Boiler Station Research Articles

Identifikasi Bahaya Dan Penilaian Risiko Di Stasiun Boiler Menggunakan Metode Hirarc Di Pt.Kim Nagan Raya

Hazard identification and risk assessment at the PT.KIM Boiler Station is an effort to prevent work accidents for operators. The problems encountered when operating the equipment were that 2 operators suffered injuries due to bursts of fire, cuts, exposure to Boiler ash, and experienced noise disturbances, this could have occurred due to the operators' disobedience in using personal protective equipment (PPE). The aim of this research is to identify risk hazards at Boiler stations using the HIRARC method at PT.KIM Nagan Raya. This type of research is qualitative in nature which uses a natural setting for the purpose of interpreting phenomena that occur and is carried out by being involved in finding narrative images that give rise to the impact of a person's actions. The research was conducted at PT.KIM to 5 informants, of which the main informants were 3 operators at the Boiler Station, 1 Health Safety Environment (HSE) person as a key informant, and 1 process assistant as a supporting informant. Data collection techniques were carried out by observation and in-depth interviews, data analysis used the HIRARC method. The research results obtained from risk assessment using the HIRARC method with the Risk Matrix table show that a medium risk presentation of 60% is categorized as moderat , a low risk presentation of 20% is categorized as low , and a high risk presentation of 20% is categorized as high. The conclusion of the research is that at the Boiler Station, it was found that there were work accidents at a medium level of 60%, while at a low level it was 20% and at a high level it was only 20%, so it can be concluded that there are indications of work accidents occurring, and this will increase if Boiler Station operators do not use Personal Protective Equipment (PPE). The suggestion is that PT.KIM can implement the SOP optimally in using Personal Protective Equipment (PPE).

Identifikasi Potensi Bahaya pada Stasiun Boiler Menggunakan Metode Hirarc di PT. Syaukath Agro

PT Syaukath Agro is a company operating in the Agribusiness Sector which is engaged in processing palm oil Fresh Fruit Bunches (FFB) into crude palm oil (CPO), Palm Kernel (PK) and shells. The palm oil processing system consists of several stages starting from receiving Fresh Fruit Bunches (FFB) to becoming palm oil or Crude Palm Oil (CPO). The palm oil processing process can be used in several stages carried out at each station. Based on interviews conducted, each station has a different level of risk of accidents, one of the stations that has a large risk of work accidents is the boiler station which is the heart of a palm oil factory where the steam boiler is the source of power and the source of the steam that will used to process palm oil. Boilers have potential dangers or risks when operated. The risks that often occur are falls, slips, burns, scalds, heat, noise, so it is very important to supervise and provide guidance regarding work safety. The size of the accident caused will certainly have a detrimental impact on the company. The severity of the accident can be determined through identification of potential dangers and risk assessment of all boiler operating activities at PT. Syaukath Agro. Based on the results of research conducted using the hirarc method, potential hazards found in boiler stations include: Unergonomic Working Attitudes, Noise Levels >84 dB with 8 Hours/Day Exposure, Working climate temperature (hot) 31°C on exposure >8 working hours/day, and oil buildup. Types of risk of work accidents at boiler stations consist of: Falls, injuries (slipping, slippery floors) Burns (in contact with hot objects around), Heat exhausting (Heat), Work accidents (fatigue ), hearing loss (noise), blisters (burns), health problems (muscles, bones), contact dermatitis (exposed to dangerous toxic radiation). Based on the results of risk control, it was found that the most appropriate type of control recommendation is administrative control and compliance with the use of personal protective equipment (PPE). Administration (Administration Control) is carried out by creating or providing a work system that can reduce the possibility of someone being exposed to potential dangers. The hierarchy of control of Personal Protective Equipment (PPE) is used to provide a boundary between exposure to the body and the potential danger received by the body.

Technical Analysis of Erection in Pilot Plant Industries at Industrial Vegetable Oil or Industrial Lauric Oil

One source for improving the economy of the green fuel industry is to replace the conventional raw material CPO/CPKO (in this case, formerly processed into RBDPO) with the special palm oil IVO/ILO (industrial vegetable oil or lustrial linoleic oil). The technical aspects to be discussed are the selection of technology, production capacity and production plan, mass balance, production process description, technical equipment specifications, and availability of raw materials, including mechanical and electrical analysis. The abbreviation for the results of this study is that the raw material used is CPO/CPKO, and the product produced is IVO/ILO, which will be used as green fuel material. The process selected is the selection of the production process. IVO/ILO refers to the process of production of CPO, and RBDPO refers to the SNI standard or specification 8875:2020. Its production capacity is 10 tph, the TBS raw material requirement is +540–700 tons per day, and the energy requirement for wood work stations such as reception stations, thresher stations, pressing stations, clarification stations, seed processing stations, and earthquake amps stations Boiler Station and Bleaching Station reach 266.6 KW, where electricity and steam energy are obtained from fiber raw materials and palm fruit shells.

Analysis of the Potential Hazards of Work Accidents Department of Production Using Failure Mode Effect Analysis (FMEA) and Fault Tree Analysis (FTA) Methods in PT. XYZ

PT. XYZ is a company engaged in the business of white crystal sugar with raw sugar cane in Jombang. As the industrial world develops, companies are required to produce products both in terms of quality and quantity. Therefore, the production process has the potential to experience work accidents. To minimize this from happening, this research identified the potential hazards of work accidents in the production division. The methods used are the Failure Mode Effect Analysis (FMEA) and Fault Tree Analysis (FTA) methods. Using the FMEA method produced 3 potential hazards with the highest RPN values namely potential for exposed hot ashes at the boiler station with an RPN of 33,716. In second place is the potential collapse of the crane at the mill station with RPN 27,192. Then in third place is the potential Explosion of pipes and tanks at the evaporation station with an RPN value of 23.549. With the FTA method, the 3 potential hazards that have been obtained are used as top events and an analysis is carried out to find out the root causes of the potential accidents that occur. The analysis is grouped from human, equipment, and environmental aspects. From the human factor, it is known that the cause was workers who were not concentrating, were negligent, and did not comply with SOPs. The equipment factor comes from the age of the old tool and lack of maintenance. As well as environmental factors, namely high temperature pressure and humidity which can have an impact on corrosion of iron equipment. So that the suggestions that can be given to companies are imposing sanctions on employees who do not comply with the rules, providing job training according to their respective fields, and scheduling regular machine maintenance.

Design of an automated electro-mechanical shredder-grid-door positioner for online setting adjustments

The design of an automated electro-mechanical shredder-grid-door positioner and its components, programming, installation and commissioning are presented in this paper. The positioner can be used to vary the shredder grid setting, and so preparation to assist processing soft cane varieties through the milling train. A second purpose is to work with shredder drives (such as steam turbines) of limited power to avoid stalling the drive, which can result in factory stops. The driver for this design has been concerns in recent years that some cane varieties in the development pipeline have a fibre quality classified as soft, with some soft enough to cause processing problems in the factory. The main issues have been feeding of the cane through the milling train and high bagasse moisture, causing subsequent combustion issues and low steam pressure at the boiler station. These cane varieties are usually designated as ‘soft canes’, and their presence has been noted as far back as 60 years ago. Trials were carried out at Isis Central Mill to understand and improve the processing of existing soft cane varieties. The automated shredder-grid-door positioner was installed during October of the 2021 crushing season so that full factory trials could be carried out, including automated grid positioning. The positioner was made up of a master/slave configuration with two 5 t power jacks driven by servo gear motors controlled by two inverters.

Characterisation of physical properties of prepared cane from soft-cane varieties

Concerns have been raised that many sugarcane varieties in the development pipeline, particularly in the Central and Southern regions of Australia, have fiber quality classified as soft, with some soft enough to cause processing problems in the factory. The main issues have been feeding off the cane through the milling train and high bagasse moisture contents, causing subsequent combustion issues and low steam pressure at the boiler station. These cane varieties are usually designated as ‘soft-canes’, and their presence had been noted for at least 60 years. An attractive trait is their relatively high sugar yield per hectare. Some other general characteristics have been reported as often (but not always) having relatively low fiber content and being easier to prepare by the shredder, resulting in a larger number of smaller sized particles in the prepared cane. During the development of new cane varieties, Sugar Research Australia carries out tests for ‘fiber quality’. Experiments were carried out at Isis Central Mill to understand and improve the processing of existing soft-cane varieties. During the 2019 crushing season, a pilot-scale shredder was used to simulate the effect of shredder settings (speed and grid setting) that are known to affect preparation levels. Four existing soft-cane varieties (SRA1A, SRA4A, SRA11A and QN04-1643) were tested, along with Q208A that provided a reference as a middle-of-the-range variety (perceived to be neither a soft nor hard cane). The prepared cane produced was tested for fiber quality at the SRA fiber quality laboratory in Bundaberg. As measured at the factory, the preparation level and two physical properties (compression and permeability) were identified as important for the milling process. All the cane varieties responded similarly to speed and grid setting, with the soft-canes being part of a continuum, not a separate subset. The overall conclusion was that adjusting shredder speed and grid setting can control preparation and potentially address feeding problems at the milling train through improved control strategies.

Relayout of Palm Coconut Factories in West Sumatera

One of the plantation companies and palm oil mills in West Sumatera is part of the group and makes a positive contribution. In one of the palm oil factories in West Sumatra, there is a problem with the flow of the work process, where there is an accumulation of products of different sizes in the factory area. This hinders the product transfer process. In addition, this situation will affect the use of the land area. Therefore, it is necessary to consider how to make or change the layout of facilities more effectively and efficiently. An activity Relationship Chart will be used as a method to make recommendations for the layout design of palm coconut factories. The flow of the crude palm oil production process from the proposed layout design weighs the car and bunches of fresh fruits before heading to isolation until the bunches of ripe fruits are stored in the storage tank before being transferred to the transport car. Based on the proposed layout redesign, the management of the oil palm mill can consider improving the placement of the area in the boiler station, as well as the placement of production not too far from the production process.

KAJIAN PENGENDALIAN RESIKO KESELAMATAN DAN KESEHATAN KERJA DENGAN METODE HAZARD INDENTIFICATION RISK ASSESSMENT AND RISK CONTROL ( HIRARC ) DI PT. LANGKAT NUSANTARA KEPONG

PT. Langkat Nusantara Kepong is one of the KSO companies engaged in the oil palm plantation business. In carrying out the operational activities of one PKS unit, PT. Langkat Nusantara Kepong is supported by more than 100 workers who interact directly with machines and other work equipment. Every workplace contains a high potential for hazards, so a prevention and control effort is needed to prevent work accidents. The occurrence of work accidents is caused by the actions of people who do not comply with work safety (unsafe actions) and environmental conditions or processes from unsafe systems (unsafe conditions). Hazard Identification Risk Assessment and Risk Control (HIRARC) is an effort to prevent work accidents and OHS risks. This research was conducted using a qualitative descriptive method which describes the identification and assessment of work risks. Data collection regarding identification and risk assessment was analyzed with HIRARC. HIRARC Results at PKS Gohor Lama PT. Langkat Nusantara Kepong that the highest number of risk levels is at the boiler station.

THE EFFECT OF CHEMICAL ADDITION FACTORS ON EXTERNAL WATER PURIFICATION WITH MICROSOFT EXCEL APPLICATION

<em>This study aims to see the influence of chemical addition factors such as Alum, Soda ash, and Flocculand in external water treatment on water purification that will be used in processing in palm oil mills does not form scale / sediment on the walls, especially at boiler stations / boilers. This study was conducted in the laboratory using jartes with each triplo experiment / 3 times with the addition of a predetermined chemical dose and seen the turbidity / level of clarity and recorded processed into data. Then the results of the recapitulation of the research data obtained will be processed using</em> the <em> statistical analysis method using the complete random design (RAL) method of 3 factorials and continued with the results of the anova / fingerprint test table and the data processing will use the help of the Microsoft Excel application. From the results of the research obtained using the RAL (Complete Random Design) method 3 factorials the result that the influence of the addition of alum and flocculant chemicals will have a real effect on water purification which means </em> that the <em>Fhitung > Ftabel </em> value, <em>then Ho is rejected, alum and flocculants have the function of forming flocs that aim to precipitate dirt so that the water can be purified, it is very dominantly needed, While on the addition of chemical soda ash with the result of the decision obtained F count 0.186746989 < F table 3.168245967 So it can be concluded that Ho is accepted at the real level of ά. which means that the treatment has no real effect on the observed response. This is because soda ash has a function that can only be used as a pH regulator for the water to be purified in the palm oil mill.</em>

Ecological and chemical safety assessment of RDF as alternative fuel for boiler stations

In this paper, an ecological and chemical safety assessment of using RDF (Refuse-derived fuel) is considered. It is shown that production and consumption wastes, including combustible unclaimed fractions of secondary material resources from household solid waste, which have undergone preliminary sorting and preparation, in terms of grinding and cleaning from non-combustible inert materials, are used as raw materials for its manufacture. It has been established that it is expedient to use this type of fuel during thermal decomposition (pyrolysis) with a working temperature of about 1200-1500 °C, since at this temperature all substances pass into the composition of flue gases. Installation "Mark 1" is proposed, which can be used in boiler station for burning RDF. The technological scheme and the principle of operation of the proposed installation are described. An assessment of the impact of the operation of this installation on the environment was carried out. It is shown that the concentrations of pollutants from the heating system, according to the protocol for measuring quantitative chemical analysis (QCA) of emissions into the atmosphere at control points at a distance of 25 meters from the mouth of the boiler station pipe, using the example of pilot tests of RDF, do not exceed the MPC. Thus, the ecological and chemical safety of RDF is confirmed and its use in combustion plants equipped with swirling-type furnaces is justified.

ANALISA DAN REDESAIN SPROCKET ASSEMBLY CONVEYOR RAKE C2 DI STASIUN KETEL PG NGADIREJO

Abstract. In the Ngadirejo sugar plant, sprocket shaft on the east C2 rake conveyor at the boiler station always failure every year. This conveyor is used for the process of fuel dregs supply at the boiler station. In this research, the analysis of failure and fatigue with the finite element method in Ansys will be carried out. The material analyzed is HQ705 with static loading. The analysis carried out includes static structural analysis and fatigue analysis on the sprocket shaft. Based on this analysis, found that the maximum displacement is 0.001163 m, the maximum equivalent stress is 71.8 MPa, the minimum life is 17.237 cycles, the maximum shear stress is 38.44 MPa, the minimum safety factor is 0.557744. The failure in the FEM analysis results in accordance with the actual failure location. The redesign process was carried out with HQ709 material, with this material the minimum life value is 50539 cycles.

ANALISA PERFORMA KERJA STERILIZER OF CRUDE PALM OIL

Boiling is one of the main factors that determine the success of the palm oil production process. Palm oil processing mills obtain Crude Palm Oil (CPO) through a boiling process at the sterilizer station to separate loose fruit and empty fruit, which will then be pressed into CPO. Boiling at the sterilizer station used is saturated steam with a pressure of 1.5-3 bar which is injected from the back pressure vessel (BPV). The selected boiling system is always adjusted to the ability to provide steam at the boiler station that produces steam. In this case, the supply of steam is considered sufficient, so that the boiling system used is the Triple Peak system, and the boiling time is ± 90 minutes.

ANALISIS INTERVAL PEMELIHARAAN KOMPONEN KRITIS UNIT FUEL CONVEYOR DENGAN PENDEKATAN RELIABILITY CENTERED MAINTENANCE (RCM

The scheduling of the machine maintenance system is a system that can assist companies in preventing machine damage which results in disrupted production processes. Corrective treatment methods have not been able to guarantee a smooth production process. This research will plan preventive maintenance activities to increase the reliability of production machines using the Reliability Centered Maintenance (RCM) approach. The result shows the highest downtime was boiler station with a percentage of 22.25%. The machine that works at the boiler station which has the highest level of damage was the fuel conveyor 2 with a percentage of 35.10%. The critical components which are the root causes of the highest damage problems in the fuel conveyor 2 machine were electromotor, chain coupling, and gearbox. In the electromotor, chain coupling, and gearbox components, preventive maintenance scheduling based on the results of each simulation were when t = 158, t = 190, and t = 67, respectively. The results of critical component maintenance scheduling indicated the achievement of the reliability value from before. After doing preventive maintenance, the reliability value of each component increased by 12%, 32%, and 8%, respectively. The frequency of periodic inspection every month on electromotor, chain coupling, and gearbox components were at least 4 times, 3 times, and 10 times, respectively. Keywords: downtime, maintenance, preventive maintenance. reliability, scheduling

Research and Application of Double-Reheat Boiler in China

The ultra-supercritical (USC) double-reheat technology is an immediate area of research focus in China, since the thermal efficiency of USC double-reheat unit is higher than the USC single-reheat unit. The parameters and capacity of USC double-reheat unit in China have made major breakthroughs, and the thermal efficiency of the units are as high as 47–48%, which is the highest in the world. USC double-reheat boiler is one of the most important devices for USC double-reheat unit, and the design concept and precision have a vital effect on the operation of boiler and power station. The most difficult and important factors in the design of double-reheat boiler are the layout of heating surface and the steam temperature regulation method. Therefore, this work summarizes the arrangement of heating surface and temperature regulation method of existing double-reheat boiler in China. It is hoped that the work will set a benchmark for the development of double-reheat boiler and the future 700 °C power generation unit in the world.

ANALISIS FAKTOR YANG BERHUBUNGAN DENGAN KEPATUHAN PEKERJA MENGGUNAKAN ALAT PELINDUNG DIRI

The implementation of occupational health and safety among the industrial circle and society in Indonesia is still relatively low, thus resulted in an occupational accident. Preventive attempts or anticipation for occupational accidents can be conducted by fostering habituation of order, discipline, and maintaining a healthy and safe environment through worker compliance to Personal Protective Equipment (PPE). The use of Personal Protective Equipment will safeguard the workers from potential hazards in the workplace. This research aims to find factors related to worker compliance in using Personal Protective Equipment in Madubaru Inc. Yogyakarta. This research is correlation research with the cross-sectional approach. The sample in this research are 86 workers, in steam boiler station and milling obtained using purposive sampling. Data collection is conducted through the Personal Protective Equipment compliance questionnaire. Additionally, data analysis is performed using a correlation analysis test with chi-square with a confidence level of 95 % (α= 0.05). The finding of this research showed that 76. 7 % of workers did not comply with the utilization of PPE. All variables were not related to the worker compliance in using PPE that is age (p-value 0. 942), education (p-value 0. 300), the length of employment (p-value 0. 077), employment status (p-value 0. 797), knowledge (p-value 0. 961), attitude (p-value 0. 780), motivation (p-value 0. 487), supervision (p-value 0.674), and PPE availability (p-value 0.222It can be concluded that individual characteristics, knowledge, attitude, motivation, supervision, and availibility had no significant correlation with PPE compliance in Madubaru Inc. Yogyakarta.

Dynamics Characteristics Analysis on Shaft Sprocket Assembly of Rake Conveyor

Every year, the Ngadirejo sugar factory encounters the same issue: The sprocket shaft of the eastern C2 rake conveyor at the boiler station fails. This conveyor is used to transfer bagasse from the mill to the kettle. As a result, when one of these components fails, the manufacturing process will be delayed. Static analysis was performed on a failing shaft in prior research, but the life cycle of the shaft was still relatively long. In this research, by employing HQ705 shaft materials, the modal and random vibration on the sprocket shaft was analyzed to determine the cause of this failure further. The analysis was carried out by using Ansys to implement the finite element method. This model used 8523 nodes and 4118 elements in the mesh. For modal analysis, as the number of orders increased, so did the frequency. The fourth and fifth-order vibrations included torsional vibration, with the most complex form, among others, with frequencies of 3061.6 and 3283.1 Hz. Maximum equivalent stress and maximum shear stress occurred at the exact location for static and random vibration analysis. The analysis is relevant to the actual failure that happened in reality. HIGHLIGHTS One of the common problem in the sugar company rake conveyor is failure in the sprocket shaft of the eastern C2 rake conveyor at the boiler station Modal and vibration analysis conducted in order to find the dynamic behaviour of the sprocket shaft rake conveyor Maximum equivalent stress and maximum shear stress occur on the same location for static, modal and random vibration analysis. Those analysis is relevant with the real failure that has been occur in the reality GRAPHICAL ABSTRACT

Simulation of CO2 Gas Adsorption Process Flow at Cyclone Gas Outlet in Palm Oil Mills Using Computation Fluid Dynamic Simulation

Cyclone separator is equipment used to control emissions from gas flow in industrial processes. The principle of removing particulates from the gas flow in this tool is to use the centrifugal force. The centrifugal force generated from the rotating flow will make dust particles wasted into the cyclone wall where the dust will then fall into the hopper. Adsorption is a series of processes for the accumulation of a substance (adsorbate) on the surface of another substance (adsorbent). Adsorption can occur because of the energy on the surface and the attraction force on the surface. This study aims to obtain a good CO2 adsorption efficiency from modifying the cyclone separator using an adsorption column, analyzing the CO2 gas adsorption process produced from the biomass system at the utility unit boiler station at the Palm Oil Mill (PMO) using a modified cyclone. This simulation was carried out using the Autodesk Inventor Professional 2017 (Student Version) application for the descripction of the tool as a preprocessor and Ansys 2019 R3 (Student Version) applications as a processor and post processor. The variations that were applied included the adsorption column bed height of 3100 mm and 4650 mm, respectively, CO2 gas flow rates of 10, 12.5, 15, 17.5, 20, 22.5 dan 25 m/s and mass loading 0,001 kg/s. The results obtained in the most optimal modification of the cyclone separator are at a bed height of 3100 mm with the highest adsorption percentage 93.437%, the highest flow 91.974% with a pressure drop of 1000 Pa.

An Improved Method of Serial Balancing of Hybrid Boiler Station Systems

This paper presents a prototype of a thermo-hydraulic distributor for a hybrid boiler station supplying a small hotel in Koszalin. The task of the device was to balance the hybrid system with four circuits with different operating parameters, also changing in an extremely irregular manner. A prototype of a thermo-hydraulic distributor with improved internal structure was developed, ensuring the operation of the device in accordance with the temperature logic. Dimensions of the device have been calculated in accordance with the existing design principles of hydraulic distributors.

Alternative boiler station - a new form for investments in heat supply

Alternative boiler station - a new form for investments in heat supply

USULAN PERBAIKAN SISTEM MANAJEMEN KESELAMATAN DAN KESEHATAN KERJA (SMK3) SEBAGAI UPAYA MEMINIMALISIR ANGKA KECELAKAAN KERJA MENGGUNAKAN METODE HAZOP (Studi Kasus : PT. XYZ)

PT. XYZ is a company engaged in oil palm plantations and processing with its main commodity is the oil palm plantations (Elais Queineensis Jack). In 2018, thare are several occupational safety and health problems naamely occupational accidents experienced by special employees in the production processarea. The purpose of this study is to detemine the types of work accidents, the types of hazards created based on the risk materics. This study begins by identifying Hazard and risk and then looking for potential sources of occuptional hazard so that harm can be done using the Hazard and Operability Study (HAZOP) method. The research results have been carried out based on the process (Crude Palm Oil) found 8 sources of potential danger between : Loding Ramp Station, Sterilizer Station, Tippler Station, DigesterStation, Press Station, Clarification Station, Kernel Stationdan Boiler Station, then risk assessment : low risk, medium risk, high risk and extreme risk.