DWITAMA, Akbar and Widayat, Widayat and Utomo, M.S.K. Tony Suryo (2023) PENGARUH JUMLAH PLUGGING TUBE HIGH PRESSURE FEEDWATER HEATER TERHADAP EFISIENSI PLTU 400 MW. Masters thesis, UNIVERSITAS DIPONEGORO.

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Abstract

Feedwater heater berfungsi memanaskan air umpan pada PLTU menggunakan uap ekstraksi dari turbin, sehingga efisiensi dalam pembangkit listrik meningkat, biaya produksi lebih rendah, meningkatkan kinerja serta mengoptimalkan penggunaan energi di dalam PLTU. PLTU Suralaya mempunyai 7 feedwater heater diantaranya tiga low pressure feedwater heater (LPH 1, 2 dan 3), sebuah deaerator dan tiga high pressure feedwater heater (HPH 5, 6 dan 7). HPH 5 telah mengalami penambalan sebanyak 480 dari 1579 tubes. Penambalan pada tube yang mengalami kebocoran adalah perbaikan sementara sehingga feedwater heater tetap bisa beroperasi. Jika jumlah penambalan tube mencapai batas maksimum yaitu 30,02%, maka opsi retubing feedwater heater harus dilakukan guna mengembalikan keandalan feedwater heater. Selanjutnya nilai efektifitas dan penurunan tekanan pada HPH 5 serta efisiensi unit pembangkit dihitung dan dianalisis dengan variasi jumlah penambalan tube 0%, 10%, 20% dan 30%. Nilai efektifitas menunjukkan penurunan dengan semakin naik beban & persentase penambalan tube HPH 5 sedangkan nilai penurunan tekanan menunjukkan kenaikan selaras dengan kenaikan persentase penambalan tube HPH 5 dan beban unit. 3. Efisiensi unit pembangkit mengalami penurunan selaras dengan kenaikan persentase plugging tube HPH 5. Hal ini menyebabkan kenaikan net plant heat rate unit pembangkit dimana bahan bakar yang diperlukan bertambah banyak dengan beban unit yang sama. Selain itu perhitungan kelayakan ekonomi dilakukan untuk opsi investasi retubing HPH 5 ketika mencapai penambalan tube 10%, 20% dan 30%. Hasil perhitungan menunjukkan opsi yang paling direkomendasikan adalah melakukan retubing HPH 5 ketika penambalan tube mencapai 20%, dimana berpotensi penghematan batubara sebanyak 50,07 Juta ton. Perlu adanya perencanaan yang sistematis dan teratur dalam melakukan retubing HPH 5 demi memastikan performa dan kehandalan peralatan HPH 5 selalu optimal serta efisiensi unit pembangkit dapat dipertahankan.
Kata Kunci: Feedwater heater, Penambalan tube, Efektifitas, Penurunan tekanan, Efisiensi, Retubing HPH, Kelayakan ekonomi

The function of a feedwater heater is to heat the feedwater in a thermal power plant using extracted steam from the turbine, therefore improving plant efficiency, reducing production costs, and optimizing energy utilization. The Suralaya thermal power plant has seven feedwater heaters, including three low-pressure feedwater heaters (LPH 1, 2, and 3), one deaerator, and three high-pressure feedwater heaters (HPH 5, 6, and 7). HPH 5 has undergone 480 tubes plugging out of 1579 total tubes. The tube plugging is a temporary repair to ensure that the feedwater heater can continue operation. If the maximum tube plugging limit of 30.02% is exceeded, the retubing of the feedwater heater should be considered to maintain its reliability. The effectiveness and pressure drop of HPH 5, as well as the plant efficiency, are analyzed with variations in tube plugging percentages of 0%, 10%, 20%, and 30%. The effectiveness value decreases with an increase in both the load and percentage of plugging, whereas the pressure drop increases in tandem with the percentage of tube plugging and load. The efficiency of the power plant decreases with an increase in tube plugging, leading to an increase in net plant heat rate, resulting in more fuel being required for the same unit load. Additionally, an economic feasibility analysis was conducted for the retubing investment option at a 10%, 20%, and 30% tube plugging threshold. The results show that the most recommended option is to retube HPH 5 when the tube plugging reaches 20%, with potential savings of 50.07 million tons of coal. Proper planning and systematic retubing of HPH 5 are essential to guarantee optimal performance and reliability of the equipment, and thereby maintain plant efficiency.
Keywords: Feedwater heater, Tube plugging, Effectiveness, Pressure drop, efficiency, Retubing HPH, Economic feasibility

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