Boiler Feed Research Articles

Analisa Keandalan Instrumentasi Boiler Feed Pump Menggunakan Metode Failure Mode and Effect Analysis (FMEA) di PT.PLN Nusantara Power UP Tenayan

<p><em> </em><strong>PT. PLN Nusantara Power UP Tenayan is a company operating in the power generation sector and focuses on operating PLTUs Tenayan, Indonesia. One part of the machine that influences the operation of the generator is the boiler feed pump. Lack of optimal boiler feed pump instrumentation often results in failure in operating activities. This research uses the Failure Mode and Effect Analysis (FMEA) method with the research objective of finding out the causes of failures that occur, identifying the type of failure, and determining the RPN value and the impact that occurs. The analysis results, it shows that the Boiler Feed Pump instrumentation components still meet operating standards because the Risk Priority Number (RPN) value is below 200, even though the Speed Sensor has a fairly high RPN value but is still in the reliable category, the result of identifying the type of failure that occurs is that the indicator reading is not actual, the component is not functioning, the highest RPN value for the Boiler Feed Pump component is the Speed Sensor component with an RPN value of 160 and the lowest RPN value is for the pressure indicator component with an RPN value of 30. The most important recommended action for the Speed Sensor component is to carry out maintenance for 1 month very.</strong></p><p><strong><em>Keywords</em></strong> – <em>Boiler Feed Pump, FMEA, Keandalan, Pembangkit, RPN.</em></p>

Oxygen corrosion of reboiler tube served in production of dilution steam from heat exchanger of petrochemical refinery

This paper reports the oxygen corrosion of heat exchanger tubes serviced in dilute steam generation system. The floating head heat exchanger employed in a petrochemical industry underwent remnant corrosion failures particularly at lower passes of tube bundle. Initially remote field eddy current inspection technique was employed for tube bundle conditional assessment and further, root cause of degradation of tube had been analyzed. Comprehensive experimental techniques including visual examination, tube chemistry analysis, external tube surface morphological analysis, elemental mapping, scanning electron microscopy, light microscopy and x-ray diffraction studies were employed. The tube surface at the degraded position with its cross sectional examination was rigorously evaluated as well. Moreover, actual steam parameters such as pH, conductivity and iron & chloride concentration have been monitored in the petrochemical facility. The detailed analysis concluded that dissolved oxygen in boiler feed water (BFW) was the root cause for corrosion failure. Several other foreign elements were detected and source of each element was discussed in the context of actual heat exchanger operating conditions. Simulated conditions of BFW service have electrochemically been evaluated in two different dissolved oxygen concentrations at 7.5 ppm and 12.7 ppm, respectively. Even small increase of dissolved oxygen in BFW could lead to promotion of oxygen reduction reaction. Theoretically SA179 tubes operated at pH of 9.75 could lead to formation of bicarbonate and it could protect the tube in absence of dissolved oxygen as evaluated by Molecular Dynamics simulation. However, according to obtained results, tube has been degraded due to presence of dissolved oxygen in BFW. Various contributing factors such as external paint/coat removal, absence of de-aerator system in BFW treatment and improper corrosion inhibitor programme were discussed. Several practical countermeasures have been suggested to mitigate oxygen corrosion failure in petrochemical refineries.

Evaluation of Boiler Feed Water Quality in Tofu Industry UD. FIT in Bocek Village

The UD FIT industry, situated in Bocek Village, Karangploso District, operates as a tofu factory employing modern equipment, including a fire tube boiler. The quality of feed water utilized in the boiler is essential for optimizing its efficiency. This study aimed to analyze the boiler feed water sourced from household wells at UD FIT's tofu factory, using various indicators such as turbidity, iron content, total dissolved solids (TDS), hardness, and pH levels. The test results revealed a temperature of 26°C, TDS of 253 mg/L, turbidity of 4.74 NTU, iron content of 1.123 mg/L, hardness of 180.5 mg/L, and pH of 7.89, with no detectable odor, color, or taste. Based on these findings, it is concluded that the boiler feed water utilized by UD FIT generally meet the quality standards, except for the pH parameter, which is not in accordance with the standard.

Effect Analysis of Boiler Feed Water and Exhaust Gas Turbine Generator against Steam Products

Effect Analysis of Boiler Feed Water and Exhaust Gas Turbine Generator against Steam Products

Production of sustainable methanol from aquatic biomass via thermal conversion route

Energy security is considered a basic need for the community. The development of a non-competing energy source is necessary to maintain harmony when fulfilling energy and food needs. Aquatic biomass such as algae is a promising sustainable energy source as it can be cultivated in the sea or pond which does not require productive land. By using thermal reaction, algae can be converted into methanol via gasification followed by hydrogenation reactions. The key challenge of algae utilization lies in the high moisture content. This work presents an understanding of the role of moisture on the algae for methanol production. Although moisture content has a negative impact on the syngas quality, the methanol production does not change with increasing moisture content. Under the optimum condition, the algae-to-methanol route converts ∼45% of the total energy input into energy in the form of methanol. The production of one-ton methanol from algae with 10 wt% moisture requires algae (2.7 ton), oxygen (0.9 ton), boiler feed water (1.5 ton), thermal energy (12.1 GJ) and electricity (0.7 MWh). The present work provides a clear understanding of the potential of aquatic biomass for methanol production, leading to further development to achieve a feasible algae-to-methanol route.

PERANCANGAN POMPA SENTRIFUGAL BERKAPASITAS 50,6 L/MENIT UNTUK PEMANFAATAN AIR DARI STEAM TRAP SEBAGAI AIR UMPAN BOILER

Condensate water is the result of condensing steam which has decreased in temperature and pressure due to losses from the environment. Steam trap used to separate water or dew from steam resulting from a decrease in temperature. This condensate water has a temperature of 50°C. Based on the results of condensate water testing from steam trap it has permissible criteria for boiler feed. In the existing conditions, the boiler feed water requirement is 500 liters/hour with a temperature of 25°C, while the water produced from steam trap of 230 liters/hour so that to be able to meet the needs of boiler feed water, a pump designed with a capacity of 50.6 liters/minute is needed. The purpose of this research is to design a pump to utilize steam trap water as boiler feed water. Materials are selected according to requirements and standards. Condensate water from the steam trap becomes the initial parameter for calculating Head, NPSH, Impeller Diameter, and Shaft Diameter. NPSH available must be greater than NPSH request to prevent pump cavitation, which can cause damage or loss. Based on the calculations, the NPSH req value is smaller than the NPSH available, which is 4.62 m < 11.48 m. The total head is 7.97 meters, and the number of blades is 7. The design dimensions obtained are the impeller inner diameter of 29.47 mm, outer diameter of 72.58 mm, shaft diameter of 6 mm, casing diameter of 76.215 mm.

Exergy analysis and Exergetic sustainability index of package boiler

Energy is one of the basic human needs. Economic growth and population growth in a country which continues to increase is directly proportional to the growth in energy needs required by society. Indonesia is the largest energy user in Southeast Asia, namely more than 36% of Southeast Asia's primary energy use. Utilization of the energy used will reduce the increase in production costs for an industry. The use of energy is better known as energy conservation. Energy and exergy analysis based on the first and second laws of thermodynamics is used to analyze the thermal system of industrial units. This can be applied to equipment units in the fertilizer industry to identify sources of inefficiency, determine their location and the amount of exergy destruction that occur. To reduce exergy destruction, this can be done by modifying the operating conditions of the package boiler. The results show that 94.3% of the total exergy destruction from the boiler package is obtained from the evaporator component with a value of 2.7 x 108 kJ/hr Modification of the operating conditions of the evaporator is carried out by reducing Boiler Feed Water (BFW) inlet temperature with T 100C (196 – 116 oC). The decrease BFW temperature will increase the amount of required latent heat and reduce the convection heat that will be carried by the flue gas to generate superheated steam. Optimization of the BFW temperature is performed be calculating the flue gas temperature and exergoeconomic analysis. Exergoeconomic analysis is performed by calculating the cost rate of exergy destruction (ĊD,k) and exergoeconomic factor (fk). The results obtained were that the temperature was optimum of BFW is at 161°C which resulted the reduction of exergy destruction of 6,2x106 kJ/hr and resulting difference cost losses based on actual data (196 oC) of Rp 1,370,354,743/hr. Exergetic Sustainability Index (ESI) used to demonstrate how reducing a system's environmental impact can be achieved by reducing its exergy consumption (destruction and losses) or increasing its exergetic efficiency. In this research, ESI Value was achieved at 0.918.

Techno-Economic Study on the Application of Reverse Osmosis Technology in the Process of Boiler Feed Water Demineralization PT Puncak Jaya Power 3x65 MW

The quality of boiler feed water in a Coal Power Plant generation (PLTU) needs to be considered to avoid corrosion and deposits (scale) on process equipment. Decreased water quality causes several disturbances as such disruption of power plant operations and also regeneration of the ion exchange unit is required quite frequently. This study aims to evaluate the performance of boiler feed water demineralization system with the addition of RO unit and the effect of implementing RO system on chemical consumption in demineralizer regeneration process, as well as determine long-term economic benefits. The research was conducted in the demineralization building area of PLTU PT Puncak Jaya Power 3x65 MW, a power plant owned by PT Freeport Indonesia, located in Amamapare Village, Timika, Papua. This research is divided into two phases: technical evaluation based on research data that will be optimized using the Water Application Value Engine® (WAVE) software, and economic evaluation. Good results are obtained by adding an RO unit to the boiler feed water demineralization unit. Its application allows reducing operating costs and implementing higher level water treatment automation. The chosen RO module configuration is 2 stages with 6 vessels, offering several advantages: % recovery = 70%, high average flux = 22.5 Liters/m2/hour, longer membrane life with the additional filter, reduced load in the first stage. The results of the economic evaluation indicate that the reduction in chemical consumption for ion exchange regenerant will yield 218% return on investment (ROI) with an amortization period of two years.

SIMULATION OF BOILER FEED PUMP USING CONTROLLER PROGRAM: A CASE STUDY OF SAPELE POWER BOILER FEED PUMP

The goal of this work is to automate the Sapele Power Plant Boiler Feed Pumps (BFPs) using CODESYS software to simulate BFP controlled by a proposed PLC system that was manually controlled. The boiler pressure, level, feed stream flow, and primary heat transport (PHT) pressure BFP were restored to their optimal levels within a few seconds after trip. This was possible for the standby program used for automation within 14 seconds when compared to the manual process that was in place. During the simulation, the BFP goes into standby mode after 14 seconds. The results obtained under automated condition shows the boiler pressure rises to 40.3 kg/cm-1s-2 and remained stable for 147 seconds as against 55.9 kg/cm-1s-2 in 25 seconds under unautomated conditions. The flow rate of the feed water shows a decrease of -0.172 m at 50 seconds. The boiler pressure rose further to 44 kg/cm-1s-2 at 175 seconds, which corresponds to a specific gravity value of 59.5 kg/cm3 at the same time. At 146 seconds, the feed water hits the trip setting of -2.85m owed to low specific gravity (SG) level when compared to the unautomated condition. Thus, a further increase reached fluctuation level of -10m at 200 seconds. The PHT was 88.5 kg/cm-1s-2 at 146 seconds contrary to the expected pressure of 105.6 kg/cm-1s-2 for unautomated state. This change after 146 seconds results from generator trip. The pressure increases to 90.2 kg/cm3 at approximately 148 seconds and subsequently decreases to 48 kg/cm3 consequently opening of the condenser steam discharge valve (CSDVs) and atmospheric steam discharge valve (ASDVs) during the simulation state.

Waste to Energy

Boiler feed water pumps are at the heart of new energy production.

Design of Fire Risk Estimation Method Based on Facility Data for Thermal Power Plants.

In this paper, we propose a data classification and analysis method to estimate fire risk using facility data of thermal power plants. To estimate fire risk based on facility data, we divided facilities into three states-Steady, Transient, and Anomaly-categorized by their purposes and operational conditions. This method is designed to satisfy three requirements of fire protection systems for thermal power plants. For example, areas with fire risk must be identified, and fire risks should be classified and integrated into existing systems. We classified thermal power plants into turbine, boiler, and indoor coal shed zones. Each zone was subdivided into small pieces of equipment. The turbine, generator, oil-related equipment, hydrogen (H2), and boiler feed pump (BFP) were selected for the turbine zone, while the pulverizer and ignition oil were chosen for the boiler zone. We selected fire-related tags from Supervisory Control and Data Acquisition (SCADA) data and acquired sample data during a specific period for two thermal power plants based on inspection of fire and explosion scenarios in thermal power plants over many years. We focused on crucial fire cases such as pool fires, 3D fires, and jet fires and organized three fire hazard levels for each zone. Experimental analysis was conducted with these data set by the proposed method for 500 MW and 100 MW thermal power plants. The data classification and analysis methods presented in this paper can provide indirect experience for data analysts who do not have domain knowledge about power plant fires and can also offer good inspiration for data analysts who need to understand power plant facilities.

Improving the Quality of Boiler Feed Water Based on the PDCA Cycle by Integrating Seven Tools

A boiler is an equipment that produces steam, which is used as a heater, drives a turbine to produces electricity, and so on. In order to avoid reducing efficiency boilers and save operational costs due to the formation of scale and corrosion on pipes, special treatment is required for boiler water. However, the facts in the field are that many BFW (Boiler Feed Water) products are found that do not meet the quality requirements set by the company. PT. Petrokimia Gresik is an industrial chemical company that uses boilers to assist its production process. The method used in this study is quality control analysis with the PDCA approach and Seven Tools in the form of check sheets, histograms, Pareto diagrams, control charts, fishbone diagrams, and FMEA to identify the factors causing the occurrence of defective products and see the corrective actions that must be taken based on the factors causing the occurrence of defective products. Preventive maintenance was carried out to create and schedule socialization of SOPs, collect data on spare part replacements, and check the chemical content in work unit wastewater. Based on the research results, it reveals that the PDCA approach and Seven Tools can minimize defects and succeed in reducing SO3 and PO4 parameter defects by 67,5%. The proposed improvement efforts include preventive maintenance, monitoring the consistency of SOP implementation, identifying replacement spare parts, as well as checking chemical content in work unit wastewater.

Crown ether functionalized silver nanoparticles for colorimetric detection of alkali earth metals in real boiler feed water samples

Crown ether functionalized silver nanoparticles for colorimetric detection of alkali earth metals in real boiler feed water samples

A Boiler Feed Pump Speed Control to Reduce Its Own Power Consumption According to Pump Affinity Law

The change in water flow required at the BFP pump at the Barru Power Plant is only regulated by a valve located on the pressure side, causing excess power consumption and its own power consumption. One effort to save energy usage is to make frequency adjustments that refer to the right pressure and water flow. To determine the effect of frequency adjustments on the expected pump pressure, a simulation of frequency inverter modeling is performed using the SPWM switching method based on the pump affinity law using Matlab application software. The simulation results obtained that by adjusting the frequency range of the inverter from 45.5 Hz to 50 Hz and keeping the pump pressure above the minimum limit of 13.2 MPa, the operating power savings of the BFP motor are obtained from 46 kW to 378 kW.

Expert System for Control and Maintenance of Steam Package Boiler Drum and Feed Water Using Rule-Based Fuzzy Logic Techniques

Expert System for Control and Maintenance of Steam Package Boiler Drum and Feed Water Using Rule-Based Fuzzy Logic Techniques

Investigation on stall characteristics of marine centrifugal pump considering transition effect

Marine centrifugal pumps are used as boiler feed pumps and condensate pumps in ocean engineering. Centrifugal pump stall is a transient flow structure, which may disrupt the uniformity of the flow field and have destructive effects on the pump. Centrifugal pump simulations are usually limited to the application of turbulence, ignoring the transition characteristics of the blade boundary layer. Aiming at the transient characteristics of centrifugal pump stall vortex, the calculation strategy considering the transition effect is established. This strategy determines the near-wall mesh based on the transition flow parameters and is applied to calculate the centrifugal pump stall for the first time. It is found that at deep stall conditions, the number of stall cells calculated by the transition model increases, while the stall frequency decreases. The microscopic flow structure calculated by the transition model and its relationship with the hump of the centrifugal pump head is obtained. The laminar separation bubbles near the blade leading edge will increase as the flow rate decreases, causing an increase in the friction loss on the blade surface, which lead to a hump in the pump head characteristics. The dynamic mode decomposition (DMD) method is used to extract the characteristic frequencies and corresponding modes of the 0.2Qd condition. In the high-order mode of the stall flow field with transition, a low-pressure zone formed at the head of the blade has a tendency to fall off from the wall, which shows the high-order motion characteristics of the stall vortex. The results could guide centrifugal pump design and operation.

How to extend the lifetime of RO membrane? From the perspective of the end-of-life RO membrane autopsy

The lifetime of reverse osmosis (RO) membranes would be shortened by membrane fouling during the applications, resulting in the generation of a huge number of discarded RO membrane modules each year. To extend the lifetime of RO membranes, in this work, end-of-life RO membranes collected from four typical RO applications, including boiler feed water treatment, water reuse, surface water treatment, and seawater desalination were autopsied to reveal the fouling layer characteristics. The morphologies and primary compositions of the membrane fouling layers were evaluated. It was found that proteins, polysaccharides, and the scales of Si, Fe, and Al presented in all the fouling layers of the analyzed end-of-life RO membranes, while the contents varied depending on the applications. On this basis, the formation process of the fouling layers was revealed; the general and specific lifetime extension strategies of the RO membrane for various water treatment processes were proposed.

Nutrient digestibility, gut microflora, carcass yield, and meat microbiology of broilers fed diets supplemented Ethiopian pepper (Xylopia aethiopica), cloves (Syzygium aromaticum), and their composite

The effect of dietary supplementation of Ethiopian pepper (Xylopia aethiopica) and clove (Syzygium aromaticum) and their composite on nutrient digestibility, gut microflora, carcass yield, and meat microbiology were investigated in a 52-day boiler feeding trial. Three hundred and sixty unsexed Ross broilers were used for the study. Four experimental diets were formulated for the starter (0-28days) and finisher (29-56days) phases: diet 1 was the control without phytogenic supplementation, diet 2 (supplemented with 1% Ethiopian pepper (EP)), diet 3 (supplemented with 1% clove (CL)), and diet 4 (supplemented with 1% mix of equal quantity (0.5% each) of Ethiopian pepper and clove (EPCL)). Each treatment was replicated 6 times with 15 birds per replicate. Nutrient digestibility was determined on days 28 and 56, gut microflora was determined for the small intestine and caecum on day 56, carcass yield, organ weights, and meat microbiology were also determined on day 56. Data obtained were subjected to a one-way analysis of variance using SAS 2000 and significant means were separated using Tukey's test in the same software. At day 28, broilers fed the diet supplemented EPCL had the highest (P < 0.05) dry matter digestibility (DMD, 86.81%) crude protein digestibility (CPD, 71.28%), and ash digestibility (64.24%). Broilers fed EP supplemented diet had reduced (P < 0.05) DMD (70.50%). Increased (P < 0.05) ether extract digestibility (EED) was observed for broilers fed the diet supplemented CL (75.27%) and EPCL (76.43%). Ash digestibility (AD) was lowest (P < 0.05) for broilers fed control diet (50.30%). At day 56, broilers fed the diet supplemented CL and those fed the EPCL supplemented diet had higher (P < 0.05) CPD (78.07%, 79.35%) and EED (70.20%, 71.42%) than other treatments. Ash digestibility was higher (P < 0.05) for broilers fed diet supplemented EPCL (74.60%) than other treatments. Intestinal clostridium count reduced (P < 0.05) and lactobacillus count increased (P < 0.05) in the intestine and caecum of broilers fed the diet supplemented CL and those fed EPCL supplemented diet. Intestinal coliform and salmonella count reduced (P < 0.05) for broilers fed the diet supplemented EP and those fed the EPCL supplemented diet. Dietary supplementation of EPCL resulted in the highest (P < 0.05) body weight (BW, 2551.38g), dressing percentage (DP, 81.68%), and percentage of breast muscle (20.01%). Supplementation of EP, CL, and EPCL in the diet of broilers resulted in higher (P < 0.05) spleen weight while dietary supplementation of EP and EPCL resulted in higher (P < 0.05) thymus weight. Clostridium count was reduced (P < 0.05) in the meat of broilers fed the diet supplemented CL and EPCL and the lowest (P < 0.05) salmonella count was observed in the meat of broilers fed the diet supplemented with EPCL. In conclusion, the current study reveals that dietary supplementation with EP and CL composite improves nutrient digestibility, gut microflora, and dressing percentage with reduced meat microbial load of broilers.

Optimal Matching Method of Structural Parameters of Hydro-mechanical Transmission Device

In this paper, for the hydro-mechanical transmission device with constant speed input and variable speed output, an optimization model is constructed, which takes the structural parameters of the fixed gear train, the rotating gear train, and the circular diameter of the torque converter as the design variables and the weighted comprehensive efficiency as the objective function. The optimization model considers the influence of the change of the stator opening on the original characteristics of the torque converter, and limits the value of the structural parameters of the planetary gear train by the reference value of the transmission ratio of the planetary gear train given in the mechanical design manual, and gives the steps to solve the optimization model by using the search algorithm. The value range of the hydraulic torque converter is limited by reversely calculating the circulation circle diameter of the hydraulic torque converter within the speed range, so as to improve the search efficiency. The optimization model and solution method are verified by taking a boiler feed pump of a thermal power plant as the load.

Failure in power plant system related to mitigations and economic analysis; A study case from steam power plant in Suralaya, Indonesia

The failure mitigation and economic analysis related to the damage of the boiler tube in the power plant system were evaluated in the present study. The research was conducted at Indonesia's Suralaya power plant (PP). The boiler was built in 2011 and experienced a boiler tube failure after operating for less than 5 years. This condition is not common since boilers generally can be used with a lifetime of approximately 30 years. In the present study, different analyses were used i.e., macro-fractography, metallography inspection, hardness test, SEM/XRD analysis, and hydro test. These tests investigated the failure modes, evaluated the tube's mechanical properties, and assessed the boiler water feed's quality. The results showed that the damage is caused by the below-standard quality materials and is triggered by the poor quality of boiler feed water and exhibit corrosion. It is proven that the high value of sodium, conductivity, and silica content causes corrosion of the inner tube, which came out from methane gas. It is also shown that the damage drastically decreased the quality of the water wall tube strength, indicated by the HRV value from 179 HRV to 112 HRV. The analysis was a brief study that can be used for manufacturers and industries that use the boiler to check the material quality and the detailed specification. Moreover, the below-standard materials have proven to cause economic loss and burden many sectors' maintenance and operation costs.