TONAPA, Anton and Widayat, Widayat and Silviana, Silviana (2026) ANALISIS SISTEM REDUNDANT CLOTH BAG FILTER PLTU UNTUK PELUANG PENINGKATAN EFISIENSI PEMBANGKIT. Masters thesis, UNIVERSITAS DIPONEGORO.

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Abstract

Sistem cloth bag filter pada PLTU Tidore merupakan komponen kritis dalam pengendalian emisi partikulat dan menjaga stabilitas operasi pembangkit. Namun, konfigurasi jalur tunggal pada sistem eksisting menyebabkan unit harus dihentikan setiap terjadi kerusakan pada bag filter, mengakibatkan forced outage dengan durasi rata-rata ±96 jam, menurunkan Equivalent Availability Factor (EAF), meningkatkan Maintenance Outage Hours (MOH), dan menambah ketergantungan pada PLTD sebagai pembangkit substitusi. Penelitian ini bertujuan merancang dan mengevaluasi sistem redundant cloth bag filter yang memungkinkan penggantian filter dilakukan tanpa mematikan unit, sekaligus memastikan kenaikan pressure loss tetap dalam batas kemampuan ID Fan eksisting. Metode yang digunakan meliputi pengumpulan data eksisting dari observasi lapangan dan sistem DCS, perhitungan pressure loss menggunakan metode Darcy-Weisbach, serta pemodelan dan validasi melalui Computational Fluid Dynamics (CFD). Analisis dilakukan pada konfigurasi eksisting dan rancangan sistem redundant untuk menilai perubahan rugi tekanan, distribusi aliran, keseimbangan jalur, serta kecocokan terhadap kurva performa ID Fan. Evaluasi lingkungan juga dilakukan untuk menilai kontribusi sistem redundant terhadap pengendalian emisi, termasuk dalam konteks operasi dengan skenario co-firing biomassa. Hasil penelitian menunjukkan bahwa tambahan rugi tekanan akibat konfigurasi redundant sangat kecil: ΔP = 26,04 Pa pada unit 1 dan ΔP = 28,52 Pa pada unit 2. Hasil CFD menghasilkan total pressure loss ≈ 2030 Pa, hanya berselisih 0,07% dari perhitungan manual, sehingga model tervalidasi dan tidak ditemukan recirculation zone signifikan. Tekanan total hasil simulasi (≈2028,52 Pa) masih jauh di bawah kapasitas ID Fan yang mampu menghasilkan hingga 3100 Pa pada debit rendah, sehingga redesign aman tanpa penggantian fan. Implementasi sistem redundant di PLTU Tidore pada 2025 menghasilkan perbaikan performa yang sangat signifikan: MWh losses turun dari 3.632,54 MWh menjadi 0 MWh, MOH turun dari 518,93 jam menjadi 0 jam, EAF naik dari 91,65% menjadi 94,45%, dan SOF turun dari 6,98% menjadi 4,12%. Kesimpulannya, penerapan sistem redundant cloth bag filter pada PLTU Tidore layak secara teknis, operasional, dan lingkungan. Sistem ini terbukti dapat meningkatkan keandalan pembangkitan, mengurangi risiko forced outage, dan memperbaiki performa pengendalian emisi tanpa memerlukan modifikasi besar pada ID Fan, sekaligus membuka peluang optimalisasi efisiensi pembangkit di masa mendatang.
Kata Kunci : Redundant Bag Filter, Pressure Loss, CFD, Keandalan Pembangkit, Emisi Partikulat

The cloth bag filter system at PLTU Tidore is a critical component for particulate emission control and maintaining power plant operational stability. However, the existing single-line configuration requires the unit to be shut down whenever a bag filter failure occurs, resulting in forced outages averaging ±96 hours. This condition reduces the Equivalent Availability Factor (EAF), increases Maintenance Outage Hours (MOH), and heightens reliance on PLTD as a substitute generator. This study aims to design and evaluate a redundant cloth bag filter system that enables filter replacement without shutting down the unit, while ensuring that the additional pressure loss remains within the capacity of the existing ID Fan. The methodology includes data acquisition from field observations and DCS systems, pressure loss calculations using the Darcy–Weisbach method, and modeling and validation through Computational Fluid Dynamics (CFD). Analyses were conducted on both the existing configuration and the proposed redundant system to assess changes in pressure loss, flow distribution, line balancing, and compatibility with the ID Fan performance curve. Environmental evaluations were also performed to assess the contribution of the redundant system to emission control, including under biomass co-firing scenarios. The results show that the additional pressure loss caused by the redundant configuration is minimal: ΔP = 26.04 Pa for Unit 1 and ΔP = 28.52 Pa for Unit 2. CFD simulations indicate a total pressure loss of approximately 2030 Pa, differing by only 0.07% from manual calculations, thus validating the model and confirming the absence of significant recirculation zones. The simulated total pressure (≈2028.52 Pa) remains well below the ID Fan’s capacity, which can reach up to 3100 Pa at lower flow rates, confirming that the redesign is safe without requiring fan replacement. The implementation of the redundant system at PLTU Tidore in 2025 resulted in substantial performance improvements: MWh losses decreased from 3,632.54 MWh to 0 MWh, MOH dropped from 518.93 hours to 0 hours, EAF increased from 91.65% to 94.45%, and SOF declined from 6.98% to 4.12%. In conclusion, the application of the redundant cloth bag filter system at PLTU Tidore is technically, operationally, and environmentally feasible. The system effectively enhances plant reliability, reduces forced outage risks, and improves emission control performance without major ID Fan modifications, while enabling further optimization of plant efficiency in the future.
Keywords: Redundant Bag Filter, Pressure Loss, CFD, Power Plant Reliability, Particulate Emissions

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