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    Boster Fan Improvement Presentation

    Uploaded by

    Arif Susetyo
    This document discusses modifications made to the control logic for booster fans at a power plant to avoid unit derating when fans trip. [1] Previously, a single booster fan trip would cause the unit load to reduce to 40% through a runback sequence. [2] The new logic forces the FGD bypass dampers to open immediately if a fan trips to maintain full unit load. [3] Testing of the modified logic successfully kept the unit online at full load when a booster fan was tripped, while keeping SO2 emissions within regulatory limits.

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    Boster Fan Improvement Presentation

    Uploaded by

    Arif Susetyo
    140 views18 pages
    This document discusses modifications made to the control logic for booster fans at a power plant to avoid unit derating when fans trip. [1] Previously, a single booster fan trip would cause the unit load to reduce to 40% through a runback sequence. [2] The new logic forces the FGD bypass dampers to open immediately if a fan trips to maintain full unit load. [3] Testing of the modified logic successfully kept the unit online at full load when a booster fan was tripped, while keeping SO2 emissions within regulatory limits.

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    Boster Fan Improvement presentation

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    This document discusses modifications made to the control logic for booster fans at a power plant to avoid unit derating when fans trip. [1] Previously, a single booster fan trip would cause the unit load to reduce to 40% through a runback sequence. [2] The new logic forces the FGD bypass dampers to open immediately if a fan trips to maintain full unit load. [3] Testing of the modified logic successfully kept the unit online at full load when a booster fan was tripped, while keeping SO2 emissions within regulatory limits.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    140 views18 pages

    Boster Fan Improvement Presentation

    Uploaded by

    Arif Susetyo
    This document discusses modifications made to the control logic for booster fans at a power plant to avoid unit derating when fans trip. [1] Previously, a single booster fan trip would cause the unit load to reduce to 40% through a runback sequence. [2] The new logic forces the FGD bypass dampers to open immediately if a fan trips to maintain full unit load. [3] Testing of the modified logic successfully kept the unit online at full load when a booster fan was tripped, while keeping SO2 emissions within regulatory limits.

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    Operation Performance Improvement Initiative

    Optimasi Kontrol Booster Fan guna menghindari Unit Derating


    Click to edit Master subtitle style

    Jepara, 4 Oktober 2012 Oleh : Muhammad Arif Susetyo 2/7/13 OPI Local Coach Technical System

    Latar Belakang
    Kontrol

    Eksisting : Booster Fan Trip menyebabkan runback atau unit trip terjadi 2 kali trip booster fan pada periode Juli-agustus 2012 yang menyebabkan runback 50% produksi listrik : 7 jam x 330MWh = 2310 MWh

    Telah

    Kegagalan

    2/7/13

    Apakah Booster Fan?

    Merupakan Main Equipment pada Unit 3 Phase Motor Kapasitas Motor : 2 MW Power Factor : 0.775

    2/7/13

    Apakah Booster fan?


    Bypass Damper A Bypass Damper B Booster Fan A Booster Fan B FG D Stack Atmosphe re ID Fan 2x 50 %

    Boiler

    ESP

    Fan

    Axial untuk mendorong gas buang menuju Flue Gas Desulfirizer absorber untuk mengatasi head loss pada FGD Absorber 2 x 50%
    2/7/13

    Berguna

    Kapasitas

    Cakupan Studi
    Memodifikasi

    DCS logic guna menghilangkan runback ketika booster fan trip potensi improvement karena adanya FGD Bypass Line dilakukan FGD bypass, booster fan tidak diperlukan modifikasi : Membuka FGD bypass pada kejadian trip booster fan. 2/7/13

    Ada

    Ketika

    Tujuan

    Dasar Analisa : Runback Unit 4 pada 16/6/2012


    Tripnya
    Booster Fan 4B Trip Runback Sequence commenced : ID Fan 4B, PA Fan 4B, FD Fan 4B Trip Unit Load Reduced to 40 % Load

    Booster Fan 4B menyebabkan Runback, dengan mentripkan ID fan 4B, PA Fan 4B, dan FD Fan 4B. dengan Logic Existing

    sesuai

    2/7/13

    Filosofi Proteksi Boiler


    Konfigurasi

    FD FAN 2x50% PA FAN 2x50%

    fan boiler adalah 2x50% eksiting ; Tripnya salah satu dari 3 fan utama (IDF , PAF, & FDF & BUF) akan mematikan fan lainnya dan menurunkan 2/7/13 beban unit

    BOILER

    ID FAN 2x50 %

    Kontrol

    Booster Fan 3A Trip

    Runback Sequence not Permitted due to ID Fan 3A & 3B Damper In manual Mode (Loss Power) Furnace Pressure & Booster Fan Inlet Pressure Increase Booster Fan Inlet pressure high alarm activated FGD Bypass Damper 3A Open Furnace Pressure & Booster Fan Inlet Pressure Normalized

    Justifikasi Modifikasi OLD 16/6/2012 sama, Pada hari yang


    Booster Fan 3A Juga mengalami Trip
    Karena

    FGD Bypass Damper 3B Open Booster Fan 3B Trip Unit Full Load Maintained (684 MW Gross)

    ada gangguan electrical pada damper ID fan, maka ID fan tidak bisa trip, sehingga runback permit tidak terpenuhi ini menyebabkan Tekanan Inlet Booster Fan 2/7/13 tinggi, dan FGD bypass

    Hal

    Unit Full Load

    Single Booster Fan Trip

    Filosofi Kontrol Booster Fan & Unit Load (OLD)


    Both Booster Fans Trip Runback Permit? Yes

    Tripnya

    Runback Permit? Yes 1st layer protection Trip single train of ID Fan, PA Fan, FD Fan. No

    Booster fan inlet pressure increase 2nd layer protection FGD Bypass Open (after 35s integration time) Unit Load Maintained -PROVED Unit Runback (Risk of Main 40% Load Fuel Trip due to 35s integration time)

    1st layer protection Trip Both train of ID Fan, PA Fan, FD Fan, & Main Fuel Trip

    No

    Booster fan inlet pressure increase

    1 Booster Fan akan menyebabkan Runback Unit (1st Layer Protection)

    2nd layer protection FGD Bypass Open (after 35s integration time) POSSIBLITY of Unit Trip Unit Load Maintained (Risk of Main Fuel Trip due to 35s integration time)

    Apabila

    Runback tidak memungkinkan , Maka FGD 2/7/13 Bypass damper

    Kesimpulan Kontrol Booster Fan Eksisting (OLD)Eksisting Tidak Optimal dari sisi Kontrol
    mempertahankan beban Unit
    Posisi

    1st dan 2nd Layer Protection perlu dibalik FGD bypass damper akan menaikkan emisi SO2, namun regulasi KLH cukup toleran (750 mg/Nm3 24 hours average) Kontrol Booster fan dapat 2/7/13

    Dibukanya

    Optimasi

    Unit Full Load

    Single Booster Fan Trip

    Both Booster Fans Trip

    1st layer protection FGD Bypass damper forced open ? After 5 seconds, FGD Bypasss damper A&B still fully closed? No

    1st layer protection FGD Bypass damper Open ?

    DCS Logic Modificatio n Trip Booster


    fan akan memicu dibukanya FGD Bypass

    Yes

    2nd layer protection Booster Fan Runback Operate 1 Train of ID, PA, FD Fan Trip

    After 5 seconds, FGD Bypasss No damper A&B still fully closed? 2nd layer Yes protection Booster Fan Runback Operate 1 Train of ID, PA, FD Fan Trip

    Apabila

    Unit Load Maintained

    Unit Runback 40% Load

    Unit Load Maintained

    Possibility of Unit Trip

    FGD Bypass A&B masih tertutup 5 detik setelah Booster Fan trip, 2/7/13 maka

    DCS Ladder Diagram Modification Part 1


    A to B IF BUF A trip OR BUF B TRIP THEN Bypass damper Forced Open B
    Point

    A
    2/7/13

    DCS Ladder Diagram Modification Part 2


    Point

    A to B IF after 5 Second from BUF A OR BUF B Trip AND FGD Bypass A AND FGD Bypass B Closed THEN Booster Fan Runback Operate

    2/7/13

    Implementation and Testing


    Implementasi Testing

    modifikasi dilakukan di Unit 3

    dilakukan Pada Beban 361 MW nett @ 14/9/2012 test dengan melakukan trip booster

    Metode

    fan A

    2/7/13

    Hasil Test
    FGD

    Bypass A&B : Berhasil langsung Terbuka Pressure : Vakuum Normal MW : Normal

    Boiler

    Generator SO2

    CEMS : Normal

    2/7/13

    2/7/13

    Kesimpulan Modifikasi
    Kontrol

    Eksisting booster fan dititikberatkan untuk emisi. DCS efektif untuk optimasi kontrol Booster Fan guna menjaga beban unit di saat booster fan trip emisi dalam batas toleransi peraturan KLH (SO2 750 mg/nm3 2hrs average) Booster Fan Trip Harus
    2/7/13

    Modifikasi

    Naiknya

    Penyebab

    Terima Kasih
    There is no knowledge that is not power -Ralph Waldo Emerson

    2/7/13

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