operation boiler bed 130 t for steam blowing

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SEQUENCE OPERATION FOR STEAM BLOWING(BOILER BED 130 T/H JERANJANG 1X25MW)

GEDUNG WASA, Jl. Raya Cakung Cilincing KM 1 No. 11 Jakarta Timur 13910 Indonesia Telp. : 021 4619381 & 021 4604958 (Operator) Facs. : 021 4619382 Jl Email : dodopnt@yahoo.com, ahmad_junaidi_gkb@yahoo.co.id

PT. BUMIMITRA ADIPERSADA COOLING TOWER & MAKE UP WATERCOOLING WATER / COOLING TOWERVALVE OUTLET & RETURN COOLING WATER POSISINYA HARUS BUKA START MOTOR COOLING WATER A / B START MOTOR COOLING FAN ATAS A / B CHECK AMPERE HARUS KURANG DARI ....... A CHECK PRESSURE INDICATOR TIDAK BOLEH LEBIH DARI 0.5 Mpa ~ 0.6 Mpa CHECK WATER LEVEL HARUS DIATAS SUCTION PIPE PUMP CHECK TEMPERATURE COOLING TOWER JANGAN SAMPAI MELEBIHI 65C CHECK LINE PIPE DARI COOLING TOWER SAMPAI KEMBALI KE COOLING TOWER, SEMUA VALVE CIRCULATION COOLING WATER HARUS BUKA & MELEWATI STRAINER ( LINE BY PASS HARUS DITUTUP )

FILLING WATER TO DEAERATOR & CONDENSOR

CHECK MANUAL VALVE DARI MAKE UP WATER PUMP KE DEAERATOR & CONDENSOR HARUS POSISI BUKA CHECK LEVEL MAKE UP WATER TANK CHECK PRESS MAKE UP WATER PUMP OUTLET JANGAN SAMPAI MELEBIHI 5 MPA START MAKE UP WATER PUMP DARI LOCAL PANEL MONITOR AMPERE JANGAN SAMPAI MELEBIHI 12 A CHECK LEVEL WATER DEAERATOR & CONDENSOR LEVEL DEAERATOR JANGAN SAMPAI MELEBIHI 2300mm LEVEL CONDENSOR JANGAN SAMPAI MELEBIHI DARI 800mm HARUS SELALU MEMONITOR DAN KOORDINASI DENGAN DCS

02

PT. BUMIMITRA ADIPERSADA DEAERATOR & CONDENSOR02DEAERATOR LEVEL LOW - LOW LEVEL LOW LEVEL NORMAL LEVEL HIGH LEVEL HIGH HIGH LEVEL HIGH HIGH CONDENSER LEVEL LOW LEVEL NORMAL LEVEL HIGH LEVEL HIGH HIGH : : : : : : 1300 mm 1900 mm 1950 ~ 2250 mm GOES UP TO 2300 mm (CLOSE OVER FLOW VALVE) GOES UP TO 2350 mm (OPEN OVER FLOW VALVE) GOES UP TO 2600 mm (OPEN EMERG DISCHARGE VALVE)

FILLING WATER TO CONDENSER & DEAERATOR

: 500 mm : 650 mm : 800 mm :

03

PT. BUMIMITRA ADIPERSADA CONDENSOR PUMP03

- VALVE INLET MOTOR & OUTLET MOTOR HARUS DI BUKA - VALVE CIRCULATION DARI CONDENSER KE CONDENSER HARUS DI BUKA - VALVE KE LP HEATER 1,2 & 3 HARUS DI BUKA DAN BY PASS VALVE DI TUTUP

CONDENSATE MOTOR 1,2 & 3

- RUNNING CONDENSER CIRCULATION- CHECK PRESSURE PUMP CONDENSOR HARUS KURANG LEBIH ..... - CHECK VALVE GLAND SHIEL IN DAN OUT HARUS DI BUKA & BY PASS DI TUTUP - CHECK WATER SHIEL BFP

04

PT. BUMIMITRA ADIPERSADA04LUBE OIL MOTOR BFP CHECK LEVEL HYDROULIC COUPLER DI POSISI MAX CHECK WATER OUTLET PUMP BFP HARUS POSISI TERTUTUP CHECK POSISI HYDROULIC COUPLER POSISI HARUS 0% PRESSURE LUBE OIL LOW : 0,08 Mpa (STOP MANUAL & AUTO START) PRESSURE LUBE OIL LOW - LOW : 0,06 Mpa (TRIP) PRESSURE DIFF FILTER : 0,35 Mpa (ALARM) PRESSURE TRANSMITTER PT 333 : 0,35 Mpa (BFP TRIP)

LUBE OIL MOTOR BFP RUN

MOTOR BFP BEFORE RUN

CHECK HYDROULIC COUPLER 0%CHECK MINI FLOW VALVE OPEN POSITION CHECK OUTLET VALVE MV 301 & MV 302 CLOSE POSITION

MOTOR BFP RUN

CHECK MANUAL VALVE INLET OUTLET HP HEATER 1 & 2 OPEN POSITION CHECK MV 105 & MV 110 CLOSE POSITION MOTOR BFP RUN CIRCULATION FROM DEAERATOR TO DEAERATOR

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PT. BUMIMITRA ADIPERSADA05URUTAN RUNNING BFP: START LUBE OIL : CHECK PRESSURE LUBE OIL 0.12Mpa START BFP : MONITOR PRESSURE LUBE OIL SETELAH BFP RUNNING AKAN TURUN DARI 0.12Mpa MENJADI 0.08Mpa HYDROULIC COUPLER : BUKA HYDROULIC COUPLER DARI 0% KE 10% MAKA PRESSURE AKAN NAIK MENJADI 0.085Mpa (SEMAKIN HYDROULIC DIBUKA LEBIH MAKA PRESSURE LUBE OIL JUGA AKAN SEMAKIN NAIK TETAPI BERPENGARUH KE WATER OUTLET BY MINI FLOW AKAN BERGETAR DIARENAKAN DESIGN PIPING TERLALU KECIL), MAKA USAHAKAN JANGAN BUKA HYDROULIC COUPLERNYA MELEBIHI 10% SETELAH HYDROULIC COUPLER OPEN, PRESSURE LUBE OIL AKAN NAIK DI ATAS 0.08Mpa, LUBE OIL PUMP BISA DI STOP MANUAL & LUBRICATE AKAN PINDAH DARI INTERNAL HYDROULIC COUPLER SENDIRI START BFP SELALU MONITOR AMPERE & COORDINASI DENGAN DCS KALAU TERJADI PENYUMBATAN DI LINE LUBE OIL PT 333 MENCAPAI PRESSURE 0.35Mpa MAKA BFP AKAN TRIP DAN PRESSURE LUBE OIL AKAN TURUN KE 0.08Mpa DAN LUBE OIL PUMP AKAN START AUTO UNTUK MEMBACK UP LUBRICATE.

LUBE OIL MOTOR BFP RUN

MOTOR BFP RUN

06

PT. BUMIMITRA ADIPERSADA06OPEN VALVE VENT MV 101A & B

PREPARE FILLING BOILER

OPEN VALVE BLOWDOWN CV 107 & CV 108 OPEN VALVE MANUAL AT SUPERHEATER FOR WASHING CHECK ROUTING VALVE WASHING FROM MOTOR WASHING / DRAIN PUMP OPEN MANUAL VALVE DRAIN ECONOMISER START MOTOR WASHING

CHECK QUALITY WATER AT DRAINSTOP MOTOR WASHING AFTER WATER GOOD QUALITY CLOSE ALL VALVE DRAIN INCLUDED CV 107 & CV 108 CLOSE MANUAL VALVE WASHING AT SUPERHEATER

START FILLING BOILER

OPEN VALVE VENT MV 101 A&B OPEN VALVE MV 110 & MV 105 OPEN & ADJUST CV 101/ CV 102 / CV 103 OPEN VALVE MV 301 / MV 302 ADJUST HYDROULIC COUPLER CLOSE VALVE MINI FLOW MONITOR LEVEL BOILER DRUM LEVEL HIGH : +100 mm LEVEL HIGH - HIGH : GOES UP TO +175 mm (5 SEC. BOILER SHOULD BE STOP) LEVEL LOW - LOW : GOES DOWN TO -150 mm (BOILER EMERGENCY STOP) LEVEL NORMAL : -50mm ~ +50 mm (KEEP NORMAL LEVEL) ADJUST HYDROULIC COUPLER UP TO 0% CLOSE CV 101 / CV 102 / CV 103 CLOSE VALVE MV 110 & MV 105 OPEN VALVE MINI FLOW

07

PT. BUMIMITRA ADIPERSADA07

BOILER AIR & FLUE GAS SYSTEMBEFORE START IDF DAMPER MD 103 A&B CLOSED MANUAL DAMPER TO CHIMNEY CLOSE DAMPER MD 102 CLOSE

IDF RUN

DAMPER MD 101 CLOSEIDF READY TO START BEFORE START PAF

PAF RUN

DAMPER MD 101 CLOSED PAF READY TO START DAMPER MD 102 OPEN (ADJUST WITH DAMPER IDF KEEP PRESSURE FURNACE -100 ~ -20 Pa) BEFORE START SAF

SAF RUN

KEEP PRESSURE FURNACE -100 ~ -20 Pa SAF READY TO START DAMPER MD 101 OPEN (ADJUST WITH DAMPER IDF KEEP PRESSURE FURNACE -100 ~ -20 Pa)

BEFORE START RECIRCULATION BLOWERKEEP PRESSURE FURNACE -100 ~ -20 Pa

RECIRCULATION BLOWER RUN

OPEN MANUAL DAMPER OUTLET RECIRCULATION BLOWER READY TO START ADJUST WITH DAMPER IDF KEEP PRESSURE FURNACE -100 ~ -20 Pa

08

PT. BUMIMITRA ADIPERSADA08

BOILER AIR & FLUE GAS SYSTEM

IDF RUN

UNTUK START IDF / PAF / SAF / RBF ERHATIKAN DIBAWAH INI:1. 2. 3.

SEBELUM START CHECK CONDISI FISIK MOTOR DALAM KONDISI AMAN CHECK CONDISI DAMPER YAKINKAN COOLING WATER DALAM KONDISI CIRCULATION YAKINKAN OIL LUBE KONDISI TIDAK LOWWER PADA WAKTU START MOTOR CHECK AMPERE, TEMPERATURE, VIBRATION & NOISE

PAF RUN

4. 5.

6.

SELALU MONITOR & KOORDINASI DENGAN DCS DIKARENAKAN LOCAL HARUS MENYESUAIKAN KONDISI DAMPER

SAF RUN

RECIRCULATION BLOWER RUN

09

PT. BUMIMITRA ADIPERSADA09

PERFORMANCE PRIMARY AIR FANSTART IDF (CHECK PRESSURE FURNACE) START PAF (CHECK PRESSURE DIFFERENTIAL UNDER BED & UPPER BED 3140 Pa.DESIGN PRESSURE DROP OF PRIMARY AIR FAN DIFFUSION RESISTANCE OF 1st AIR INLET H1 : 1 Pa AIR PREHEATER RESISTANCE H2 : 555 Pa st AIR INLET H3 CONSTRUCTION RESISTANCE OF 1 : 5 Pa RESISTANCE OF 1st AIR HOT FLUE H4 (FROM AIR PREHEATER TO AIR CHAMBER) : 300 Pa AIR DISTRIBUTION RESISTANCE H5 (EMPIRICAL VALUE) : 3140 Pa COMBUTION CHAMBER PRESSURE DROP H6 : 6480Pa TOTAL CALCULATION RESISTANCE OF 1st AIR FLUE H = H1+H2+H3+H4+H5+H6 : 10481Pa STACK DRAFT : -40 Pa

10

PT. BUMIMITRA ADIPERSADA10 BOILER OIL FIRING SYSTEM / STARTING BURNERBEFORE START OIL BURNER VALVE MV 193 & MV 194 CLOSED (FOR AIR COMPRESSOR) VALVE MV 191 & MV 192 CLOSED ( FOR FUEL) VALVE MV 190 & CV 181 OPEN (FOR SUPPLY & RETURN FUEL) COMPRESSOR READY TO START CHECK PRESSURE GAUGE AIR SUPPLY AT BURNER SHOULD BE READY TO USED START OIL PUMP & RECIRCULATON FROM HSD TO HSD CHECK PRESSURE GAUGE OIL PUMP & PRESSURE GAUGE BURNER VALVE MV 193 & MV 194 OPEN (FOR AIR COMPRESSOR) VALVE CV 181 ADJUST GOES DOWN TO 50% IGNITION READY TO ENERGIZED VALVE MV 191 & MV 192 OPEN VALVE CV 181 ADJUST GOES DOWN TO 0% BUT CAN ADJUSTMENT TO OPEN ACCORDING TO TEMPERATURE FURNACE FUEL BURNER KEEP TEMPERATURE FURNACE & TEMPERATURE BED TEMPERATURE FURNACE GOES UP TO : 450C TEMPERATURE BED GOES UP TO : 450C KEEP PRESSURE FURNACE : -100 ~ -20 Pa PRESSURE LOW ALARM GOES DOWN TO : -200 Pa PRESSURE LOW - LOW GOES DOWN TO : -300 Pa PRESSURE HIGH ALARM GOES UP TO : +150 Pa PRESSURE HIGH HIGH GOES UP TO : +300 Pa EMERG STOP IF PRESSURE GOES TO DOWN 350 Pa & GOES TO UP +300 Pa

11

PT. BUMIMITRA ADIPERSADA11

BOILER COAL FIRING SYSTEMBEFORE START COALBURNER KEEP TEMPERATURE BED 850c (FUEL BURNER WILL STOP) PREPARED START COAL FEEDER ( CLOSED VALVE INLET & OUTLET )

START OPERATION COAL FEEDEROPEN VALVE MV 126 / 127 / 128 OPEN MANUAL VALVE INLET COAL FEEDER & ADJUST WITH SPEED CONVEYOR CHECK & KEEP TEMPERATURE FURNACE 900C ~ 950C TEMPERATURE GOES DOWN TO 750C ALARM LOW TEMPERATURE TEMPERATURE GOES DOWN TO 650C (EMERGENCY STOP) TEMPERATURE GOES UP TO 1000C ALARM HIGH TEMPERATURE TEMPERATURE GOES UP TO 1150C (EMERGENCY STOP)

KEEP TEMPERATURE FURNACE : 900C ~ 950C IF TEMPERATURE FURNACE GOES UP TO 960C BEFORE ALARM GOES UP TO 1000C DAMPER PA OPEN MORE & REDUCE COAL FEEDING IF TEMPERATURE FURNACE GOES DOWNTO 850C BEFORE ALARM GOES DOWN TO 750C DAMPER PA CLOSE MORE & ADDITIONALCOAL FEEDING

12

PT. BUMIMITRA ADIPERSADA12

BOILER STEAM SYSTEMKEEP PRESSURE BOILER DRUM 11 ~ 11.50 Mpa DRUM PRESSURE GOES UP TO 11.60 Mpa (OPEN VENT MV 101 A&B) DRUM PRESSURE GOES UP TO 11.69 Mpa ALARM HIGH (OPEN VENT MV 101 A&B)

DRUM PRESSURE GOES UP TO 11.89 Mpa (SAFETY VALVE OPEN & OPEN VENT MV 101 A&B) AND SHUT DOWNDRUM PRESSURE GOES DOWN TO 10.8 Mpa ALARM LOW (CHECK VALVE VENT SHOULD BE CLOSE) DRUM PRESSURE GOES UP TO 10.5 Mpa (OPEN VENT MV 101 A&B AND SHUTDOWN)

KEEP SUPER HEATER PRESSURE 9.75 Mpa ~ 9.85 Mpa SUPER HEATER PRESSURE GOES UP TO 9.90 Mpa (OPEN VENT MV