SEQUENCE OPERATION FOR STEAM BLOWING

(BOILER BED 130 T/H JERANJANG 1X25MW)

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

VALVE OUTLET & RETURN COOLING WATER POSISINYA HARUS BUKASTART MOTOR COOLING WATER A / BSTART MOTOR COOLING FAN ATAS A / BCHECK AMPERE HARUS KURANG DARI ....... ACHECK PRESSURE INDICATOR TIDAK BOLEH LEBIH DARI 0.5 Mpa ~ 0.6 MpaCHECK WATER LEVEL HARUS DIATAS SUCTION PIPE PUMPCHECK TEMPERATURE COOLING TOWER JANGAN SAMPAI MELEBIHI 65°CCHECK LINE PIPE DARI COOLING TOWER SAMPAI KEMBALI KE COOLING TOWER, SEMUA VALVE CIRCULATION COOLING WATER HARUS BUKA & MELEWATI STRAINER ( LINE BY PASS HARUS DITUTUP )

CHECK MANUAL VALVE DARI MAKE UP WATER PUMP KE DEAERATOR & CONDENSOR HARUS POSISI BUKACHECK LEVEL MAKE UP WATER TANKCHECK PRESS MAKE UP WATER PUMP OUTLET JANGAN SAMPAI MELEBIHI 5 MPASTART MAKE UP WATER PUMP DARI LOCAL PANEL MONITOR AMPERE JANGAN SAMPAI MELEBIHI 12 ACHECK LEVEL WATER DEAERATOR & CONDENSORLEVEL DEAERATOR JANGAN SAMPAI MELEBIHI 2300mmLEVEL CONDENSOR JANGAN SAMPAI MELEBIHI DARI 800mmHARUS SELALU MEMONITOR DAN KOORDINASI DENGAN DCS

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FILLING WATER TO DEAERATOR & CONDENSOR

COOLING WATER / COOLING TOWER

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COOLING TOWER & MAKE UP WATER

DEAERATORLEVEL LOW - LOW : 1300 mmLEVEL LOW : 1900 mmLEVEL NORMAL : 1950 ~ 2250 mmLEVEL HIGH : GOES UP TO 2300 mm (CLOSE OVER FLOW VALVE)LEVEL HIGH – HIGH : GOES UP TO 2350 mm (OPEN OVER FLOW VALVE)LEVEL HIGH – HIGH : GOES UP TO 2600 mm (OPEN EMERG DISCHARGE VALVE)

CONDENSERLEVEL LOW : 500 mmLEVEL NORMAL : 650 mmLEVEL HIGH : 800 mmLEVEL HIGH – HIGH :

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FILLING WATER TO CONDENSER & DEAERATOR

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DEAERATOR & CONDENSOR

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- 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

- 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

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03

CONDENSATE MOTOR 1,2 & 3

CONDENSOR PUMP

LUBE OIL MOTOR BFP

CHECK LEVEL HYDROULIC COUPLER DI POSISI MAXCHECK WATER OUTLET PUMP BFP HARUS POSISI TERTUTUPCHECK 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)

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LUBE OIL MOTOR BFP

RUN

MOTOR BFP RUN

MOTOR BFP BEFORE RUNCHECK HYDROULIC COUPLER 0% CHECK MINI FLOW VALVE OPEN POSITIONCHECK OUTLET VALVE MV 301 & MV 302 CLOSE POSITIONCHECK MANUAL VALVE INLET OUTLET HP HEATER 1 & 2 OPEN POSITIONCHECK MV 105 & MV 110 CLOSE POSITIONMOTOR BFP RUN CIRCULATION FROM DEAERATOR TO DEAERATOR

URUTAN 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.

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LUBE OIL MOTOR BFP

RUN

MOTOR BFP RUN

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06 OPEN VALVE VENT MV 101A & BOPEN VALVE BLOWDOWN CV 107 & CV 108OPEN VALVE MANUAL AT SUPERHEATER FOR WASHINGCHECK ROUTING VALVE WASHING FROM MOTOR WASHING / DRAIN PUMPOPEN MANUAL VALVE DRAIN ECONOMISERSTART MOTOR WASHINGCHECK QUALITY WATER AT DRAIN STOP MOTOR WASHING AFTER WATER GOOD QUALITYCLOSE ALL VALVE DRAIN INCLUDED CV 107 & CV 108CLOSE MANUAL VALVE WASHING AT SUPERHEATER

OPEN VALVE VENT MV 101 A&BOPEN VALVE MV 110 & MV 105OPEN & ADJUST CV 101/ CV 102 / CV 103OPEN VALVE MV 301 / MV 302ADJUST HYDROULIC COUPLERCLOSE VALVE MINI FLOWMONITOR LEVEL BOILER DRUMLEVEL HIGH : +100 mmLEVEL 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 103CLOSE VALVE MV 110 & MV 105OPEN VALVE MINI FLOW

START FILLING BOILER

PREPARE FILLING BOILER

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BOILER AIR & FLUE GAS SYSTEM07

IDF RUN

BEFORE START IDFDAMPER MD 103 A&B CLOSEDMANUAL DAMPER TO CHIMNEY CLOSEDAMPER MD 102 CLOSEDAMPER MD 101 CLOSEIDF READY TO START

PAF RUN

BEFORE START PAFDAMPER MD 101 CLOSEDPAF READY TO STARTDAMPER MD 102 OPEN (ADJUST WITH DAMPER IDF KEEP PRESSURE FURNACE -100 ~ -20 Pa)

SAF RUN

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

RECIRCULATION BLOWER RUN

BEFORE START RECIRCULATION BLOWERKEEP PRESSURE FURNACE -100 ~ -20 PaOPEN MANUAL DAMPER OUTLETRECIRCULATION BLOWER READY TO STARTADJUST WITH DAMPER IDF KEEP PRESSURE FURNACE -100 ~ -20 Pa

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BOILER AIR & FLUE GAS SYSTEM08

IDF RUNUNTUK START IDF / PAF / SAF / RBF ERHATIKAN DIBAWAH INI:1. SEBELUM START CHECK CONDISI FISIK MOTOR DALAM KONDISI AMAN2. CHECK CONDISI DAMPER3. YAKINKAN COOLING WATER DALAM KONDISI CIRCULATION4. YAKINKAN OIL LUBE KONDISI TIDAK LOWWER5. PADA WAKTU START MOTOR CHECK AMPERE, TEMPERATURE, VIBRATION

& NOISE 6. SELALU MONITOR & KOORDINASI DENGAN DCS DIKARENAKAN LOCAL

HARUS MENYESUAIKAN KONDISI DAMPER

PAF RUN

SAF RUN

RECIRCULATION BLOWER RUN

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PERFORMANCE PRIMARY AIR FAN09

START IDF (CHECK PRESSURE FURNACE)START PAF (CHECK PRESSURE DIFFERENTIAL UNDER BED & UPPER BED ≤ 3140 Pa.

DESIGN PRESSURE DROP OF PRIMARY AIR FANDIFFUSION RESISTANCE OF 1st AIR INLET ∆H1 : ≤ 1 Pa AIR PREHEATER RESISTANCE ∆H2 : ≤ 555 PaCONSTRUCTION RESISTANCE OF 1st AIR INLET ∆H3 : ≤ 5 PaRESISTANCE OF 1st AIR HOT FLUE ∆H4 (FROM AIR PREHEATER TO AIR CHAMBER)

: ≤ 300 PaAIR DISTRIBUTION RESISTANCE ∆H5 (EMPIRICAL VALUE) : ≤ 3140 PaCOMBUTION CHAMBER PRESSURE DROP ∆H6 : ≤ 6480PaTOTAL CALCULATION RESISTANCE OF 1st AIR FLUE ∑∆H = ∆H1+∆H2+∆H3+∆H4+∆H5+∆H6 : 10481PaSTACK DRAFT : -40 Pa

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BOILER OIL FIRING SYSTEM / STARTING BURNER10

BEFORE START OIL BURNERVALVE 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 STARTCHECK PRESSURE GAUGE AIR SUPPLY AT BURNER SHOULD BE READY TO USEDSTART OIL PUMP & RECIRCULATON FROM HSD TO HSDCHECK PRESSURE GAUGE OIL PUMP & PRESSURE GAUGE BURNERVALVE MV 193 & MV 194 OPEN (FOR AIR COMPRESSOR)VALVE CV 181 ADJUST GOES DOWN TO 50%IGNITION READY TO ENERGIZEDVALVE MV 191 & MV 192 OPENVALVE CV 181 ADJUST GOES DOWN TO 0% BUT CAN ADJUSTMENT TO OPEN ACCORDING TO TEMPERATURE FURNACE FUEL BURNER

KEEP TEMPERATURE FURNACE & TEMPERATURE BEDTEMPERATURE FURNACE GOES UP TO : 450°C TEMPERATURE BED GOES UP TO : 450°CKEEP PRESSURE FURNACE : -100 ~ -20 PaPRESSURE LOW ALARM GOES DOWN TO : -200 PaPRESSURE LOW - LOW GOES DOWN TO : -300 PaPRESSURE HIGH ALARM GOES UP TO : +150 PaPRESSURE HIGH – HIGH GOES UP TO : +300 Pa EMERG STOP IF PRESSURE GOES TO DOWN – 350 Pa & GOES TO UP +300 Pa

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BOILER COAL FIRING SYSTEM 11

BEFORE START COALBURNERKEEP TEMPERATURE BED 850°c (FUEL BURNER WILL STOP)PREPARED START COAL FEEDER ( CLOSED VALVE INLET & OUTLET )START OPERATION COAL FEEDEROPEN VALVE MV 126 / 127 / 128OPEN MANUAL VALVE INLET COAL FEEDER & ADJUST WITH SPEED CONVEYORCHECK & KEEP TEMPERATURE FURNACE 900°C ~ 950°CTEMPERATURE GOES DOWN TO 750°C ALARM LOW TEMPERATURETEMPERATURE GOES DOWN TO 650°C (EMERGENCY STOP)TEMPERATURE GOES UP TO 1000°C ALARM HIGH TEMPERATURETEMPERATURE GOES UP TO 1150°C (EMERGENCY STOP)

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

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BOILER STEAM SYSTEM 12

KEEP PRESSURE BOILER DRUM 11 ~ 11.50 MpaDRUM 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 MpaSUPER HEATER PRESSURE GOES UP TO 9.90 Mpa (OPEN VENT MV 101 A&B)SUPER HEATER PRESSURE GOES UP TO 10.29 Mpa (SAFETY VALVE OPEN & OPEN VENT MV 101 A&B)

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BOILER STEAM SYSTEM 13

START COMPRESSORE & CHECK PRESSURE HEADERMANUAL VALVE ASH INLET HOPPER 1,2,3 &4 SHOULD BE CLOSECHECK ALL SELECTOR SWITCH IN SIDE LOCAL PANEL SHOULD BE AUTOCHECK MANUAL VALVE AIR INLET SHOULD BE OPENCHECK BAG FILTER TOP FLY ASH SILO SHOULD BE OPERATIONFLY ASH SILO TRANSPORTER 1,2,3 & 4 START OPERATION AUTOAFTER SEQUENCE COMPLITED, OPEN MANUAL VALVE ASH INLET

SEQUENCE FLY ASH SYSTEM:1. OPEN ASH INLET & VENT TRANSPORTER2. HAVE 2 AUTO (LEVEL & TIMER)3. AFTER LEVEL HIGH / TIMER WORKING, ASH INLET & VENTING WILL

CLOSE4. AIR INLET , AUXILIARY & FLY ASH SILO INLET WILL OPEN5. PRESSURE WILL GO UP TO 200 Kpa / 2 BAR & ASH OUTLET

TRANSPORTER WILL OPEN6. AIR INLET, AUXILIARY, FLY ASH SILO INLET & ASH OUTLET

TRANSPORTER WILL CLOSE AFTER PRESSURE GO DOWN TO 50 Kpa7. ASH INLET & VENT WILL OPEN ( 1 STEP SEQUENCE )

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BOILER OPERASIONAL & MAINTENANCE 12

By : AHMAD JUNAIDI

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BOILER OPERASIONAL & MAINTENANCE 14

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BOILER WATER SAMPLING & CHEMICAL DOSING 15