Studi Analisis Kerusakan Tube Area Waterwall Boiler Akibat Hydrogen Damage Pada Pltu Batubara

Kustiawan, Agung Sidang (2020) Studi Analisis Kerusakan Tube Area Waterwall Boiler Akibat Hydrogen Damage Pada Pltu Batubara. Masters thesis, Institut Teknologi Sepuluh Nopember.

Preview	Text 02111750078020 Agung Sidang Kustiawan.pdf Download (7MB) | Preview
	Text 02111750078020-Master_Thesis.pdf Download (7MB)

Abstract

Boiler merupakan salah satu peralatan utama dalam PLTU berbahan bakar batubara yang berfungsi untuk mengubah air umpan boiler (demin water) menjadi uap panas (superheated dan reheated steam). Uap hasil produk dari boiler ini digunakan sebagai penggerak turbin uap untuk memutar generator listrik. Pada boiler PLTU Banten Suralaya kondisi tube area water wall sering mengalami kebocoran yang diindikasikan dari hydrogen damage sejak tahun 2011-2019. Dampak kebocoran tube boiler menyebabkan kerugian yang besar terutama losses produksi. Kerugian dari kebocoran tube adalah menurunkan penilaian kinerja PLTU antara lain mengurangi nilai EAF (Equivalent Availability Factor) dan menaikkan nilai EFOR (Equivalent Force Outage Rate). Dari tingkat frequency kebocoran tube dan dampak kerugian yang besar, perlu dilakukan studi dan analisis secara menyeluruh pada tube water wall boiler PLTU Banten Suralaya. Hal ini bertujuan untuk memastikan sumber penyebab permasalahan dan metode pencegahan agar tidak berulang. Metode pengujian untuk menganalisis kerusakan tube menggunakan uji tensile, uji hardness, uji SEM (Scanning Electron Microscopes), uji struktur micro dan uji XRD pada deposit yang terbentuk. Data operasi dan maintenance dan referensi pendukung dipergunakan memperkuat hasil penelitian dan rekomendasi yang diberikan. Dari hasil penelitian diperoleh bahwa kerusakan tube boiler disebabkan oleh hydrogen damage. Hydrogen damage yang terjadi dipicu dari kebocoran tube kondensor yang menyebabkan penurunan kualitas air boiler akibat kontaminan air laut. Penurunan kualitas air boiler berupa penurunan nilai PH dan kenaikan kadar sodium yang melebihi batasan. Sodium pada air boiler akan merusak magnetit layer pada internal tube boiler. Akibat kerusakan magnetit layer sodium akan bereksi dengan pearlite dan membentuk metana (CH4) yang berdifusi ke batas butir. Difusi metana (CH4) ke batas butir menyebabkan terbentuk nya micro void dan micro crack dan menurunkan kekuatan tube. Kondisi ini dapat divalidasi dari penurunan sisi hardness sisi dalam tube baik tube yang rusak dan tube sample area boiler. Dari penelitian didapatkan bahwa kondisi tube boiler area water wall secara keseluruhan telah mengalami indikasi hydrogen damage. Dampak kondisi ini perlu dilakukan pemantauan parameter operasi terkait kualitas air dan kondisi pembakaran secara menyeluruh pada boiler untuk mengurangi potensi terjadi nya kebocoran tube boiler.
===============================================================================================================================
The boiler is one of the main equipment in the coal-fired power plant which functions to convert boiler feed water (demin water) into hot steam (superheated and reheated steam). Steam products from this boiler are used as a steam turbine drive to turn an electric generator. In Banten Suralaya power plant boilers the condition of the water wall tube area often experiences leaks that are indicated from hydrogen damage since 2011-2019. The impact of boiler tube leakage causes large losses, especially production losses. The disadvantage of leakage tubes is to reduce the performance evaluation of PLTU, among others, reducing the value of EAF (Equivalent Availability Factor) and increasing the value of EFOR (Equivalent Force Outage Rate). From the frequency of tube leakage and the impact of large losses, a thorough study and analysis need to be done on the Suralaya Banten PLTU tube water wall boiler. This aims to ensure that the source of the problem and prevention methods are not repeated. Test methods to analyze tube damage using tensile test, hardness test, SEM (Scanning Electron Microscopes) test, microstructure test and XRD test on the formed deposit. Operation and maintenance data and supporting references are used to confirm the results of the study and the recommendations given. From the results of the study, it was found that the damage to the boiler tube was caused by hydrogen damage. Hydrogen damage that occurs is triggered by condenser tube leakage which causes a decrease in boiler water quality due to seawater contaminants. A decrease in boiler water quality in the form of a decrease in PH value and an increase in sodium levels that exceeds the limit. Sodium in boiler water will damage the magnetite layer on the internal boiler tube. As a result of damage to the sodium, layer magnetite will react with pearlite and form metana (CH4) which diffuses to the grain boundary. The diffusion of metana (CH4) to the grain boundary causes the formation of microvoids and micro-cracks and reduces the strength of the tube. This condition can be validated by a decrease in the hardness of the inner side of the tube, both the damaged tube and the boiler area sample tube. From the research, it was found that the condition of the tube boiler area of the water wall as a whole has experienced an indication of hydrogen damage. The impact of these conditions requires monitoring of operating parameters related to water quality and overall combustion conditions on the boiler to reduce the potential for boiler tube leakage.

Item Type:	Thesis (Masters)
Additional Information:	RTM 621.183 Kus a-1
Uncontrolled Keywords:	Boiler, water wall, hydrogen damage, sodium
Subjects:	T Technology > TJ Mechanical engineering and machinery > TJ263.5 Boilers (general)
Divisions:	Faculty of Industrial Technology > Mechanical Engineering > 21101-(S2) Master Thesis
Depositing User:	Agung Sidang Kustiawan
Date Deposited:	06 Mar 2025 06:48
Last Modified:	06 Mar 2025 06:48
URI:	http://repository.its.ac.id/id/eprint/75335

Actions (login required)

View Item