Analisis Kondisi HP Superheater Tube HRSG Tanjung Uncang pada Bukaan Fully Open dengan Variasi Mass Flow Steam Menggunakan Simulasi Numerik

Yubelium, Alfandaru Talita (2025) Analisis Kondisi HP Superheater Tube HRSG Tanjung Uncang pada Bukaan Fully Open dengan Variasi Mass Flow Steam Menggunakan Simulasi Numerik. Other thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Pada PLTGU (Pembangkit Listrik Tenaga Gas dan Uap) pasti terjadi siklus CCGT (Combine Cycle Gas Turbine), dan salah satu PLTGU yang menggunakan siklus ini adalah PLTGU Tanjung Uncang, Batam. Siklus CCGT ini juga terjadi di HRSG. HRSG merupakan sistem yang memanfaatkan panas dari gas buang dari gas turbine generator (GTG). Dalam mengoperasikan HRSG tersebut, terdapat standar operasional prosedur (SOP) pada kondisi cold start. Dimana membutuhkan temperatur setidaknya 400oC untuk mengatur gas buang GT. Akan tetapi, turbin gas PLTGU Tanjung Uncang memiliki base load 5 MW dan kisaran temperatur 560oC hingga 580oC. Oleh karena itu, perlu dilakukan pelepasan beban gas turbin atau FSNL (Full Speed No Load) untuk menurunkan inlet temperatur dari gas turbin masing-masing dengan waktu 45 menit, karena ditakutkan apabila flue gas langsung masuk ke HRSG, akan terjadi thermal stress, salah satunya yaitu di tube. Akibatnya, FSNL menyebabkan total kerugian kurang lebih 14,5 miliar rupiah. Hal tersebut melatarbelakangi tujuan dari penelitian ini untuk memodelkan karakteristik aliran dan perpindahan panas yang terjadi pada HRSG, ketika beroperasi pada kondisi fully open. Pemodelan dilakukan menggunakan Solidworks 2024, dan ANSYS Fluent 2022 R1 sebagai aplikasi untuk CFD (computational fluid dynamics). Kemudian, digunakan variasi temperatur 400oC dengan 580oC untuk kondisi fully open, untuk membandingkan thermal stress di HP Superheater tube. Selain variasi temperatur, untuk mengetahui kondisi variasi steam terhadap thermal stress pada HP Superheater tube ketika fully load, maka ditambahkan variasi mass flow steam, yaitu 0.1 kg/s (kondisi kosong), 4.35 kg/s, 8.5 kg/s, 12.75 kg/s, dan 17 kg/s. Hasil yang didapatkan yaitu peningkatan msteam (4-20 kg/s) dan Tsteam (175-456oC) meningkatkan efisiensi perpindahan panas HP SH tube, dengan fluktuasi temperatur berkurang pada flue gas 400oC. pada Tfg 580oC, kondisi msteam rendah (0.1-4 kg/s) berisiko gagal material akibat thermal stress (SIF 54.12 MPa mm). Material SA-213 T91 SAFE (aman) pada 400oC tetapi membutuhkan optimasi pada 580oC, dimana FAIL (gagal) pada msteam rendah (0.1-4 kg/s) dengan Tsteam 100oC hingga 175oC. Optimasi aliran menghasilkan penghematan operasi Rp 6,017,617,021.28 (58.51%)
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In a gas and steam power plant (PLTGU), the CCGT (Combine Cycle Gas Turbine) cycle is always present, and one of the PLTGU facilities that utilizes this cycle is the Tanjung Uncang power plant in Batam. This CCGT cycle also takes place in the Heat Recovery Steam Generator (HRSG). The HRSG system utilizes heat from the exhaust gases of the gas turbine generator (GTG). When operating the HRSG, there are standard operating procedure (SOP) for cold start conditions, which require a minimum temperature of 400oC to manage the exhaust gases from the gas turbine. However, the gas turbine at the Tanjung Uncang power plant hase base load of 5 MW and operates within a temperature range of 560oC to 580oC. Therefore, it is necessary to perform a gas turbine over a period of 45 minutes. This precaution is taken to prevent thermal stress, particularly in the tubes, that could occur if the flue gas were to enter the HRSG directly. As a result, the FSNL process incurs a total loss of approximately 14.5 billion rupiah. This background leads to thye objectives of the research, which is to model the flow characteristic and heat transfer occuring in the HRSG when operating under fully open conditions. The modeling is conducted using Solidworks 2024, and ANSYS Fluent 2022 R1 as the application for computational fluid dynamics (CFD).Variations in the temperature of 400oC and 580oC are used for the fully open condition to compare thermal stress in the high-pressure superheater tubes. Additionally, to understand the effect of varying steam conditions on thermal stress in the high-pressure superheater tubes under full load, variations in steam mass flow are introduced: 0.1 kg/s (empty condition), 4.25 kg/s, 8.5 kg/s, 12.75 kg/s, and 17 kg/s. The results indicate that increasing msteam (4-120 kg/s) and Tsteam (175-456oC) enhances heat transfer efficiency in HP SH tubes, with reduced temperature fluctuations at flue gas temperatures of 400oC. At Tfg 580oC, low msteam conditions (0.1-4 kg/s) pose a risk of material failure due to thermal stress (SIF 54.12 MPa mm). The SA-213 T91 material is SAFE at 400oC but requires optimization at 580oC, where it is FAIL under low msteam (0.1-4 kg/s) with Tsteam ranging from 100oC to 175oC. Flow optimization achieves operational savings of Rp 6,017,617,021.28 (58.51%) loaded.

Item Type:	Thesis (Other)
Uncontrolled Keywords:	Full Speed No load, Heat Recovery Steam Generator, HP Superheater, Thermal Stress, Full Speed No load, Heat Recovery Steam Generator, HP Superheater, Thermal Stress
Subjects:	T Technology > TJ Mechanical engineering and machinery > TJ164 Power plants--Design and construction
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21201-(S1) Undergraduate Thesis
Depositing User:	Alfandaru Talita Yubelium
Date Deposited:	05 Feb 2025 01:01
Last Modified:	05 Feb 2025 01:01
URI:	http://repository.its.ac.id/id/eprint/118254

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