum

Mud Drum

Superheater

Steam Drum

31-G-64/65/66

Mud Drum

Superheater

Steam Drum

Mud Drum

Superheater

Steam Drum

31- F - 0731- F - 08

31-D-21A 31-D-21B

Rancangan line pipa

North

East

South

West

rancangan Isometric chart

2" x 1” reducer

20

0 c

m

70

cm

60

cm

10

0 c

m

Reducing tee1" x ¾” SW

¾” pipe sch 80

Straight tee ¾” SW

Union pipe ¾” SW

Gate valve ¾” 800 lbs

Elbow 90 degree ¾” SW

Coupling ¾” SW

Angle 1½” x 1½” 1 Ft

With u bolt

Condensate Tank

31 G-16/17/18Pipe Demine

Water 8"

Pipe Demine Water 2"

31-F-10 31-F-231-F-4 31-F-131-F-331-F-531-F- 631-F-731-F-831-F-9

Pipe Demine Water 8"

Pipe Demine Water 2"

Pipe Demine Wash 3/4

"

Chemical Tank

31-D-331-D-23

31-F-11

31 G-63/64/65

Chemical Tank

31-D-1B 31-D-2A31-D-21B

South

North

West East

Source A

Source B

Flow = 147 m3/jam ΔP = 6,6 kgf/cm2

BF

W T

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Ch

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ical T

an

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BF

W T

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BF

W T

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ical T

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BF

W T

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Flow = 147 m3/jam ΔP = 6,6 kgf/cm2

31-D-21A

SCHEMATIC DIAGRAM LINE DEMINERALIZER WATER

Bill of Material

No Deskripsi material Unit Keterangan Harga /unit Cost

1 Pipe Seamless ¾”, Sch 80 Wall Thickness 0,154", Length 20 Ft Weight 1,47 lbs/ft, CS, ASTM 106 or 5L Gr : B 29 Batang Rp 350.000,00 Rp 10.150.000,00

2 Elbow Pipe SW 90 Degree Size ¾" Rate 3000 lbs CS, ASTM A350 55 EA Rp 83.378,00 Rp 4.585.790,00

3 Tee Straight CS ¾” Rate 3000 lbs CS ASTM A105 SW 7 EA Rp 32.000,00 Rp 224.000,00

4 Tee Reducing SW 1" x ¾" Rate 3000 lbs, CS, ASTM A106, Gr : B 2 EA Rp 44.556,00 Rp 89.112,00

5Valve Gate ¾” Rate 800 lb Treaded and SW End Trim 13%

CR, Body MATL, CS, ASTM A105, Non Renewable Seat, Solid Wedge, Handwhell Operational

6 EA Rp 540.500,00 Rp 3.243.000,00

6 Union Pipe SW Size ¾” Rate 3000 lbs CS ASTM A105 6 EA Rp 49.500,00 Rp 297.000,00

7 U-bolt Galvanis for Ø ¾" Pipe with 2 Nuts 40 EA Rp 3.000,00 Rp 120.000,00

8 Angle CS 1 ½" x 1 ½" ASTM A36 20 Ft/Length 20 Ft Rp 27.000,00 Rp 540.000,00

9 Coupling ¾” CS SW 8 EA Rp 26.400,00 Rp 211.200,00

Total Bill of Material Rp 19.460.102,00

Bill of Fabrication

No Item Fabrikasi Unit Keterangan Harga/Unit Cost

1 Pemotongan Pipa 55 Joint Rp. 79.075,88 Rp. 4.349.173,40

2 Pengelasan Pipa 137 Joint Rp. 183.255,64 Rp. 25.106.022,68

3 Fabrikasi Pipa 28.302 6 Meter Rp. 236.903,80 Rp. 6.704.851,35

Total Bill of Fabrication Rp. 36.160.047,43

Cost yang diperlukan untuk Pembuatan Line Pipa Baru

adalah Sebesar Rp. 55.620.149,43

Cost Estimation

Sumber air demin untuk fasilitas cleaning Boiler di Utilities-I diambil dari chemicals injection facilities di dekat Boiler 31F-2/3 dan 31F-7/8.

Rancangan line pipa baru dengan pipa bermaterial dasar baja karbon

Nominal pipe size yang digunakan sebesar ¾”

Metode penyambungan pipa dengan metode Socket Welded Joint

Estimasi biaya dibutuhkan untuk pembuatan line pipa baru sebesar Rp. 55.620.149

PT Badak memasang fasilitas baru untuk cleaning Boiler di Utilities-I dengan sumber line air demin di

Chemicals Injection Tank 31D-1A/2A dan 31D-21A/B