Studi Numerik Pengoperasian Air Cooled Heat Exchanger Pada Pelumas Generator Secara Seri Dan Paralel Untuk Peningkatan Kehandalan Gtg#1.3 Up Muara Karang

Kurniawan, Aris (2021) Studi Numerik Pengoperasian Air Cooled Heat Exchanger Pada Pelumas Generator Secara Seri Dan Paralel Untuk Peningkatan Kehandalan Gtg#1.3 Up Muara Karang. Masters thesis, INSTITUT TEKNOLOGI SEPULUH NOPEMBER.

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Abstract

Pembangkit Listrik Tenaga Gas dan Uap (PLTGU) Muara Karang blok 1 mulai beroperasi komersial tahun 1992. PLTGU Muara Karang blok 1 mempunyai kapasitas total 506 MW, terdiri dari PLTG berkapasitas 3 x 107 MW (GE MS9001E) ditambah turbin uap berkapasitas 185 MW. Peralatan utama yang digunakan pada PLTGU antara lain adalah turbin gas, HRSG (heat recovery and steam generator) dan turbin uap dan generator. Pada 12 Oktober 2012 dilakukan penggantian generator pada turbin gas 1.3, penggantian ini memiliki beberapa perbedaan dengan generator unit lain terutama pada sistem pendingin pelumas bearing generator yang terpisah dengan sitem pendingin turbin gas. Sistem pendingin pelumas generator pada turbin gas 1.3 dengan cara mengalirkan pelumas di dalam tube dan dihembuskan udara dari sisi luar tube. Alat pendingin pelumas disebut air cooled heat exchanger (ACHE) yang telah beroperasi selama 9 tahun. ACHE telah mengalami penurunan kehandalan karena menyebabkan unit trip sebanyak 5 kali, berdasarkan analisis menggunakan fishbone diagram penyebabnya berasal dari kegagalan pengoperasian fan. Dari penelitian-penelitian terdahulu tentang ACHE dapat diduga bahwa cooling capacity di ACHE pelumas generator GTG#1.3 mengalami kurang maksimal dan tingkat kehandalannya rendah ketika terjadi kegagalan pengoperasian fan. Penelitian ini bertujuan untuk 1). mengetahui cooling capacity Air Cooled Heat Exchanger pelumas generator GTG#1.3 kondisi existing, 2). mengetahui pengaruh modifikasi variasi jumlah fan yang beroperasi terhadap cooling capacity, pressure outlet dan temperature outlet pelumas dengan susunan paralel dan seri Air Cooled Heat Exchanger Pelumas Generator GTG#1.3, 3). mengetahui pola pengoperasian Air Cooled Heat Exchanger Pelumas Generator GTG#1.3 yang paling optimal. Penelitian ini dilakukan dengan memodelkan dan mensimulasikan ACHE sesuai dengan dimensi aktual menggunakan software Computational Fluid Dynamic (CFD). Simulasi tersebut akan dilakukan validasi dengan data aktual operasional. Hasil yang diharapkan dari simulasi numerik ini adalah diperoleh pengoperasian yang optimal dan handal ACHE sehingga dapat dijadikan referensi untuk pengoperasian aktual pada generator GTG#1.3. Hasil penelitian menunjukkan bahwa pengoperasian ACHE seri dengan pengoperasian 4 fan memiliki kapasitas pendinginan tertinggi yaitu 247.57 kW sehingga suhu pelumas outlet ACHE sebesar 312,02 K dan tekanan outlet ACHE sebesar 169341 Pa. Oleh karena itu untuk mendapatkan keandalan dan pengoperasian yang optimal maka dipilih model pengoperasian ACHE seri dengan pengoperasian 4 fan dan apabila 1 fan mengalami kegagalan operasi masih mampu menjaga temperatur pelumas oulet ACHE sebesar 315.31 K. Batasan temperatur maksimal pelumas outlet ACHE sebesar 320 K dan batasan tekanan minimum pelumas outlet ACHE sebesar 150000 Pa. Pengoperasian ACHE seri dengan 4 fan membutuhkan biaya pengoperasian cukup besar dibandingkan dengan pengoperasian model lain yaitu sebesar Rp. 189,741,600 tetapi hal tersebut sebanding dengan kehandalannya untuk mempertahankan unit pembangkit untuk tetap operasi. ==================================================================================================== Muara Karang Block 1 Gas and Steam Power Plant (PLTGU) started commercial operations in 1992. Muara Karang PLTGU block 1 has a total capacity of 506 MW, consisting of a 3 x 107 MW PLTG (GE MS9001E) plus a steam turbine with a capacity of 185 MW. The main equipment used in the PLTGU includes a gas turbine, HRSG (heat recovery and steam generator) and a steam turbine and generator. On October 12, 2012, the generator was replaced on a gas turbine 1.3, this replacement has several differences with other generator units, especially in the generator bearing lubricating cooling system which is separate from the gas turbine cooling system. Generator lubricant cooling system in gas turbine 1.3 by flowing lubricant in the tube and blowing air from the outside of the tube. The lubricant cooling device is called an air cooled heat exchanger (ACHE) which has been operating for 9 years. ACHE has experienced a decrease in reliability because it causes the unit to trip 5 times, based on an analysis using a fishbone diagram the cause comes from the failure of the fan operation. From previous studies on ACHE, it can be assumed that the cooling capacity in ACHE GTG#1.3 generator lubricant is less than optimal and the level of reliability is low when fan operation failure occurs. This study aims to 1). knowing the cooling capacity of Air Cooled Heat Exchanger for GTG#1.3 generator lubricant existing conditions, 2). determine the effect of the modification of the number of fans operating on cooling capacity, outlet pressure and temperature outlet lubricants with parallel and series arrangement of Air Cooled Heat Exchanger Generator Lubricant GTG#1.3, 3). knowing the optimal operation pattern of the GTG#1.3 Generator Lubricant Air Cooled Heat Exchanger. This research was conducted by modeling and simulating ACHE according to the actual dimensions using Computational Fluid Dynamic (CFD) software. The simulation will be validated with actual operational data. The expected result of this numerical simulation is that the optimal and reliable operation of ACHE can be obtained so that it can be used as a reference for the actual operation of the GTG#1.3 generator. The results showed that the operation of the ACHE series with the operation of 4 fans had the highest cooling capacity of 247.57 kW so that the ACHE outlet lubricant temperature was 312.02 K and ACHE outlet pressure was 169341 Pa. Therefore, to obtain reliability and optimal operation, the ACHE series operating model is selected with the operation of 4 fans and if 1 fan fails the operation is still able to maintain the ACHE outlet lubricant temperature of 315.31 K. The maximum temperature limit for ACHE outlet lubricant is 320 K and the minimum pressure limit for ACHE outlet lubricant is 150000 Pa. The operation of the ACHE series with 4 fans requires quite a large operating cost compared to the operation of other models, which is Rp. 189,741,600 but this is comparable to its reliability to maintain the generating unit to keep operating.

Item Type: Thesis (Masters)
Uncontrolled Keywords: air cooled heat exchanger (ACHE), cooling capacity, Computational Fluid Dynamic (CFD) air cooled heat exchanger (ACHE), cooling capacity, Computational Fluid Dynamic (CFD)
Subjects: T Technology > T Technology (General) > T57.62 Simulation
T Technology > TJ Mechanical engineering and machinery > TJ263 Heat exchangers
Divisions: Faculty of Industrial Technology and Systems Engineering (INDSYS) > Mechanical Engineering > 21101-(S2) Master Thesis
Depositing User: ARIS KURNIAWAN
Date Deposited: 24 Aug 2021 03:26
Last Modified: 24 Aug 2021 03:26
URI: https://repository.its.ac.id/id/eprint/89770

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