Analisa Dampak Program Pigging Terhadap Peningkatan Performa Unit Hrsg Cogeneration Plant

Ibadurrahman, Ibadurrahman (2026) Analisa Dampak Program Pigging Terhadap Peningkatan Performa Unit Hrsg Cogeneration Plant. Masters thesis, Institut Teknologi Sepuluh Nopember.

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Abstract

Peningkatan performa Heat Recovery Steam Generator (HRSG) merupakan factor penting dalam menjamin keandalan suplai uap dan listrik pada fasilitas Cogeneration Plant di industri minyak dan gas. Akumulasi deposit CaCO₃ di dalam tube HRSG menurunkan efisiensi perpindahan panas dan mengancam integritas mekanis sistem. Penelitian ini mengevaluasi dampak program pigging terhadap performa HRSG Unit 2 pada kasus pigging terakhir tahun 2017, melalui dua pendekatan yang saling melengkapi yaitu perhitungan efisiensi ASME PTC 4.4 untuk mengukur penurunan performa, dan simulasi Computational Fluid Dynamics (CFD) untuk menjelaskan mekanisme perpindahan panas dan risiko kegagalan tube. Data operasi diperoleh melalui PI ProcessBook, sedangkan simulasi CFD menggunakan ANSYS dengan pendekatan Conjugate Heat Transfer. Hasil penelitian menunjukkan pigging meningkatkan efisiensi termal HRSG dari 83,99% menjadi 85,24%, naik 1,25%, dan turun menjadi 83,67% setelah tujuh tahun tanpa pigging. Trending temperatur firing Duct Burner 2 terbukti efektif sebagai indicator diagnostik fouling. Simulasi CFD menunjukkan outlet temperature flue gas meningkat dari 431°C menjadi 566°C pada scale 0,1 inch, dengan kenaikan temperatur dinding tube row 3-4 dan 7-8 berkorelasi dengan kebocoran aktual 2021. Kedua hasil ini menjadi dasar penentuan interval pigging optimal yang mempertimbangkan performa produksi dan keandalan tube
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Maintaining Heat Recovery Steam Generator (HRSG) performance is critical for reliable steam and electricity supply in oil and gas cogeneration plants. CaCO₃ deposits inside HRSG tubes degrade heat transfer efficiency and threaten the system's mechanical integrity. This study evaluates the impact of pigging on HRSG Unit 2 performance during the 2017 pigging, through two complementary approaches: ASME PTC 4.4 efficiency calculations to quantify performance loss, and Computational Fluid Dynamics (CFD) simulation to explain the underlying heat transfer mechanism and tube failure risk. Operational data were acquired through PI ProcessBook, while CFD simulations used ANSYS with a Conjugate Heat Transfer approach. Results show that pigging improved HRSG thermal efficiency from 83.99% to 85.24%, a 1.25% increase, before declining to 83.67% after seven years without pigging. Duct Burner 2 firing temperature trending proved effective as a diagnostic indicator for fouling. CFD simulations show flue gas outlet temperature rising from 431°C to 566°C at 0.1-inch scale thickness, with elevated wall temperatures at rows 3-4 and 7-8 correlating with actual tube failures in 2021. Together, these results provide a basis for an optimal pigging interval balancing production performance and tube reliability.

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Cogeneration Plant, HRSG, pigging, efisiensi termal Cogeneration Plant, HRSG, pigging, thermal efficiency
Subjects:	T Technology > T Technology (General) > T57.5 Data Processing T Technology > TJ Mechanical engineering and machinery > TJ223.P76 Programmable controllers
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21101-(S2) Master Thesis
Depositing User:	Ibadurrahman Ibadurrahman
Date Deposited:	29 Jul 2026 19:59
Last Modified:	29 Jul 2026 19:59
URI:	http://repository.its.ac.id/id/eprint/141177

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