Pengaruh Lapisan Oksida Terhadap Remaining Life Tube Boiler PLTU Suralaya

Purwadi, Diki (2021) Pengaruh Lapisan Oksida Terhadap Remaining Life Tube Boiler PLTU Suralaya. Masters thesis, Institut Teknologi Sepuluh November.

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Abstract

Boiler adalah sistem utama untuk mengubah energi pembakaran dari batubara menjadi energi uap di pembangkit listrik. Berdasarkan histori pada kasus pembangkit yang menjadi objek penelitian diketahui terjadi 3(tiga) kali kegagalan tube boiler yang disebabkan oleh overheating karena lapisan oksida. Dalam rezim creep seperti di superheater dan reheater, ketebalan lapisan oksida di internal tube akan mempengaruhi perpindahan panas yang dapat menyebabkan overheating dan mempengaruhi umur tube. Dalam tesis ini, dilakukan analisis tentang pengaruh lapisan oksida terhadap sisa umur tube. Metode yang digunakan yaitu tahap pertama adalah pengumpulan data terkait pertumbuhan oxide dengan metode non destruktif dan insitu aktual pengukuran, yang kedua adalah identifikasi mekanisme kegagalan dan pengambilan sampel dari tube yang gagal dengan melakukan pengujian laboratorium meliputi Visual Test, chemical composition test, Hardness Test, Microstructure Test, Deposit Test, serta creep test dan yang terakhir menggunakan hasil pengukuran dari uji laboratorium dan insitu pengukuran untuk mensimulasikan prediksi sisa umur akibat lapisan oksida dalam hal ini diambil kasus secondary superheater (SSH out). Berdasarkan analisis diketahui bahwa lapisan oksida yang terbentuk merupakan akibat dari temperatur, waktu operasi, dan juga pola operasi boiler. Tube yang beroperasi diatas 200.000 jam dengan temperature < 575ᵒC ketebalan lapisan oxide tumbuh sekitar 300 - 500 micrometer, sedangkan yang beroperasi pada temperature > 575ᵒC lapisan oxide dapat tumbuh >900 micrometer. Tube yang hanya mengalami penipisan, usia tube dapat melebihi 200.000 jam operasi, namun jika terjadi kombinasi antara penipisan dan overheating akibat adanya oxide, umur tube menjadi 93% lebih pendek serta probabilitas kegagalan akan lebih besar sekitar 97% jika tube boiler mengalami penipisan dan degradasi material. Hasil penelitian yang diperoleh dapat diaplikasikan sebagai pertimbangan pengambilan keputusan life cycle boiler area superheater dan selanjutnya dapat digunakan sebagai guideline operasi dan pemeliharaan di dunia pembangkit dalam menjaga keandalan dan mengendalikan umur tube boiler.
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Boilers are the main system for converting combustion energy from coal into
steam energy in power plants. Based on the history of the case of the generator which
is the object of research, it is known that there have been 3 (three) tube boiler failures
caused by overheating due to the oxide layer. In creep regimes such as in superheaters
and reheaters, the thickness of the oxide layer on the internal tube will affect heat
transfer which can cause overheating and affect tube life. In this thesis, an analysis of
the effect of the oxide layer on the remaining life of the tube is carried out. The method
used in the first stage is collecting data related to oxide growth with non-destructive
methods and actual in-situ measurements, the second is identifying the failure
mechanism and taking samples from the failed tube by conducting laboratory tests
including Visual Test, chemical composition test, Hardness Test, Microstructure Test,
Deposit Test, and creep test and the last one uses the measurement results from
laboratory tests and in situ measurements to simulate the prediction of remaining life
due to the oxide layer, in this case, the secondary superheater (SSH out) case is taken.
Based on the analysis, it is known that the oxide layer formed is the result of
temperature, operating time, and also the boiler operating pattern. Tubes that operate
above 200,000 hours with temperatures < 575ᵒC, the thickness of the oxide layer
grows about 300 - 500 micrometers, while those that operate at temperatures > 575ᵒC
the oxide layer can grow >900 micrometers. Tubes that only experience thinning, tube
life can exceed 200,000 hours of operation, but if there is a combination of thinning
and overheating due to the presence of oxide, the tube life will be 93% shorter and the
probability of failure will be greater around 97% if the boiler tube experiences
thinning and material degradation. The results obtained can be applied as
consideration for decision making in the life cycle boiler area for superheater and can
then be used as a guideline for operation and maintenance in the world of power plants
in maintaining reliability and controlling the life of the boiler tube

Item Type:	Thesis (Masters)
Uncontrolled Keywords:	Kegagalan Boiler, Lapisan Oksida, Temperature Operasi, Umur Tube
Subjects:	T Technology > TJ Mechanical engineering and machinery > TJ263.5 Boilers (general)
Divisions:	Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21101-(S2) Master Thesis
Depositing User:	Diki Purwadi
Date Deposited:	24 Aug 2021 07:18
Last Modified:	25 Aug 2021 09:01
URI:	http://repository.its.ac.id/id/eprint/89916

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