REVERSE ENGINEERING SPARE PART PLTGU TANJUNG PRIOK PT. INDONESIA POWER

PT PLN (Persero) PUSAT PEMELIHARAAN KETENAGALISTRIKAN

LAPORAN PRELIMINARY SURVEY

REVERSE ENGINEERING SPARE PART PLTGU TANJUNG PRIOK PT. INDONESIA POWER

Agustus, 2015


PT PLN PUSHARLIS

Spare Part PLTGU TANJUNG PRIOK

No Dokumen :

DAFTAR ISI 1. 2. 3. 4. 5.

DASAR INVESTIGASI SPARE PART ............................................................. 2 TUJUAN .......................................................................................... 2 LINGKUP PEKERJAAN ........................................................................... 2 LOKASI PEKERJAAN ............................................................................. 2 OVERVIEW FOTO KOMPONEN .................................................................. 2 5.1 Hot Gas Casing (HGC) type GT13E1..................................................... 2 5.2 Inner Combustion Liner................................................................... 4 5.3 C-Segment.................................................................................. 5 6. KAJIAN TEKNIS & HASIL SURVEY .............................................................. 6 6.1 PRELIMINARY SURVEY ..................................................................... 6 6.1.1 SUMMARY.............................................................................. 6 6.1.2 PRELIMINARY SURVEY PROCEDURES ............................................... 6 6.1.3 FINDING DURING PRELIMINARY SURVEY ........................................... 6 6.1.3.1 Hot Gas Chamber (OEM Part & Non-OEM Parts)............................... 6 6.1.3.2 Inner Combustion Liner........................................................... 7 6.1.3.3 C-Segment.......................................................................... 8 7. Metallurgical Investigation .................................................................... 8 8. Validasi Data untuk Design Reverse Engineering dan Lingkup Kerja .................... 8 8.1 Hot Gas Chamber.......................................................................... 8 8.2 Inner Combustion Liner................................................................... 9 8.3 C-Segment.................................................................................. 9 9. General Photos Documentation.............................................................. 10 REFERENSI : .......................................................................................... 13

File: Laporan Survey RE PLTG Tanjung Priok PT Indonesia Power

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Halaman 1 dari 13


PT PLN PUSHARLIS


No Dokumen :

1. DASAR INVESTIGASI SPARE PART Pelaksanaan Investigasi ini berdasarkan surat : Surat PT PLN (Persero) Pusat Pemeliharaan Ketenagalistrikan No. 0171/KIT.02.01/PUSHARLIS/2015 tanggal 28 Juli 2015, perihal Surey Hot Parts PLTGU Tanjung Priok. 2. TUJUAN Tujuan dari pelaksanaan survey ini adalah untuk mengetahui komponen apa saja yang potensial untuk dapat dilakukan proses manufaktur dengan metode reverse engineering. 3. LINGKUP PEKERJAAN Lingkup pekerjaan ini adalah survey spare part PLTU Indramayu yang bersifat fix/stationary atau tetap dan tidak bergerak untuk Turbin Gas Merk Alstom type GT13E1 single burner yang terdiri dari : a. Hot Gas Casing. b. Inner Combustion liner c. C-Segment 4. LOKASI PEKERJAAN PLTGU Tanjung Priok PLN (Persero) Indonesia Power 5. OVERVIEW FOTO KOMPONEN 5.1 Hot Gas Casing (HGC) type GT13E1

Gbr.1 Overview of Hot Gas Casing GT13E1 (Copyright by PT Alstom Power Energy Systems) File: Laporan Survey RE PLTG Tanjung Priok PT Indonesia Power

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PT PLN PUSHARLIS


No Dokumen :

Gbr. 2 Cooling Air Casing Halves, (GT Block Dismantling-Hot Gas Casing & Cooling Air Casing, page: 11-3) Tabel. 1 Indeks gambar 2, Cooling Air Casing Halves figure 1.Hot Gas Casing, Upper 12. Turbine Casing, Lwer 2.Cooling Air Casing, Upper Half 13. Tapered Pin (4 off) 3.Lifting Lug 14. Safety Sleeve 4.Safety Sleeve 15. Expansion Bolt 5.Expansion Bolt 16. Lifting Lug 6.Tappered Pin (4 off) 17. Dowel Pin 7.Lifting Lug 18. Keyway 8.Jacking Bolt (4 off) 19. Bolt 9.Hot Gas Casing, Lower 20. Tab Washer 10. Lifting Lug 21. Dowel Pin 11. Cooling Air casing, Lower 22. Cooling Air Casing


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PT PLN PUSHARLIS


No Dokumen :

5.2 Inner Combustion Liner

Gbr.3 Combustor –General View, (GT Block Dismantling-Combustor, page:4-3) Tabel. 2 Indeks gambar 3, Combustor –General View. 1. Burner and Igniter Assembly 12. Combustor Flange Bolts 2. Platform 13. Inner Liner 3. Combustor Cover 14. Intermediate Liner 4. Swirl basket 15. Lower Combustion Chamber Insert 5. Lower Cone/Upper Cone 16. Support Bolt 6. Finned Segment Unit 17. Finned Segment Support Bolt 7. Upper Combustion Chamber Insert 18. Finned Segment Liner 8. Sight Glass (MBM30 AX004) 19. Middle Platform 9. Outer Casing 20. Flame Monitor(MBM30CR001-003) 10. Sight Glass (MBM30 AX005) 21. Speed Measuring Points (MBM30 11. Pressure Measuring Point (MBM30CP01) CS01-012


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PT PLN PUSHARLIS


No Dokumen :

5.3 C-Segment

Gbr.4 Turbine Vane Carrier Inlet Segment

Gbr. 5 Turbine Vane Carrier

(*all pictures refer to GT Block Dismantling-Turbine Vane Carrier, Page 12-5 and 12-12)

Tabel. 3 Indeks gambar 4, Turbine Vane Carrier Inlet Segment. 1. Spring 2. Pin 3. Inlet Segment 4. Spring 5. Pressure Pin 6. Turbine Vane Casing Tabel. 4 Indeks gambar 3, Turbine Vane carrier 1. Nut 9. Lower Half Casing 2. Guide Rod 10. Lateral Alignment Dowel 3. Upper Half Casing 11. Support Flange 4. Upper Guide Ring 12. Jacking Bolt 5. Heat Shield Segment 13. Lifting Bollard 6. Inlet Segments 14. Dowel 7. Fixed Vanes 15. Expansion Stud 8. Lower Guide Ring 16. Washer


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PT PLN PUSHARLIS

No Dokumen :


6. KAJIAN TEKNIS & HASIL SURVEY 6.1 PRELIMINARY SURVEY 6.1.1 SUMMARY Component Name

Part Identification Check No

Serial No

Hot Gas Casing Inner Combustion Liner C-Segment

Not recorded

Not recorded

1

Not recorded

Not recorded

1

Not recorded

Not recorded

1

Note

Part quantity Part Condition on survey Scrap/ Fallout Scrap/ Fallout New

- Need a new part to check and collect dimensional part for next RE process. - Metallurgical sample test must applied

6.1.2 PRELIMINARY SURVEY PROCEDURES 1. Identification check 2. Disassembling ( If needed) 3. Visual Inspection 4. Dimensional check (if enable) 5. Wall thickness (if enable) 6. Embossing of reverse engineering identification number (if allowable) 7. Wall thickness after sandblasting and locally grinding for welding test (will be applied on material check) 8. Welding test ((will be applied on material check & welding check) 9. Incoming Inspection Report 10. Spare part technical data collecting 11. Maintenance data collecting 12. Operational and performa data sheet collecting 13. General photos documentation 6.1.3

FINDING DURING PRELIMINARY SURVEY

6.1.3.1 Hot Gas Chamber (OEM Part & Non-OEM Parts) Notes : Komponen HGC (Hot Gas Chamber) yang menjadi sample preliminary survey ada 2 set upper & lower chamber OEM PHYSICAL FINDING ON SAMPLE 1. Inside / Corrosion and erosion 2. Rubbing on the Hooks and Collar 3. Welded add. Parts on the Hooks / Collar and Repair welds of Collar 4. Cracks on inner side of Collar File: Laporan Survey RE PLTG Tanjung Priok PT Indonesia Power

Rev : 00

Yes Yes Yes Yes Halaman 6 dari 13


PT PLN PUSHARLIS


No Dokumen :

5. Rubbing on Guide Keys 6.Lower part — erosion and corrosion outside and 7. Flow Separator/ Corrosion, erosion, spallation of TBC 8. Rubbing on Suspension Rings on the Upper and Lower part

Yes Yes Yes Yes

DATA FINDING (Manual, Drawing, OEM Referensi and Literatur) 1. Data referensi untuk kriteria kerusakan Lite/light, Medium dan High tidak ditemukan 2. Data dimensi detail

N/A N/A

6.1.3.2 Inner Combustion Liner Notes : Inner Combustion Liner yang menjadi sample preliminary survey ada 2 set upper & lower chamber. Komponen 1 merupakan komponen OEM yang telah dipakai. Komponen ke 2 merupakan komponen Non-OEM yang telah dipakai. PHYSICAL FINDING ON SAMPLE 1. Inside / Corrosion and erosion 2. Rubbing on the Hooks and Collar 3. Welded add. Parts on the Hooks / Collar and Repair welds of Collar 4. Cracks on inner side of Collar 5. Rubbing on Guide Keys 6. Flow Separator/ Corrosion, erosion, spallation of TBC 7. Komponen Non-OEM memiliki contour ring body pada upper chamber yang tidak sama persis dengan komponen OEM atau lebih kecil DATA FINDING (Manual, Drawing, OEM Referensi and Literatur) 1. Data referensi untuk kriteria kerusakan Lite/light, Medium dan High tidak ditemukan 2. Data dimensi detail


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yes Yes Not checked Not checked Not checked yes Detailed on attachment file

N/A N/A

Halaman 7 dari 13


PT PLN PUSHARLIS


No Dokumen :

6.1.3.3 C-Segment Notes : C-Segment pernah dicoba melakukan rekondisi oleh Non-OEM & OEM namun hasilnya kurang baik. Komponen mengalami deformasi setelah proses rekondisi sehingga sulit untuk diassembly pada turbine vane carrier (clearence assembly berubah). PHYSICAL FINDING ON SAMPLE : (New Sample) 1. Cracks on C-Segment 2. Rubbing on C-Segment 3. Corrosion, erosion, spallation of TBC DATA FINDING (Manual, Drawing, OEM Referensi and Literatur) 1. Data referensi untuk kriteria kerusakan Lite/light, Medium dan High tidak ditemukan 2. Data dimensi detail

No No No

N/A N/A

7. Metallurgical Investigation Tidak ada proses investigasi metallurgi yang dilakukan 8. Validasi Data untuk Design Reverse Engineering dan Lingkup Kerja 8.1 Hot Gas Chamber 1. Data Pemeriksaan Komposisi material 2. Data Pemeriksaan type coating 3. Data Pemeriksaan material coating 4. Data Pemeriksaan ketebalan coating 5. Data Pemeriksaan dan pengujian kekuatan coating 6. Data Pemeriksaan kekuatan lekat coating pada base metal 7. Data Pengujian kemampuan transfer panas 8. Data Pengukuran desain metode scanning 3D modelling 9. Data Pembuatan gambar persection dan Assembly 10. Desain Jig & Fixtures manufaktur 11. Desain Jig & Fixtures Assembly 12. Data flow simulation 13. Data flow laboratrium test 14. Data pengujian impact 15. Data pengujian tarik 16. (detail scope akan disampaikan/proposed)


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PT PLN PUSHARLIS


No Dokumen :

8.2 Inner Combustion Liner 1. Data Pemeriksaan Komposisi material 2. Data Pemeriksaan type coating 3. Data Pemeriksaan material coating 4. Data Pemeriksaan ketebalan coating 5. Data Pemeriksaan dan pengujian kekuatan coating 6. Data Pemeriksaan kekuatan lekat coating pada base metal 7. Data Pengujian kemampuan transfer panas 8. Data Pengukuran desain metode scanning 3D modelling 9. Data Pembuatan gambar persection dan Assembly 10. Desain Jig & Fixtures manufaktur 11. Desain Jig & Fixtures Assembly 12. Data flow simulation 13. Data flow laboratrium test 14. Data pengujian impact 15. Data pengujian tarik 16. (detail scope akan disampaikan/proposed)

8.3 C-Segment 1. Data Pemeriksaan Komposisi material 2. Data Pemeriksaan type coating 3. Data Pemeriksaan material coating 4. Data Pemeriksaan ketebalan coating 5. Data Pemeriksaan dan pengujian kekuatan coating 6. Data Pemeriksaan kekuatan lekat coating pada base metal 7. Data Pengujian kemampuan transfer panas 8. Data Pengukuran desain metode scanning 3D modelling 9. Data Pembuatan gambar persection dan Assembly 10. Desain Jig & Fixtures manufaktur 11. Desain Jig & Fixtures Assembly 12. Data flow simulation 13. Data flow laboratrium test 14. Data pengujian impact 15. Data pengujian tarik 16. (detail scope akan disampaikan/proposed)


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PT PLN PUSHARLIS


No Dokumen :

9. General Photos Documentation

Gbr. 9.1 Intermediate Combustion Liner (a)

Gbr. 9.2 Intermediate Combustion Liner (b)

Gbr. 9.3 Inner Combustion Liner (a) File: Laporan Survey RE PLTG Tanjung Priok PT Indonesia Power

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Halaman 10 dari 13


PT PLN PUSHARLIS


No Dokumen :

Gbr. 9.4 Inner Combustion Liner (b) Non-OEM

Gbr. 9.5 Spesial tool Inner Combustion Liner

Gbr. 9.7 Hot Gas Casing


Gbr. 9.6 Inner Combustion Liner –lower side

Gbr. 9.8 Lower Hot Gas Casing

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PT PLN PUSHARLIS


No Dokumen :

Gbr 9.9 Upper Hot Gas Casing

Gbr. 9.10 C-Segment (a)

Gbr. 9.11 C-Segment (b)

Gbr. 9.11 Rapat pembahasan rencana proses RE di PT Indonesia Power


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PT PLN PUSHARLIS


No Dokumen :

REFERENSI : 1. GT13E1 Gas Turbine Block, Dismantling & Reassembly, GT block dismatling – Combustor. 2. GT13E1 Gas Turbine Block, Dismantling & Reassembly, GT block dismatling - Hot gas & cooling air casing. 3. GT13E1 Gas Turbine Block, Dismantling & Reassembly, GT block dismatling Turbine vane carrier 4. GT13E1 Manual drawing, Appendix 9 - Combustor-Parts List to Appendix 1_ HTCT693054 V0001B. 5. GT13E1 Manual drawing, Appendix 9 - Hot Gas Casing & Cooling Air Casing-Parts List to Appendix 1_HTCT693056 V0003. 6. GT13E1 Manual drawing, Appendix 9 - Turbine Vane Carrier-Parts List to Appendix 1_HTCT693057 V0001A. 7. GT13E1 Material guide, Damage mechanism of GT component. 8. GT13E1 Material guide, FSI TGP - welding split line HGC. 9. GT13E1 Material guide, Super alloy composition. 10. GT13E1 Material guide, Material HGP GT13E1. 11. Inner liner Non-OEM, copyright@SULZER. 12. ABB material design cross reference (DIN Standard). 13. Appendix 3 - GT13E1 Gas Turbine Expected Component Life Time. 14. Laporan Performance Test C Inp GT 1.1 Januari 2015 (copy). 15. General Recondition Process, Inlet Segment GT13E1; Page 15 of 17. 16. General Recondition Process, Performed Test and Quality Checks; Page 17 of 17.


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Halaman 13 dari 13

LAMPIRAN - LAMPIRAN

Combustor - Parts List -

en

HTCT 693 054 V0001 B

Total pages: 26

Fig.1 Combustor Details

2

HTCT 693 054 V0001 B

en

Manufacturer

Type

ALSTOM

GT13E

Drw-Pos

Order-

Designation

Qty

Pos 999

en

Combustion chamber assy, compl., MBM30

1

1

1

Swirler complete

1

2

2

Lower combustion chamber insert

1

3

3

Combustion chamber outer shell, complete

1

4

4

Combustion chamber cover

1

5

5

Bolt

4

6

6

Expansion stud, M24 x 100

80

7

7

Flange

6

8

8

Hex nut M42

96

9

9

Hex head screw, M24 x 90

16

10

10

Hex nut M24

16

11

11

Bush

4

12

12

Bolt

4

13

13

Mounting plate

1

14

14


2

15

15

Flange

4

16

16


28

17

17

Measuring stud, M36 x 180

4

18

18

Hex nut M36

32

HTCT 693 054 V0001 B

3


4

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

25

25


18

26

26

Measuring stud, M42 x 180

2

27

27

Plain washer, M42

20

28

28

Nut M42

20

29

29

Blind cap

4

30

30

Gasket

4

31

31

Support

1

32

32

Locking plate 9/18ST

4

33

33

Pointer thermometer, MBM30 CT001

1

34

34


4

35

35

Holding plate

1

36

36

Pointer thermometer, MBM30 CT002/3

2

37

37

Mounting for thermometer

1

38

38

Socket

3

39

39

Hex nu, M4

9

40

40

Vibration pad

9

41

41

Cable clip

20

42

42

Self tapping screw 3.5 x 9.5

20

43

43

Expansion bolt, M64 x 380

80

44

44

Plain washer, M64

80

45

45

Nut M64

80

46

46

Cap, complete, M64

80

47

47

Gasket 115 x 120 x 1

2

48

48


16

HTCT 693 054 V0001 B

5


6

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

55

55

Hex head screw,F85 M24 x 180

4

56

56

Flame monitor support

3

57

57

Sight glass arrangement

1

58

58

Hex nut 0.8D M20

24

59

59

Gasket

3

60

60

Gasket

3

61

61

Socket head cap screw, M10 x 20

6

62

62


24

63

63

Protection tube

3

64

64

Swivel tube

3

65

65

Gasket 47/33 x 1cu

12

66

66

Hex head blanking screw

12

67

67

Ring

1

68

68

Support

2

69

69

Guide bolt, M64 x 500

2

HTCT 693 054 V0001 B

7

Fig.4 Upper Combustion Chamber Insert

8

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

75

75

Upper combustion chamber insert complete

1

76

76

Upper cone, complete

1

77

77

Lower cone, complete

1

78

78

Guide

1

79

79

Ring

1

80

80

Cover plate

8

81

81

Socket head cap screw MD5

8

82

82

Spring washer 20 ST-NR

8

83

83

Secondary ring

1

84

84

Distance block

16

85

85

Plate

6

86

86

Rib

2

HTCT 693 054 V0001 B

9

Fig.5 Upper Combustion Chamber Insert

10

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

91

91

Pin

1

92

92

Dowel pin

1

93

93

Hex. head bolt M16

12

94

94

Locking plate

12

95

95

Sealing ring

1

HTCT 693 054 V0001 B

11

Fig.6 Finned Segment Frame

12

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

100

100

Frame, complete

1

101

101

Support

6

102

102

Ring

1

103

103

Ring

1

104

104

Ring

1

105

105

Segment

6

106

106

Segment

6

107

107

Segment

6

108

108

Bush

6

109

109

Bush insert

6

110

110

Rib

24

HTCT 693 054 V0001 B

13

Fig.7 Finned Segments

14

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

115

115

Brick inserts complete

116

116

Finned segment

89

117

117

Finned segment

144

118

118

Finned segment

229

119

119

End segment

1

120

120

End segment

1

121

121

End segment

1

122

122

End segment 81 - 120

1

123

123

End segment 30 - 79

2

124

124

Support liner complete

1

125

125


1

126

126


1

127

127


1

128

128


1

129

129


1

130

130

Suspension bracket

36

131

131

Support

40

132

132

Support

30

133

133

Sealing ring D1830

1

134

134

Sealing ring D1876

1

135

135

Sealing ring D1922

1

136

136

Sealing ring D1968

1

137

137

Sealing ring D2014

1

138

138

Distance piece

36

139

139

Distance piece

40

140

140

Distance piece

30

HTCT 693 054 V0001 B

15

Fig.8 Stuffing Box Assembly

16

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

145

145

Stuffing box assembly complete

2

146

146

Locknut 0.5D M72 x 4

1

147

147

Ring

1

148

148

Adjustment nut

1

149

149

Flange

1

150

150

Gland

1

151

151

Ring

1

152

152

Sealing gasket, 8mm, lenght 3m

1

153

153

Stuffing box

1

HTCT 693 054 V0001 B

17

Fig.9 Flame Monitor Assembly

18

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

160

160

Pressure portion, complete

3

161

161

Flame monitor attachment, compl.

3

162

162

Hex head screw, M10 x 12 - 8.8 - A2G

8

163

163

Tabwasher 10.5 - St

8

164

164

Segment

8

165

165

Dowel 4 x 20 - FDST

3

166

166

Cooling pipe

1

167

167

Dowel 4h8 x 40 - St 50k

1

168

168

Hex head screw, M6 x 12 - 8.8 - A2G

2

169

169

Locking plate 6.6/20 - St

1

170

170

Guard plate

1

171

171

Testing pin

1

172

172

Compression spring

1

173

173

Nozzle

1

174

174

Sealing ring

2

175

175

Sealing air flange

1

176

176

Screw plug G1A - 5.8

1

177

177

Copper sealing ring 48/36 x 1

1

178

178

Cylinder screw,F181 M12 - T x 60 - St 460 TS

2

179

179

Socket head cap screw

3

180

180

Washer

4

181

181

Sealing ring

10

182

182

Glass disc

5

183

183

Sightglass holder

1

184

184

Loose flange

1

185

185

Expansion stud, M16 - T x 140

4

186

186

Hex nut M16 - GA

4

HTCT 693 054 V0001 B

19

Fig.10 Sight Glass Mountings

20

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

195

195

Swivel tube

1

196

196

Swivel tube

1

197

197

Guide bush

1

198

198

Support

1

199

199

Sightglass mounting

1

200

200

Sightglass mounting

1

201

201

Sightglass mounting

1

202

202

Segment

1

203

203

Bracket

1

204

204

Locking screw

1

205

205

Guide bush

1

HTCT 693 054 V0001 B

21

Fig.11 Sight Glass Assemblies

22

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

210

210

Sightglass support complete

1

211

211

Sightglass attachment, compl.

3

212

212

Sightglass support

1

213

213

Spacer

1

214

214

Gasket

1

215

215

Expansion stud, M16 - T x 80

4

216

216

Hex nut 0.8D EP, M16

4

217

217

Cooling pipe

1

218

218

Hollow cap nut, M48 x 2

1

HTCT 693 054 V0001 B

23

Fig.12 Lower Combustion Chamber Insert

24

HTCT 693 054 V0001 B

en

Drw-Pos

Order-

Designation

Qty

Pos

en

230

230

Liner

1

231

231

Liner

1

232

232

Liner

1

233

233

Nozzle complete

8

234

234

Guide

3

235

235

Key

3

236

236

Support

4

237

237

Bolt

4

238

238

Bush

4

239

239

Ring

4

240

240

Rib

8

241

241

Rib

8

242

242

Bush

1

244

244

Strut

12

245

245

Bracket

12

HTCT 693 054 V0001 B

25

Blank page

26

HTCT 693 054 V0001 B

en

C

Lng. Status Rev. Released

C

Hot Gas Casing & Cooling Air Casing GT13E1 M

9560 HTCT693056

Dept. Document No.

Type

2008-09-04 EN Approved

MBA30 HA200 MBA30 HA150

en

HTCT 693 056 V0003

Total pages: 11

Fig. 1 Cooling Air Casings

2

HTCT 693 056 V0003

en

Type

C

Dept. Document No.

9560 HTCT693056

C

Lng. Status


Rev. Released

Manufacturer

Type

ALSTOM

GT13E1M

Drw-Pos

Order-

Designation

Qty

Pos

Lng. Status

Cooling air casing, LH upper part

1

2

2

Cooling air casing, RH upper part

1

3

3

Cooling air casing, lower part

1

4

4

Bush

1

5

5

Bush

2

6

6

Seal

8 8

Socket head cap screw M10 x 55-GA

16

9

9

Spring

32

10

10

Safety sleeve

26

11

11

Expansion bolt M36-TK x 110

26

12

Taper pin 16 x 160 - ST460TS

4

13

Hex head screw DIN 00561

4

C

Seal

8

C

7

8

Type

7

13

9560 HTCT693056

Rev. Released

1

1

12

en

Cooling air casing cpl. MBA30 HA150

1

Dept. Document No.


999

HTCT 693 056 V0003

3

Fig. 2 Cooling Air Casing Heat Shielding Plates

4

HTCT 693 056 V0003

en

Type

C

Dept. Document No.

9560 HTCT693056

C

Lng. Status


Rev. Released

Drw-Pos

Order-

Designation

Qty

Lng. Status

1

20

20

Shielding plate

1

21

21

Shielding plate

1

22

22

Shielding plate

1

23

23

Shielding plate

1

24

24

Shielding plate

1

25

25

Shielding plate

1

26

26

Shielding plate

1

27

27

Shielding plate

1

28

28

Shielding plate

1

29

29

Shielding plate

1

30

30

Shielding plate

1

31

31

Locking bolt

48

32

32

Disc

96

33

33

Securing plate

2

34

34

Hex head nut DIN 934-M24-A2-70

48

35

35

Washer DIN 125-A25-A2-70

48

36

36

Securing plate

2

37

37

Securing plate

2


Shielding plate

C

Rev. Released Type

19

9560 HTCT693056

Dept. Document No.

19

C

Pos

en

HTCT 693 056 V0003

5

Fig. 3 Hot Gas Casing

6

HTCT 693 056 V0003

en

Type

C

Dept. Document No.

9560 HTCT693056

C

Lng. Status


Rev. Released

Drw-Pos

Order-

Designation

Qty

Lng. Status

998

Hot gas casing cpl. MBA30 HA200

1

45

45

Dowel

8

46

46

Orifice cap

1

201

201

Hot gas casing, upper part

1

202

202

Hot gas casing, lower part

1

203

203

Flow seperator

1

204

204

Guide sleev

1

205

205

Bush

1

210

210

Clamping bar complete

22

211

211

UP Ring half - compressor end

1

212

212

UP Ring half - turbine end

1

213

213

LP Ring half - compressor end

1

214

214

LP Ring half - turbine end

1

C 9560 HTCT693056

C

Type Dept. Document No.

Rev. Released


Pos

en

HTCT 693 056 V0003

7

Type

C

Dept. Document No.

9560 HTCT693056

C

Lng. Status


Rev. Released

203

Fig. 4 Hot Gas Casing Flow seperator

8

HTCT 693 056 V0003

en

Fig. 5 Hot Gas and Cooling Air Casing Mountings

en

HTCT 693 056 V0003

9

Type

C

Dept. Document No.

9560 HTCT693056

C

Lng. Status


Rev. Released

Drw-Pos

Order-

Designation

Qty

Lng. Status

Support bolt

4

84

Pressure plate

4

86

86

Bearing bolt D158 x 396

2

87

87

Blind flange

2

90

90

Shim plate 40

8

91

91

Socket head cap screw M6-T x 40/ST-GA

8

92

92

Socket head cap screw M8-T x 30

4

93

93

Plain washer 6.4/12.5 ST/2N

8

94

94

Seal D248/160

2

95

95

Expansion stud M24-TK x 125

16

96

96

Expansion sleeve 24.3

16

97

97

Hex nut 0.8D ED M24 460TS

16

98

98

Hex head screw M16-T x 45

16

99

99

Locking washer DIN 93-17-A2-70

16

100

100

Dowel 16 H8 x 36

4

102

Expansion stud M.36-TK x 220

7

C

Rev. Released

83

84

C

Type

83

102 103

103

Measuring stud M.36-TK x 220

1

104

104

Washer

8

105

105

Expansion sleeve D36.4

8

106

106

Hex head nut DIN 934-M36-J

8

220

220

Seal segment cpl. (Belt seal)

1

221

221

Tension spring

22

222

222

Assembly shim

22

223

223

Seal segment

22

224

224

Base plate

22

225

225

Hex-S screw M8 TX12

22

226

226

Key way

2

227

227

Support disc

8

228

228

Fuel drain pipe

1

229

229

Key guiding

1

230

230

P Pin 16X20 GA

5

231

231

Hex head screw M16X70 8.8/ZN

4

9560 HTCT693056

Dept. Document No.


Pos

10

232

232

Hex nut 0.8D M16 8/ZN

4

233

233

Expansion stud M16-TX110

8

234

234


8

235

235

FL-Gasket 142/ 90X1,5 PN40

1

HTCT 693 056 V0003

en

Type

C

Dept. Document No.

9560 HTCT693056

C

Lng. Status


Rev. Released

Drw-Pos

236

en OrderPos 236

Designation Hex nut 0.8D M16 GA

HTCT 693 056 V0003

Qty 8

11

Turbine Vane Carrier - Parts List -

en

HTCT 693 057 V0001 A

Total pages: 18

2

HTCT 693 057 V0001 A

en

Manufacturer

Type

ALSTOM

GT13E

Drw-Pos

Order-

Designation

Qty

Pos 999

en

Turbine vane carrier - complete MBA30 HA300

1

1

1

Turbine vane carrier - upper

1

2

2

Turbine vane carrier - lower

1

3

3

Expansion stud M64 - TK x 500

12

4

4

Nut M48

2

5

5

Washer 111.5 x 15

12

6

6

Washer 83.5 x 12

2

7

7

Nut M64

12

8

8

Expansion stud M48 - TK x 300

2

9

9

Taper pin 024 x 245 - ST460TS

4

10

10

Round key 036 x 55

4

11

11

Socket head cap screw M16 x 40 GA

4

12

12

Hex head screw M36 x 380-8.8-A.G

2

13

13

Guide ring - upper

1

14

14

Guide ring - lower

1

16

16

Alignment tool

2

HTCT 693 057 V0001 A

3

4

HTCT 693 057 V0001 A

en

Drw-Pos

Order-

Designation

Qty

Pos

en

21

21

Bellows seal

1

22

22

Bellows seal

1

23

23

Bellows seal

1

24

24

Bellows seal

1

25

25

Bellows element

4

26

26

Bellows element

4

27

27

Bellows element

4

28

28

Cover plate

4

29

29

Cover plate

2

30

30

Cover plate

2

31

31

Cover plate

12

32

32

Semi-circular metal plate

2

33

33

Threaded boss G3/8A ST

8

34

34

Socket head cap screw VS-SHR G3/8A ST

24

35

35

Hex head screw M42 x 340-5.6

6

HTCT 693 057 V0001 A

5

6

HTCT 693 057 V0001 A

en

Drw-Pos

Order-

Designation

Qty

Pos

en

40

40

Entry segment cover

24

41

41

Cooling air cage

24

42

42

Profile segment

24

43

43

Sealing plate

24

44

44

Guide segment

24

45

45

Ring - 6 parts

1

46

46

Ring - 6 parts

1

47

47

Ring - 8 parts

1

48

48

Holding plate

1

49

49

Holding plate

1

50

50

Socket head cap screw M10 x 30

4

51

51

Bolt

24

52

52

Spring Ø 7.9/1.8 x 37.5

25

53

53

Locking bolt M18 x 277

1

54

54

Screw, special M16

1

55

55

Locking pin Ø 12 x 24

1

56

56

Spring loaded bolt Ø 19.8 x 34

24

57

57

Spring Ø 14/2.5 x 29

24

58

58

Spring Ø 15.6/1.7 x 17.5

24

59

59

Seal profile 16 x 4.1

5

60

60


12

61

61


12

62

62

Dowel 6M 6 x 14-A2-70

24

63

63

Locking screw M8 x 16

4

64

64

Bolt

48

65

65

Bearing pad

48

66

66

Threaded bush

48

67

67

Dowel

48

68

68

Nut Ø 70 x 12

48

HTCT 693 057 V0001 A

7

8

HTCT 693 057 V0001 A

en

Drw-Pos

Order-

Designation

Qty

Pos

en

75

75

Adjusting screw

1

76

76

Eccentric pin

1

77

77

Locking cover

1

78

78

Slide disc

1

79

79

Conical seat

1

80

80

Support plate

1

81

81

Slide disc

1

82

82

Clamping ring

1

83

83

Pressure flange

1

84

84

Slide block

1

85

85

Plate

2

86

86

Shim 0.5

6

87

87

Shim 0.15

6

88

88

Shim 0.12

6

89

89

Shim 0.3

4

90

90

Shim 0.1

2

91

91

Shim 0.5

3

92

92

Shim 0.1

5

93

93

Shim 0.15

2

94

94

Shim 0.15

1

95

95

Locking washer

1

96

96

Gasket

1

97

97

Dowel

1

98

98

Spring

1

99

99

Expansion stud

6

100

100

Expansion stud

8

101

101


1

102

102


1

103

103


4

104

104


4

105

105

Hex socket nut M24

6

106

106

Hex head nut M12

8

107

107

Dowel 16 M6 x 20-GA

8

108

108


6

109

109

Expansion sleeve

8

110

110

Pin D3 x 11

1

HTCT 693 057 V0001 A

9

Drw-Pos

Order-

Designation

Qty

Pos

10

111

111

Pin D3 x 20

112

112

Pin 3 x 20-ST

1

113

113

Identification plate

2

114

114

Rivet

4

115

115

Hex. head screw

1

116

116

Keyway, bottom

1

117

117

Side support

2

HTCT 693 057 V0001 A

en

Blank page

en

HTCT 693 057 V0001 A

11

12

HTCT 693 057 V0001 A

en

Drw-Pos

Order-

Designation

Qty

Pos Turbine Vanes, item 125 to 197 MBA30 HA400

en

125

125

Stator vane stage 1

40

126

126

Stator vane stage 2

60

127

127

Stator vane stage 3

58

128

128

Stator vane stage 4

20

129

129

Stator vane stage 5

50

130

130

Vane seal stage 1

1

131

131

Vane seal stage 1

1

132

132

Vane seal stage 1

38

133

133

Vane seal stage 1

38

134

134

Vane seal stage 2

1

135

135

Vane seal stage 2

1

136

136

Vane seal stage 2

58

137

137

Vane seal stage 2

58

138

138

Vane seal stage 3

2

139

139

Vane seal stage 3

2

140

140

Vane seal stage 3

57

141

141

Vane seal stage 3

58

142

142

Vane seal stage 4

2

143

143

Vane seal stage 4

2

144

144

Vane seal stage 4

18

145

145

Vane seal stage 4

18

146

146

Vane seal stage 5

2

147

147

Vane seal stage 5

2

148

148

Vane seal stage 5

48

149

149

Vane seal stage 5

48

150

150

Vane end seal stage 1

56

151

151


57

152

152


58

153

153

Vane seal stage 3

1

154

154

Securing locking bolt stages 1-5

80

155

155


230

156

156

Spring 14/2, 5 x 29 stages 1-5

230

157

157

Locking strip stage 1

12

158

158


16

159

159


18

HTCT 693 057 V0001 A

13

Drw-Pos

Order-

Designation

Qty

Pos

14

160

160


18

161

161


4

162

162

Blanking plate stage 2

60

163

163

Distance wire 4 x 3.0 stages 1 & 2

164

164

Distance wire 4 x 3.0 stages 3 & 4

165

165

Distance wire 4 x 3.0 stage 5

HTCT 693 057 V0001 A

en

Blank page

en

HTCT 693 057 V0001 A

15

16

HTCT 693 057 V0001 A

en

Drw-Pos

Order-

Designation

Qty

Pos

en

170

170

Heat shield segment stage 1

19

171

171


1

172

172


20

173

173


20

174

174


20

175

175


40

176

176

Segment seal stage 1

20

177

177


20

178

178


20

179

179


20

180

180


20

181

181


20

182

182


20

183

183


20

184

184


20

185

185


20

186

186


20

187

187


40

188

188


38

189

189


80

190

190


80

191

191

Locking bolt stage 5

40

192

192

Spring 14/2 5 x 29 stages 1-5

120

193

193

Safety locking segment stage 1

20

194

194


20

195

195


14

196

196


14

197

197


14

HTCT 693 057 V0001 A

17

Blank page

18

HTCT 693 057 V0001 A

en

Component Description Reference number: Customer: OEM: Turbine type: Date:

CD adequate to ALSTOM 13E1 Inner liner ALSTOM 13 E1 inner liner long version 26/09/2011

Part

Inner liner long version

Inner liner long version

Parts to be sent in loose condition

GT 13E1 inner liner

Page 1 of 3

Component Description

Materials

ABB 13E1 inner liner Long version Inner liner assy Inner liner body, 11 corrugations Inner liner cone, 3 corrugations Inner liner outlet collar, 1 corrugation Inner liner inlet cone Inner liner inlet ring

Inconel 617 Inconel 617 Inconel 617 Inconel 617 Inconel 617

1 1 1 1 1

Material nr. 2.4663 2.4663 2.4663 2.4663 2.4663

Centering sleeve

Inconel 617

8

2.4663

Fire eye port

Inconel 617

1

2.4663

Guiding key Suspension bushes assembly

Inconel 617 Inconel 617/ Stellite

3 4

2.4663 2.4663

Hardware Guide Bolt Bush Ring Rib Rib Bush

Material

Adequate to part nr GMD5876089P0001 GMD5876075P0001 GMD5876077P0001 GMD0888054P0001 GMD5876074P0001 GMD5876074P0002 GMD5886069P0003

Quantity

Quantity 3 4 4 4 8 8 1

Coating • •

Chrome carbide (hardface) coating on outlet collar (spec A-091) Chrome carbide (hardface) coating on guiding keys (spec A-122)

Note:

Guiding keys, fire eye port and suspension bushes assembly and hardware will be delivered as loose parts and shall be installed on site

GT 13E1 inner liner

Page 2 of 3

Component Description Work scope Inner Liner adequate to ALSTOM type GT 13E1

Material of inner liner: Inconel 617 (nr. 2.4663)

New manufacturing • • • • • • • • • • • • • • • • • • • • • • • •

Pre-Production meeting Purchasing of materials Manufacturing of fixtures to limit deformation during heat treatments and welding Cutting and forming sheet metal parts (inlet flange, conical and cylindrical sections and outlet collar) Axial welding of sheet metal parts Machining of outlet collar Manufacturing of accessories Incoming inspection of parts and accessories Radial welding of conical, cylindrical sections to inlet flange and outlet collar Cutting of centering sleeve holes Welding centering sleeves and other accessories Dye penetrant inspection of all welds Cleaning by grit blasting Dimensional inspection Positioning and securing of fixtures on liner Stress relief heat treatment Removal of all fixtures Dimensional inspection Dye penetrant inspection of all welds X-ray inspection of welds Application of hard face coating on outside outlet collar and guiding keys Cleaning by grit blasting End inspection and certification New manufacture report

GT 13E1 inner liner

Page 3 of 3

ThyssenKrupp VDM Auftragsnr. 377005

ThyssenKrupp VDM GmbH Produktbereich Blech

Lieferschein Handelsmarke NICROFER 5520 CO 587243 2.4663

Kleffstraße 23, D-58762 Altena Tel. +49 2392 552092 Postfach 1251, D-58742 Altena Fax +49 2392 552047 EMail [email protected]

Herstellerzeichen

Abnahmeprüfzeugnis DIN EN 10204/01.05

Spezifikation

Produkt Blech, warmgewalzt, lösungsgeglüht, entzundert, geschnitten

SULZER Turbo Services Venlo B.V. Spikweien 36 NL -5943 AD Lomm Bestellnummer

Pos. 1

Stück 1

Gew [kg]

Werkstoff

ALSTOM HZLM 00428 Rev. U / 10.05.2001 ABB HZN 00192 Rev. D 09/95 ALSTOM HTCZ 645 542 Rev. B 11/00

Dimension [mm] Charge 6,000 x 2400,0 x 6000,0 315152

Seite 1 von 1 gedruckt: 31.08.2010

NiCr 23 Co 12 Mo

Los 103407164

3312318-1

Analyse (Gew %) LE=Verbrennungsanalyse, OE=optische Emissionsanalyse , RF=Röntgenfluoreszenzanalyse Charge Erschmelzung C S Cr Ni Mn Si 315152 EO/VD/ESU 0,06 <0,002 22,1 R54,5 0,1 0,2 LE LE RF RF RF RF Probenzustand lösungsgeglüht Los 103407164

84194/0 3.1

Probe-Nr. 1-K1

Wärmebehandlung Los 1161 °C/16min/ Wasser103407164

Zugversuch 1 ISO 6892-1 B10 / Querprobe Rp0.2 Rp1.0 Rm Dehnung Temp [°C] [MPa] [MPa] [MPa] A [%] A 1 RT 381 814 5 56

Mo 8,7 RF

Ti 0,4 RF

Cu 0,1 RF

Kerbschlagprüfung 1 EN 10045-1KV / längs Z Temp. KV [°C] [J] [%] [%] 1 RT 78 76 77

aK [J/cm²]

Fe 1,3 RF

P 0,002 RF

Breitung [mm]

Al 1,1 RF

Co 11,4 RF

B 0,001 OE

Faltversuch 1 DIN EN ISO 7438 / Querprobe Biege- Winkel Faktor [°] 1 2,5 180 ohne Anrisse

Korngrösse 1 ASTM E 112

1 Nr 4.5

Spektralanalytische Verwechslungsprüfung wurde durchgeführt: ohne Beanstandung Dimensions- und visuelle Kontrolle durchgeführt: ohne Beanstandung Kerbschlagprüfung: Probendicke 5 mm Das Material ist frei von Quecksilber-, Radium-, Strahlen- oder Alfaquellenverunreinigungen. Keine Schweissreparaturen durchgeführt.

ISO 9001, AS9100, EN 9001 LRQA Approval KLN 4000941/B

Wir bestätigen hiermit, dass das Material in Übereinstimmung mit den oben genannten Spezifikationen ist Dieses Zeugnis wurde maschinell erstellt und ist ohne Unterschrift gültig *84194-0-D*

Wilhelm Zoebe, Abnahmebeauftragter

Freigabedatum: 31.08.2010

Zeichen des Sachverständigen

E

Q

Das Abnahmeprüfzeugnis darf nur als Gesamtdokument vervielfältigt werden, soweit nicht anderweitig schriftlich durch ThyssenKrupp VDM geregelt. Das Aufzeichnen falscher, fiktiver oder betrügerischer Aussagen oder Einträge und Veränderungen kann als Straftat nach Bundesgesetz geahndet werden.

4

5

1

382

2 3

DIFFERENTIAL DIMENSION OF INNER LINER OEM COMPARED TO NON OEM

OEM 1. 833 mm Impact:

N-OEM 1. 850 mm

This is dimension of accessories instead of top edge of inner liner. As that is the critical accessories to connecting between inner liner and intermediate liner (locking pin), the deviation can be impacted to mismatch of inner liner and intermediate liner assembly. That is must be avoid. OEM 2. 400 mm Impact:

N-OEM 2. 382 mm

This is a distance between rows of secondary nozzle. The deviation between each of row can be impacted to mismatch of secondary nozzle assembly, which is attached on the intermediate liner wall. Then, it will be difficult to install inner liner to the intermediate liner position. OEM 3. 4318 mm Impact:

N-OEM 3. 4312 mm

This is the height of inner liner top to bottom. The deviation of this measurement can be impacted to the distance (overlap) between bottom of inner liner and top of Hot Gas Casing. The out of dimension also can be impacted to the belt seal segment seat position as showed below:

As showed, the tolerance of H (overlap between inner liner and HGC) should be max. 4 mm. In this case the deviation of inner liner height (OEM compared to N-OEM) is about 6 mm, out of tolerance.

OEM 4. 2269 mm Impact:

N-OEM 4. 2259 mm

This is an inside diameter of top inner liner (with inner liner thickness is 6 mm). In this case, the inner liner diameter of N-OEM smaller than actual new set. It can be impacted to the position of

a (gap of

lower finned segment to lower combustion chamber insert). As showed below, the nominal gap of a

should be 1 mm (with plus 1 mm tolerance). In this case the gap of a looks like about of minus 5 mm (no gap).

OEM 5. 2080 mm Impact:

N-OEM 5. 2066 mm

This is an inside diameter of lower combustion chamber insert (with inner liner thickness is 6 mm). In this case, the inner liner diameter of N-OEM smaller than actual new set. It can be impacted to the position of

s (overlapping brick carrier lower combustion chamber insert). As showed below, the

nominal gap of s should be 8 mm (with no tolerance). In this case the gap of s looks like about of 7 mm.

LTPA APPENDIX 3 -GT COMPONENT EXPECTED LIFE TIME ( NEW PART & RECONDISI PART ) GT13E1 - PLTGU Tanjung Priok Hot Gas Path Component ROTOR BLADING / MBA30HB400 Tula 1 Tula 2 Tula 3 Tula 4 Tula 5

Expected Life Time EOH EOH Recondition New 24000 24000 / 48000 48000 48000 72000

48000 72000 72000 96000 96000

72000 72000 72000 72000

120000 120000 120000 120000

STATOR BLADING / MBA30HA400 Tule 1 Tule 2 Tule 3 Tule 4 Tule 5

24000 24000 / 48000 48000 48000 72000

48000 72000 72000 96000 96000

Heat shield stator row A Heat shield stator row B Heat shield stator row C Heat shield stator row D Heat shield stator row E

24000 24000 / 48000 48000 -

48000 72000 72000 120000 120000

Heat shield rotor row A Heat shield rotor row B Heat shield rotor row C Heat shield rotor row D

BLADE CARRIER / MBA30HA300 C - segment Compressor Diffusor / MBA80HA500 Diffuser entry Diffuser holding Diffuser transition

See comment in the price list reconditioning (Appendix 2)

24000 / 48000 24000 / 48000 24000 / 48000

72000 72000 72000

COMPRESSOR ROTOR BLADING / MBA80HB400 Rotor Blade Row 1 - 5 (Coated) Rotor Blade Row 6 - 21

(*) -

120000 120000

COMPRESSOR STATOR BLADING / MBA80HA400 Inlet guide vane (Coated) Stator Vane Row 1 - 4(Coated) Stator Vane Row 5 - 22

(*) (*) -

120000 120000 120000

24000 / 48000

72000

COMBUSTION CHAMBER / MBM30 Inner liner Complete / Lower Combustion Chamber insert

1/2

LTPA APPENDIX 3 -GT COMPONENT EXPECTED LIFE TIME ( NEW PART & RECONDISI PART ) GT13E1 - PLTGU Tanjung Priok Hot Gas Path Component Collar Inner Liner, Lower Part Tile Carrier rings 1 - 6 Tile Carrier rings repair set Burner/Fuel Oil Nozzle Burner/Fuel Oil Nozzle Exchange parts Outer swirler Inner swirler THERMAL BLOCK Hot Gas Casing MBA30HA200 HGC Belt Seal Segment Rotor / MBA80HB Radial bearing 1 Radial bearing 2 Thrust bearing

Expected Life Time EOH Recondition -

EOH New 24000 120000 48000 96000 48000 120000 48000

24000 / 48000 24000

72000 48000

-

120000 120000 120000

Note : *. Site specific operation conditions (dirt, salt contamination, etc) may cause deterioration of the protective coatings on the coated compressor rows. Scheduled inspection and timely refurbishment of these coatings ensure base material integrity over the entire cycle of the compressor stages and reduces losses in compressor efficiency due to sureface degradation. Typical reconditioning intervals are related to 2nd and 3rd C-cycle Inspection

2/2

rice list reconditioning (Appendix 2)

3/2

4/2

UNIT PEMBANGKIT PRIOK

LAPORAN PERFORMANCE TEST INSPECTION TYPE C (Tgl. 04 Agustus 2014 – 22 Desember 2014)

LAPORAN.TGP.F.02.01.I.2015

GT - 1.1

PT. INDONESIA POWER UNIT BISNIS PEMBANGKITAN PRIOK

UB. PEMBANGKITAN PRIOK

KATA PENGANTAR Berkaitan dengan kegiatan pemeliharaan tahunan di PLTGU blok I pada GT. 1-1 dan untuk mengetahui parameter keberhasilan Inspection adalah dengan pengukuran / pengambilan data Performance Test GT. 1-1 sebelum Inspection dan dibandingkan dengan setelah Inspection. Untuk mengetahui unjuk kerja (performance) Turbin Gas setelah Inspection Type C (jam kerja mesin kumulatif EOH : 194.845 jam / OH: 149.484 jam), maka kami laporkan hasil perhitungannya dengan metode campuran (direct & indirect methode), dengan mengacu pada standar DIN 1943 dan ISO 2314. Berbagai inspection yang sudah dilakukan pada unit ini sebanyak 25 x yaitu : 20 Inspection Type EOH kumulatif EOH S. inspec.terakhir OH kumulatif OH S. inspec. Terakhir Mulai Selesai Jumlah start kumulatif Jumlah Trip Kumulatif Jumlah fast Load Kum.

21

B

C

135.802 5.607 113.907 4.424 03-01-09 12-01-09 344 127 1

144.975 9.173 119.336 5.429 23-10-09 30-11-09 415 128 1

22

B

23

C

24

B

25

C

156.785 170.880 178.916 194.845 11.810 14.095 8.036 15.929 124.184 134.063 139.869 149.484 4.848 9.879 5.806 9.615 07-08-10 01-12-11 16-10-12 04-08-14 14-08-10 15-01-11 24-10-12 22-12-14 502 590 619 828 141 145 156 165 1 1 1 1

Berbagai kurva factor koreksi yang sudah dirubah dari kurva asli yang sulit dibaca menjadi bentuk table adalah (1). Correction curve for Power Output GMD 1 072 628 ; (2). Correction curve for Efficiency GMD 1 072 629 ; (3). Generator Correction Factor HTCM 647772-9 ; (4) Influence of speed on efficiency GMD 1 072 699 ; (5). Influence of speed on Power Output GMD 1 072 698 ; (6) Influence of Humidity GMD 1-072-699 ; (7) Transformer Efficiency GT 13E 1 AHX 430 002 ; (8) Expected Non Recoverable Deterioration HTCT 71 630 Demikian, laporan ini kami sampaikan dan dapat dipergunakan sebagaimana mestinya. Jakarta, 16 Januari 2015

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DAFTAR ISI Halaman

KATA PENGANTAR ............................................................................................................. 2 DAFTAR ISI ........................................................................................................................... 3 METHODE PENGAMBILAN DATA.................................................................................... 4 Perhitungan Hasil Pengukuran '' SEBELUM C – Inspection GT. 1-1'' pada Beban 122 MW dengan bahan bakar GAS ........................................................................... 5 Perhitungan Power Output dan Efficiency Terukur dikoreksi ke Kondisi yang digaransi Unit : GT. 1-1, Sebelum Inspection type C ............................................................ 6 Perhitungan Hasil Pengukuran '' SETELAH C - Inspection GT. 1-1'' pada Beban 123 MW dengan bahan bakar GAS ........................................................................... 9 Perhitungan Power Output dan Efficiency Terukur dikoreksi ke Kondisi yang digaransi Unit : GT. 1-1, Setelah Inspection type C............................................................. 11 Evaluasi Hasil Performance Test ................................................ Error! Bookmark not defined. Tabel Correction Factor of Ambient temperature for Power Output (Tranfer from GMD 1 072 628)............................................................................................................ 17 Tabel Generator Correction Factor (Tranfer from HTCM 647772-9) ............................... 18 Tabel Generator Correction Factor (Tranfer from HTCM 647772-9) ............................... 19 Tabel Relative Frequency – Relative Power (Transfer from GMD 1 072 698) ................... 20 Tabel Relative Frequency – RelativeEfficiency(Transfer from GMD 1 072 699) ............... 21 Tabel Influence of Humidity (transfer from GMD 1 072 368) ............................................ 22 Tabel Tranformer Efficiency GT 13E (transfer from 1 AHX 430 002) .............................. 23 Tabel Expected Non Recoverable Deterioration (transfer from HTCT 71 630) ................ 24

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METHODE PENGAMBILAN DATA Dalam pengambilan data digunakan peralatan Standard yang ada di Unit dan yang selama ini terpakai dengan peralatan tambahan . 1. Dengan melakukan trend grouping pada POS didapat data hasil test. 2. Dengan pembacaan parameter di lokal menggunakan log sheet . 3. Dengan menggunakan Stop Watch untuk pembacaan waktu kwh meter 4. Dengan menggunakan Altimeter/ Barometer juga RH meter 5. Berdasarkan Data Nilai Kalor Gas yang tercatat oleh PGN dan NR (Nusantara Regas) . 6. Pengujian Laboratorium untuk bahan bakar GAS 7. Pengambilan data dilakukan pada 3 (tiga) segmen beban, yaitu 100% Load, 80% Load dan 60% Load tanpa melakukan penggantian bahan bakar. 8. Hal-hal yang mempengaruhi hasil performance test disini yaitu kondisi pembebanan, pressure dan temperature ambient.

4

Perhitungan Hasil Pengukuran '' SEBELUM C-Insp: GT. 1-3'' pada Beban 78 MW dengan bahan bakar GAS Perhitungan Hasil Pengukuran '' SEBELUM C-Insp: GT. 1-1''

Bahan Bakar: GAS 1 2 3 4 5 6 7a 7a1 7a2 7a3 7b 7b1 7b2 7b3 7b4 8 8a 8b 8c 9 10 10a 10b 10c 11 11a 11b 11c

12 12a 12b 12c 13 14 15 16 17

Beban Base Load

Satuan

Rumus

Pengambilan data Amb. Temperature (4 Therm) ° Celcius t rata² Amb. Pressure Bar Abs. Amb. Rel. Humidity % Inlet Total Press. Loss. **) Mm H2O Static Press.Drop V IGV. **) Mm H2O Fuel Flow Berat ( Mf ) Vf * Fd Volume Flow rate (Vf) Berat Jenis (Fd) Fuel Oil Temp. ( t ) ° Celcius Fuel Flow Rate (Vf) scm/h Flow Counter ( Fc ) Flow of Leakage ( Fl ) Flow of Return ( Fr ) Nilai kalor bawah (LHV) Btu/Scf Active Power Gen. (Pact) Kw (KWH*3600)/t Kw Generator pada meter. Kw Waktu pengukur Kwh.(t) s Hasil pengukuran KWh. Kwh Active Power Netto (Pact,net) Kw Pact - Paux Reactive Power (Pract) GT KVAr Imp*3600/t*const Impulses of the KVArh Count. (Imp). Waktu u/ jumlah impuls pada s KVArh meter. ( t ). Constanta (const) imp/kvarh 0,096 imp/kvarh Auxiliary Power for GT (Paux) KW Imp*3600/t*const Impulse pd. KWH meter. rev Waktu u/ jumlah impuls pada s KWH meter Constant of Aux. counter *) Untuk # 11,12,21,22 2.4imp/KWh Untuk # 1.3 & GT.23 7.2imp/KWh Power Factor (Cos Phi) GT Cos[arctan(Pract/Pact)] Cos Phi Power factor terukur. Active Power Gen pd meter Mw Reactive Power Gen meter. MVArh Frequency (Turbine Speed) Hz Comp. Disch. Press. (Pk2) Bar Exhaust Gas Temp. °C Turbine Inlet Temperature. Steam Turbin Performance Operation Data. ° C

Hasil 21/07/2014 35,70 1,008 61,70 0,00 0,00 32.850 1.090 122.000 122.000 295,08 10000 121.749 35.548 20 21,10 0,096 251,4 20 127,35

2,4 7,2 0,960 0,850 122 41,95 3.002 11,9 537,50 1.070

Perhitungan Effisiensi berdasarkan Kondisi Pengukuran. 17 18 19 20 21

Eff. Pd. Output Trafo Eff. Pd. Output Generator Specific Fuel Comp. Heatrate Pd. Output Trafo Heatrate Pd. Output Gen.

% %

Pact,net/Vf*Hlhv

32,84

Pact/Vf*Hlhv

32,91

MMBtu/Kwh

Vf*3600/Pact.

0,010

kcal/kwh kcal/kwh

860/Eff.Pd Trafo 860/Eff.Pd Trafo

5

2.618 2.613

Perhitungan Power Power Output dan Terukur ke digaransi Kondisi yang Perhitungan Output danEfficiency Efficiency Terukur dikoreksidikoreksi ke Kondisi yang digaransi Unit : GT. 1-3, Sebelum Inspection type C Unit : GT. 1-1, Sebelum Inspection: Type C Inspection ke : Periode tanggal :

25 21-Jul-14

Contractual Requirements - Ambient Pressure - Ambient Temperature - Relative Humidity - Pressure Drop Inlet (total) - Frequency - Fuel type - Lower Heating Value - Power factor - Generator/GIS Out going Terminal Voltage - Unit Condition

Site Test Conditions and Measuring Data 1,013 (bar) 30 (deg.C) 83 (%) 10 (mbar) 50 (Hz) HSD 42000 (kJ/kg) 0,9 15.75/150 kV Old & Clean

HSD unit % bar deg. C kW kW kVar mmWG -

Fuel Oil Characteristic based on LMK - Density at 34.8 deg C - Net calorific Value - LHV (1 cal = 4.1868 Joule)

0,8337 (kg/l) 10210,18 (kCal/kg) 42748 (kJ/kg)

Guarantee Data for Gas Turbine Simple Cycle Test date 13 Desember 1994 at 14.00 - 14.25 - Load ( Base Load ) - Net electrical Output at HV-Terminal - Net electrical Heat rtae at HV-Terminal

100 % 128120 (kW) 10201,91 (kJ/kWh)

Measurig Uncertainties (According to DIN 1319/3) - Power Output Uncertainty for one GT (UePSC) - Efficiency Uncertainty (UeHRSC)

GAS value

- Relative Humidity (Rhamb) - barometric Pressure (Pamb) - Ambient temperature (tamb) - Power Output (Pact) - Power Auxiliary (Paux) - Reactive power (Pract) - Static Pressure Inlet system (pei) - Caloric flowrate GAS acc. BP - Fuel Gas Flow (Flow):mf HSD acc. UBP Priok Lab. - Fuel oil Flow counter (Flow):Fc l/s - Fuel Oil Leakage Flow (Lflow): Fl l/s - Fuel Oil return Flow (Rflow) : Fr l/s - Specific gravity at 60/60 F kg/dm3 - Calorific Value Gross Btu/Lb - LHV = 4310+0,7195*GHV Btu/Lb - Fuel temperature (tf) deg. C - Generator Speed rpm - Power Factor (Cosphi) - Static Pressure IGV (pIGV) - Static Press. Exhst. SysTEM (pee) - Temperature Inlet turbine (TIT) deg. C -Temperature After Turbine (TAT) deg. C - Operating Hours (05/08/2010) OH Total bfr. Insp FALSE -

0,5196 % 1,0625 %

-

unit % bar deg. C kW kW kVar mmWG Btu/scf scm/h

value 61,70 1,008 35,70 122000 251,38 35548 0 1090,4929 32850

deg. C rpm

3001,5 0,960 0 1070 537,5

deg. C deg. C OH Total 49484

bfr Insp 40311

Correction Factor For POWER OUTPUT based on Base Load for HSD and Base Load for GAS

Parameter Reference

Pamb Tamb Rhamb Frekw OH Pact Pract Cosphi Pact Cosphi

GMD 1072628 GMD 1072368 GMD 1072698 HTCT 71077 HTCM 647772-9 -

type Terukur Garansi Terukur Garansi Terukur Garansi Terukur Garansi terukur terukur Garansi

Nilai 1,013 30 83 3000

FUEL HSD Nilai item Faktor PambM PambG 1,013 CtaM CtaG 0,8944 CrhM 0,9965 CrhG 1,0075 CfrM CfrG 1,0000

- CohM - CgenM 128120 CgenG 0,85

1,0000 -

Faktor Koreksi Cpa = PambG/PambM

Cta = CtaG/CtaM Crh = CrhG/CrhM 1,011039 Cfr = CfrM/CfrG Coh = 1/CohM 1,000000 Cgen=CgenM/CgenG

terukur Terukur

-

0,9995

type Terukur Garansi Terukur Garansi Terukur Garansi Terukur Garansi

Garansi

Nilai 1,008 1,013 35,7 30 61,7 83 3002 3000

FUEL GAS Nilai item Faktor PambM 1,008 PambG 1,013 CtaM 0,8593 CtaG 0,8944 CrhM 0,9982 CrhG 1,0075 CfrM 0,9994 CfrG 1,0000

Cpa = PambG/PambM

1,004960 Cta = CtaG/CtaM 1,040907 Crh = CrhG/CrhM 1,009323 Cfr = CfrM/CfrG 0,999351 Coh = 1/CohM 0,9021 1,108578

40311 CohM 122000 35548 CgenM 0,96 128120 CgenG 0,85

Faktor Koreksi

0,9982 0,9995

Cfactor : Cpa*Cta*Crh*Cfr*Coh*Cgen

- Cfactor = Cpa*Cta*Crh*Cfr*Coh*Cgen

Power Auxiliary ( kW )

- Power Auxiliary ( kW )

Cgen=CgenM/CgenG 0,998748673

1,053817934

251,38

Power Active Neto (Pact,GenCG) keluar Generator setelah dikoreksi (kW) Pact,GenCG = (PactM * Correction Factor) - PauxM =

-

Transformer Efficiency (nTr) : (1AHX4300 02)

- Transformer Efficiency (nTr) :

Pact,GenCG = (PactM * Correction Factor) - Paux =

128314,83

0,996806307

Power Active Neto Keluar Terminal (Pact,HVCG) ( kW ) -

Pact,HVCG = Efisiensi trafo (nTr) * Pact, GenCG =

6


127905,03

Correction Factor For EFFICIENCY at Base Load for HSD and Base Load for GAS

type

Parameter Reference

tamb

GMD 1072628 GMD 1072368 GMD 1072698 HTCT 71077

Rhamb Fre

Pact Pract Cosphi Pact Cosphi

HTCM 647772-9 -

Nilai

Terukur Garansi Terukur Garansi Terukur Garansi terukur

terukur Garansi

item

30 83 3000

FUEL HSD Nilai Faktor

Faktor Koreksi - Ctae = CtaeG/CtaeM 0,9625 1,0014 Crhe = CrheG/CrheM 0,9969 0,995506 - Cfre = CfreG/CfreM 1,0000 1,000000 Cohe = 1/CohM 1,0000 1,000000

CtaeM CtaeG CrheM CrheG CfreM CfreG

- CoheM - CgeneM 128120 CgeneG 0,85

-

type Terukur Garansi Terukur Garansi Terukur Garansi terukur Terukur

Cgene=CgeneM/CgeneG

- Garansi

0,99947

Cfactor : Ctae*Crhe*Cfre*Cohe*Cgene

-

Power Auxiliary ( kW ) Efisiensi pada Output Gen (nM) % Efisiensi pada Output trafo (%) Heat rate pada output Generator ( kcal/kwh ) Heat rate pada output Trafo ( kcal/kwh )

-

Nilai 35,7 30 61,7 83 3002 3000

item CtaeM CtaeG CrheM CrheG CfreM CfreG

FUEL GAS Nilai Faktor 0,9532 0,8920 1,0007 0,9968 1,0000 1,0000

40311 CoheM 122000,4 35548,39 CgeneM 0,960 128120 CgeneG 0,85

Faktor Koreksi Ctae = CtaeG/CtaeM 0,935753 Crhe = CrheG/CrheM 0,996070 Cfre = CfreG/CfreM 1,000045 Cohe = 1/CohM 0,9352 1,069304 0,9982

Cgene=CgeneM/CgeneG

0,9995


0,998748673

0,930951261

Power Auxiliary (kW) Efisiensi pada Output Gen (nM) % Efisiensi pada Output trafo (%) Heat rate pada output Generator (kcal/kwh) Heat rate pada output Trafo (kcal/kwh)

251,381 32,906 32,838 2613,04 2618,43

nNetGenCG= nM x C.factor x (1 - (Paux/PactM))=

30,571

Efisiensi Output Generator dikoreksi ke kondisi garansi (n Gen CG) nNetGenCG= nM x C.factor x (1 - (PauxM/PactM)) =

#VALUE!

Efisiensi trafo : Effisiensi pada HV terminal GT Step up Transformer nHVCG = n NetGenCG x Effisiensi trafo (nTR) =

Efisiensi trafo :

#VALUE!

nHVCG; Efisiesi neto pada HV-Terminal Step up Transformer dikoreksi ke kondisi garansi. Heat Rate pada HV terminal GT. Step up Transformer

HRHVCG :Heat rate netto pada HV terminal Step up transformer dikoreksi ke kondisi garansi

Power Output neto pada terminal Trafo Gen

Electrical Heat rate (neto) Efficiency Termal (neto)

Transformer dikoreksi ke kondisi garansi

GAS 122000 2613,04 32,906 0,0104 121749 2618,43 32,838

satuan kW kcal/kwh % MMBTU/kWh

kW kcal/kwh %

Hasil Perhitungan Setelah Dikoreksi ke kondisi garansi Perhitungan Power Output Generator

Power output Electrical Heat rate Efficiency

HSD #VALUE!

GAS 128315 2812,64 30,571

Perhitungan Power Output pada ujung terminal HV step up Trafo


HSD #VALUE!

HRHV,CG = 860/nHV,CG (kcal/kwh) = HRHVCG :Heat rate netto pada HV terminal Step up

SUMMARY Satuan kW kcal/kwh % Ltr/kWh kW kcal/kwh %

30,473

Transformer dikoreksi ke kondisi garansi.

-

HSD -

nHVCG = nNetGenCG x Effisiensi trafo (nTR) = nHVCG; Efisiesi neto pada HV-Terminal Step up

HRHV,CG = 860/nHV,CG (kcal/kwh) =

Hasil Pengukuran Aktual (site) Power Output Aktual Gross Electrical Heat rate Efficiency Termal Specific Fuel Consumption

0,9968

Effisiensi Neto pada HV terminal GT Step up Transformer

GAS 127905 2821,651 30,473

7

2822

Perhitungan Hasil Pengukuran '' SETELAH C-Insp: GT. 1-3'' pada Beban 78 MW dengan bahan bakar GAS Perhitungan Hasil Pengukuran '' SEBELUM C-Insp: GT. 1-1'' 1 2 3 4 5 6 7a

Satuan

Rumus

Pengambilan data Amb. Temperature (4 Therm) Amb. Pressure Amb. Rel. Humidity Inlet Total Press. Loss. **) Static Press.Drop V IGV. **) Fuel Flow Berat ( Mf )

° Celcius Bar Abs. % Mm H2O Mm H2O

t rata²

7a1 7a2 7a3 7b

Volume Flow rate (Vf) Berat Jenis (Fd) Fuel Oil Temp. ( t ) Fuel Flow Rate (Vf)

7b1 7b2 7b3 7b4 8

Flow Counter ( Fc ) Flow of Leakage ( Fl ) Flow of Return ( Fr ) Nilai kalor bawah (LHV) Active Power Gen. (Pact)

8a 8b 8c 9

Kw Generator pada meter. Waktu pengukur Kwh.(t) Hasil pengukuran KWh. Active Power Netto (Pact,net)

10

Reactive Power (Pract) GT

10a 10b 10c 11 11a 11b 11c

12 12a 12b 12c 13 14 15 16 17

Beban 100 MW

Bahan Bakar: GAS

Vf * Fd

Impulses of the KVArh Count. (Imp). Waktu u/ jumlah impuls pada KVArh meter. ( t ). Constanta (const) Auxiliary Power for GT (Paux)

° Celcius scm/h

Fc - Fl - Fr

Btu/Scf Kw

(KWH*3600)/t

Kw s Kwh Kw

Pact - Paux

KVAr

Imp*3600/t*const

12,99

s imp/kvarh KW

Hasil 21/07/2014 35,95 1,006 67,50 0,00 0,00 30.450 1.090 103.004 102.500 349,50 10000 102.904 57.737 20

0,096 imp/kvarh Imp*3600/t*const

Impulse pd. KWH meter. rev Waktu u/ jumlah impuls pada s KWH meter Constant of Aux. counter *) Untuk # 11,12,21,22 2.4imp/KWh Untuk # 1.3 & GT.23 7.2imp/KWh Power Factor (Cos Phi) GT Cos[arctan(Pract/Pact)] Cos Phi Power factor terukur. Active Power Gen pd meter Mw Reactive Power Gen meter. MVArh Frequency (Turbine Speed) Hz Comp. Disch. Press. (Pk2) Bar Exhaust Gas Temp. °C TurbineTurbin Inlet Temperature. Steam Performance Operation Data. ° C

0,096 100,3 20 355,00 2,4 7,2 0,872 0,800 103 57,45 2.999 0,0 0,00 0



% % MMBtu/Kwh kcal/kwh kcal/kwh

8

Pact,net/Vf*Hlhv Pact/Vf*Hlhv Vf*3600/Pact. 860/Eff.Pd Trafo 860/Eff.Pd Trafo

29,94 29,97 0,011 2.872 2.869

Perhitungan Hasil Pengukuran '' SETELAH C-Insp: GT. 1-3'' pada Beban 78 MW dengan bahan bakar GAS Perhitungan Hasil Pengukuran Sebelum C-Insp: Type C'' 1 2 3 4 5 6 7a

Satuan

Rumus



t rata²

7a1 7a2 7a3 7b


7b1 7b2 7b3 7b4 8


8a 8b 8c 9


10


10a 10b 10c 11 11a 11b 11c

12 12a 12b 12c 13 14 15 16 17

Beban 75 MW

Bahan Bakar: GAS


Vf * Fd

° Celcius scm/h

Fc - Fl - Fr

Btu/Scf Kw

(KWH*3600)/t

Kw s Kwh Kw

Pact - Paux

KVAr

Imp*3600/t*const

9,02

s imp/kvarh KW

Hasil 21/07/2014 32,65 1,007 53,60 4,50 0,00 25.000 1.090 75.000 75.000 480,00 10000 74.764 83.120 20


Impulse pd. KWH meter. rev Waktu u/ jumlah impuls pada s KWH meter Constant of Aux. counter *) Untuk # 11,12,21,22 2.4imp/KWh Untuk # 1.3 & GT.23 7.2imp/KWh Power Factor (Cos Phi) GT Cos[arctan(Pract/Pact)] Cos Phi Power factor terukur. Active Power Gen pd meter Mw Reactive Power Gen meter. MVArh Frequency (Turbine Speed) Hz Comp. Disch. Press. (Pk2) Bar Exhaust Gas Temp. °C TurbineTurbin Inlet Temperature. Steam Performance Operation Data. ° C

0,096 235,6 20 136,49 2,4 7,2 0,670 0,805 75 81,60 2.994 10,3 515,74 996



% % MMBtu/Kwh kcal/kwh kcal/kwh

9

Pact,net/Vf*Hlhv Pact/Vf*Hlhv Vf*3600/Pact. 860/Eff.Pd Trafo 860/Eff.Pd Trafo

26,50 26,58 0,013 3.245 3.235

Perhitungan Hasil Pengukuran '' SETELAH C-Insp: GT. 1-3'' pada Beban 78 MW dengan bahan bakar GAS Perhitungan Hasil Pengukuran '' SETELAH C-Insp: GT. 1-1''


12 12a 12b 12c 13 14 15 16 17

Satuan

Beban Base Load

Rumus

Pengambilan data Amb. Temperature (4 Therm) ° Celcius t rata² Amb. Pressure Bar Abs. Amb. Rel. Humidity % Inlet Total Press. Loss. **) Mm H2O Static Press.Drop V IGV. **) Mm H2O Fuel Flow Berat ( Mf ) Vf * Fd Volume Flow rate (Vf) Berat Jenis (Fd) Fuel Oil Temp. ( t ) ° Celcius Fuel Flow Rate (Vf) scm/h Flow Counter ( Fc ) Flow of Leakage ( Fl ) Flow of Return ( Fr ) Nilai kalor bawah (LHV) Btu/Scf Active Power Gen. (Pact) Kw (KWH*3600)/t Kw Generator pada meter. Kw Waktu pengukur Kwh.(t) s Hasil pengukuran KWh. Kwh Active Power Netto (Pact,net) Kw Pact - Paux Reactive Power (Pract) GT KVAr Imp*3600/t*const Impulses of the KVArh Count. (Imp). Waktu u/ jumlah impuls pada s KVArh meter. ( t ). Constanta (const) imp/kvarh 0,096 imp/kvarh Auxiliary Power for GT (Paux) KW Imp*3600/t*const Impulse pd. KWH meter. rev Waktu u/ jumlah impuls pada s KWH meter Constant of Aux. counter *) Untuk # 11,12,21,22 2.4imp/KWh Untuk # 1.3 & GT.23 7.2imp/KWh Power Factor (Cos Phi) GT Cos[arctan(Pract/Pact)] Cos Phi Power factor terukur. Active Power Gen pd meter Mw Reactive Power Gen meter. MVArh Frequency (Turbine Speed) Hz Comp. Disch. Press. (Pk2) Bar Exhaust Gas Temp. °C Turbine Inlet Temperature. °C Steam Turbin Performance Operation Data.

Hasil 06/01/2015 35,50 1,009 57,50 33,00 0,00 33.500 1.045 123.077 123.000 292,50 10000 122.824 53.957 20 13,90 0,096 252,8 20 126,60

2,4 7,2 0,916 0,800 123 54,00 3.001 11,95 510 1.042



% %

Pact,net/Vf*Hlhv

33,91

Pact/Vf*Hlhv

33,98

MMBtu/Kwh

Vf*3600/Pact.

0,010

kcal/kwh kcal/kwh

860/Eff.Pd Trafo 860/Eff.Pd Trafo

10

2.535 2.530

Perhitungan Power Output dan Efficiency Terukur dikoreksi ke Kondisi yang digaransi Perhitungan Power Output danSebelum Efficiency Terukur dikoreksitype ke Kondisi Unit : GT. 1-3, Inspection C yang digaransi Unit : GT. 1-1, Setelah Inspection type C

Inspection ke : Periode tanggal :

25 06-Jan-15

Contractual Requirements - Ambient Pressure - Ambient Temperature - Relative Humidity - Pressure Drop Inlet (total) - Frequency - Fuel type - Lower Heating Value - Power factor - Generator/GIS Out going Terminal Voltage - Unit Condition

Site Test Conditions and Measuring Data 1,013 (bar) 30 (deg.C) 83 (%) 10 (mbar) 50 (Hz) HSD 42000 (kJ/kg) 0,9 15.75/150 kV Old & Clean

Fuel Oil Characteristic based on LMK - Density at 34.8 deg C - Net calorific Value - LHV (1 cal = 4.1868 Joule)

0,8337 (kg/l) 10210,18 (kCal/kg) 42748 (kJ/kg)

Guarantee Data for Gas Turbine Simple Cycle Test date 13 Desember 1994 at 14.00 - 14.25 - Load ( Base Load ) - Net electrical Output at HV-Terminal - Net electrical Heat rtae at HV-Terminal

100 % 128120 (kW) 10201,91 (kJ/kWh)

Measurig Uncertainties (According to DIN 1319/3) - Power Output Uncertainty for one GT (UePSC) - Efficiency Uncertainty (UeHRSC)

0,5196 % 1,0625 %

HSD unit % bar deg. C kW kW kVar mmWG -

GAS value

- Relative Humidity (Rhamb) - barometric Pressure (Pamb) - Ambient temperature (tamb) - Power Output (Pact) - Power Auxiliary (Paux) - Reactive power (Pract) - Static Pressure Inlet system (pei) - Caloric flowrate GAS acc. BP - Fuel Gas Flow (Flow):mf HSD acc. UBP Priok Lab. - Fuel oil Flow counter (Flow):Fc l/s - Fuel Oil Leakage Flow (Lflow): Fl l/s - Fuel Oil return Flow (Rflow) : Fr l/s - Specific gravity at 60/60 F kg/dm3 - Calorific Value Gross Btu/Lb - LHV = 4310+0,7195*GHV Btu/Lb - Fuel temperature (tf) deg. C - Generator Speed rpm - Power Factor (Cosphi) - Static Pressure IGV (pIGV) - Static Press. Exhst. SysTEM (pee) - Temperature Inlet turbine (TIT) deg. C -Temperature After Turbine (TAT) deg. C - Operating Hours (01/11/2012) OH Total bfr. Insp FALSE -

-

unit % bar deg. C kW kW kVar mmWG Btu/scf scm/h

value 57,50 1,009 35,50 123077 252,77 53957 33 1044,56 33500

deg. C rpm

3001 0,916 0 1042 510

deg. C deg. C OH Total 195453

bfr Insp 183643

Correction Factor For POWER OUTPUT based on Base Load for HSD and Base Load for GAS

Parameter Reference

Pamb Tamb Rhamb Frekw OH Pact Pract Cosphi Pact Cosphi

GMD 1072628 GMD 1072368 GMD 1072698 HTCT 71077 HTCM 647772-9 -

type Terukur Garansi Terukur Garansi Terukur Garansi Terukur Garansi terukur terukur Garansi

Nilai 1,013 30 83 3000

FUEL HSD Nilai item Faktor PambM PambG 1,013 CtaM CtaG 0,8944 CrhM 0,9965 CrhG 1,0075 CfrM CfrG 1,0000

- CohM - CgenM 128120 CgenG 0,85

1,0000 -


Cta = CtaG/CtaM Crh = CrhG/CrhM 1,011039 Cfr = CfrM/CfrG Coh = 1/CohM 1,000000 Cgen=CgenM/CgenG

type Terukur Garansi Terukur Garansi Terukur Garansi Terukur Garansi

Nilai 1,009 1,013 35,5 30 57,5 83 3001 3000

terukur

183643 CohM

Terukur -

0,9995

FUEL GAS Nilai item Faktor PambM 1,009 PambG 1,013 CtaM 0,8378 CtaG 0,8944 CrhM 0,9981 CrhG 1,0075 CfrM 0,9992 CfrG 1,0000

Garansi

123077 53957 CgenM 0,92 128120 CgenG 0,85


1,004412 Cta = CtaG/CtaM 1,067506 Crh = CrhG/CrhM 1,009430 Cfr = CfrM/CfrG 0,999234 Coh = 1/CohM 0,8907 1,122758 0,9988

0,9995

Cfactor : Cpa*Cta*Crh*Cfr*Coh*Cgen

- Cfactor = Cpa*Cta*Crh*Cfr*Coh*Cgen

Power Auxiliary ( kW )

- Power Auxiliary ( kW )

Cgen=CgenM/CgenG 0,999289919

1,080729927

252,77

Power Active Neto (Pact,GenCG) keluar Generator setelah dikoreksi (kW) Pact,GenCG = (PactM * Correction Factor) - PauxM =

-

Transformer Efficiency (nTr) : (1AHX4300 02)

- Transformer Efficiency (nTr) :

Pact,GenCG = (PactM * Correction Factor) - Paux =

132760,15

1,00

Power Active Neto Keluar Terminal (Pact,HVCG) ( kW ) -


11


132299,18

Correction Factor For EFFICIENCY at Base Load for HSD and Base Load for GAS

type

Parameter Reference

tamb Rhamb Fre OH Pact Pract Cosphi Pact Cosphi

GMD 1072628 GMD 1072368 GMD 1072698 HTCT 71077

Terukur Garansi Terukur Garansi Terukur Garansi terukur

HTCM 647772-9 -

terukur Garansi

Nilai

item

FUEL HSD Nilai Faktor

Faktor Koreksi - Ctae = CtaeG/CtaeM 0,9625 1,0014 Crhe = CrheG/CrheM 0,9969 0,995506 - Cfre = CfreG/CfreM 1,0000 1,000000 Cohe = 1/CohM 1,0000 1,000000

- CtaeM 30 CtaeG - CrheM 83 CrheG - CfreM 3000 CfreG - CoheM - CgeneM 128120 CgeneG 0,85

-

Cgene=CgeneM/CgeneG

type Terukur Garansi Terukur Garansi Terukur Garansi terukur Terukur

- Garansi

0,99947


Nilai

item

35,5 CtaeM 30 CtaeG 57,5 CrheM 83 CrheG 3001 CfreM 3000 CfreG

FUEL GAS Nilai Faktor 0,9456 0,8920 1,0008 0,9968 0,9999 1,0000

183643 CoheM 123076,9 53956,83 CgeneM 0,916 128120 CgeneG 0,85

Faktor Koreksi Ctae = CtaeG/CtaeM 0,943317 Crhe = CrheG/CrheM 0,996029 Cfre = CfreG/CfreM 1,000063 Cohe = 1/CohM 0,9276 1,078021 0,9988

-

0,999289919

0,9995

- Cfactor : Ctae*Crhe*Cfre*Cohe*Cgene

Power Auxiliary ( kW ) Efisiensi pada Output Gen (nM) % Efisiensi pada Output trafo (%) Heat rate pada output Generator ( kcal/kwh ) Heat rate pada output Trafo ( kcal/kwh )

Cgene=CgeneM/CgeneG

0,9389627 0,9389627

Power Auxiliary (kW) Efisiensi pada Output Gen (nM) % Efisiensi pada Output trafo (%) Heat rate pada output Generator (kcal/kwh) Heat rate pada output Trafo (kcal/kwh)

252,767 33,984 33,914 2530,17 2535,38

Efisiensi Output Generator dikoreksi ke kondisi garansi (n Gen CG) nNetGenCG= nM x C.factor x (1 - (PauxM/PactM)) =

#VALUE!

Efisiensi trafo : Effisiensi pada HV terminal GT Step up Transformer nHVCG = n NetGenCG x Effisiensi trafo (nTR) =

Efisiensi trafo :

#VALUE!

HRHVCG :Heat rate netto pada HV terminal Step up transformer dikoreksi ke kondisi garansi

Electrical Heat rate (neto) Efficiency Termal (neto)

Transformer dikoreksi ke kondisi garansi

GAS 123077 2530,17 33,984 0,0100 122824 2535,38 33,914

satuan kW kcal/kwh % MMBTU/kWh

kW kcal/kwh %

Hasil Perhitungan Setelah Dikoreksi ke kondisi garansi Perhitungan Power Output Generator


HSD #VALUE!

GAS 132760 2700,19 31,844

Perhitungan Power Output pada ujung terminal HV step up Trafo


HSD #VALUE!

HRHV,CG = 860/nHV,CG (kcal/kwh) = HRHVCG :Heat rate netto pada HV terminal Step up

SUMMARY

Power Output neto pada terminal Trafo Gen

nHVCG = nNetGenCG x Effisiensi trafo (nTR) =

31,733

Transformer dikoreksi ke kondisi garansi.

-

Satuan kW kcal/kwh % Ltr/kWh kW kcal/kwh %

0,9965

nHVCG; Efisiesi neto pada HV-Terminal Step up

HRHV,CG = 860/nHV,CG (kcal/kwh) =

HSD -

31,844

Effisiensi Neto pada HV terminal GT Step up Transformer

nHVCG; Efisiesi neto pada HV-Terminal Step up Transformer dikoreksi ke kondisi garansi. Heat Rate pada HV terminal GT. Step up Transformer

Hasil Pengukuran Aktual (site) Power Output Aktual Gross Electrical Heat rate Efficiency Termal Specific Fuel Consumption

nNetGenCG= nM x C.factor x (1 - (Paux/PactM))=

GAS 132299 #VALUE! 31,733

12

#VALUE!

Perhitungan Hasil Pengukuran '' SETELAH C-Insp: GT. 1-3'' pada Beban 78 MW dengan bahan bakar GAS Perhitungan Hasil Pengukuran '' SETELAH C-Insp: GT. 1-1''


12 12a 12b 12c 13 14 15 16 17

Satuan

Beban 100 MW

Rumus

Pengambilan data Amb. Temperature (4 Therm) ° Celcius t rata² Amb. Pressure Bar Abs. Amb. Rel. Humidity % Inlet Total Press. Loss. **) Mm H2O Static Press.Drop V IGV. **) Mm H2O Fuel Flow Berat ( Mf ) Vf * Fd Volume Flow rate (Vf) Berat Jenis (Fd) Fuel Oil Temp. ( t ) ° Celcius Fuel Flow Rate (Vf) scm/h Fc - Fl - Fr Flow Counter ( Fc ) Flow of Leakage ( Fl ) Flow of Return ( Fr ) Nilai kalor bawah (LHV) Btu/Scf Active Power Gen. (Pact) Kw (KWH*3600)/t Kw Generator pada meter. Kw Waktu pengukur Kwh.(t) s Hasil pengukuran KWh. Kwh Active Power Netto (Pact,net) Kw Pact - Paux Reactive Power (Pract) GT KVAr Imp*3600/t*const Impulses of the KVArh Count. (Imp). Waktu u/ jumlah impuls pada s KVArh meter. ( t ). Constanta (const) imp/kvarh 0,096 imp/kvarh Auxiliary Power for GT (Paux) KW Imp*3600/t*const Impulse pd. KWH meter. rev Waktu u/ jumlah impuls pada s KWH meter Constant of Aux. counter *) Untuk # 11,12,21,22 2.4imp/KWh Untuk # 1.3 & GT.23 7.2imp/KWh Power Factor (Cos Phi) GT Cos[arctan(Pract/Pact)] Cos Phi Power factor terukur. Active Power Gen pd meter Mw Reactive Power Gen meter. MVArh Frequency (Turbine Speed) Hz Comp. Disch. Press. (Pk2) Bar Exhaust Gas Temp. °C TurbineTurbin Inlet Temperature. °C Steam Performance Operation Data.

Hasil 06/01/2015 35,05 1,009 54,00 0,00 60,00 30.400 1.045 100.000 100.000 360,00 10000 99.754 98.039 20 7,65 0,096 245,7 20 130,50

2,4 7,2 0,714 0,700 100 75,05 2.999 10,6 481,00 969



% %

Pact,net/Vf*Hlhv

30,35

Pact/Vf*Hlhv

30,43

MMBtu/Kwh

Vf*3600/Pact.

0,011

kcal/kwh

860/Eff.Pd Trafo

2.833

kcal/kwh

860/Eff.Pd Trafo

2.826

13

Perhitungan Hasil Pengukuran '' SETELAH C-Insp: GT. 1-3'' pada Beban 78 MW dengan bahan bakar GAS Perhitungan Hasil Pengukuran '' SETELAH C-Insp: GT. 1-1'' 1 2 3 4 5 6 7a

Satuan

Rumus



t rata²

7a1 7a2 7a3 7b


7b1 7b2 7b3 7b4 8


8a 8b 8c 9


10


10a 10b 10c 11 11a 11b 11c

12 12a 12b 12c 13 14 15 16 17

Beban 76 MW

Bahan Bakar: GAS

Vf * Fd


° Celcius scm/h

Fc - Fl - Fr

Btu/Scf Kw

(KWH*3600)/t

Kw s Kwh Kw

Pact - Paux

KVAr

Imp*3600/t*const

7,65

s imp/kvarh KW

Hasil 06/01/2015 34,95 1,008 54,30 0,00 60,00 25.900 1.045 75.901 75.800 474,30 10000 74.966 98.039 20


Impulse pd. KWH meter. rev Waktu u/ jumlah impuls pada s KWH meter Constant of Aux. counter *) Untuk # 11,12,21,22 2.4imp/KWh Untuk # 1.3 & GT.23 7.2imp/KWh Power Factor (Cos Phi) GT Cos[arctan(Pract/Pact)] Cos Phi Power factor terukur. Active Power Gen pd meter Mw Reactive Power Gen meter. MVArh Frequency (Turbine Speed) Hz Comp. Disch. Press. (Pk2) Bar Exhaust Gas Temp. °C TurbineTurbin Inlet Temperature. °C Steam Performance Operation Data.

0,096 935,3 20 32,63 2,4 7,2 0,612 0,700 76 89,00 3.000 10,7 481,00 961



% %

Pact,net/Vf*Hlhv

MMBtu/Kwh

Vf*3600/Pact.

kcal/kwh

860/Eff.Pd Trafo

kcal/kwh

860/Eff.Pd Trafo

14

Pact/Vf*Hlhv

26,77 27,11 0,013 3.212 3.172

EVALUASI PERFORMANCE TEST (C inspect. GT. 1-1 tahun 2015) Dari hasil perhitungan Performance Test GT. 1-1 pada Beban Base Load MW dengan GAS sebelum inspect dan Beban Base Load MW dengan GAS setelah inspect Item Satuan Rumus Hasil Sebelum Hasil Sesudah Tanggal pengambilan data Fuel Flow Rate (vf) Nilai Kalor Bawah (LHV)

HSD GAS HSD GAS

kg/s scm/h kcal/kg Btu/scf

Active Power Gen. (Pact) Waktu Pengukuran KWh (t) Active Power Netto (Pact,net) Reactive Power (Pract) Impulse Counter kvar (imp)

kW s kW kVar imp

Waktu Pengukuran Kvar meter (t) Auxiliary Power GT (Paux) Impulse Counter Aux (imp) Waktu Pengukuran Kwh Aux. (t)

s kW imp s

Power Factor (cos phi) GT

21/07/2014 32.850,00 1.090,49

06/01/2015 33.500,00 1.044,56

122.000,40 295,08 121.749,02 35.548,39 20,00

123.076,92 292,50 122.824,16 53.956,83 20,00

21,10 251,38 20,00 127,35

13,90 252,77 20,00 126,60

(kWh * 3600)/t Pact - Paux Imp * 3600 / t * const Imp * 3600 / t * const

Cos (arctan(Pract/Pact))

Efisiensi pada Output Trafo % Efisiensi pada Output Generator % Specific Fuel Comps. HSD l/kwh GAS mmbtu/kWh Heat Rate pada Output Trafo kcal/kwh Heat Rate pada Output Generator kcal/kwh

Pact / Ff * hLHV Pacg / Ff * hLHV Vf * 3600 / Pact 860/Eff.Pd Trafo 860/Eff.Pd Trafo

0,96

0,92

32,84 32,91 0,010 2.618,43 2.613,04

33,91 33,98 0,010 2.535,38 2.530,17

Perhitungan Perbandingan Sebelum - Setelah dilakukan Inpection GT. 1-1 Berdasarkan data Heat Rate adalah : Heat Rate sebelum inspection pada Output Trafo

=

2.618,43 kcal/kwh

Heat Rate setelah inspection pada Output Trafo

=

2.535,38 kcal/kwh

Selisih Heat Rate

=

83,05 kcal/kwh

Cost Benefit Analysis (CBA) = =

24 jam x 30 hari x Base Load x 0,60

(Asumsi CF 0,60)

Asumsi Harga Bahan Bakar GAS

=

0,9243 Rp/kcal

Pendapatan per bulan

=

Produksi kWh Netto 1 bulan

=

Pendapatan yang didapat per periode C inspection (setara = dengan 34 Bulan) =

53.169.231 kWh

83,05 Kcal/kWh x 53.169.231 kWh x 0,9243 Rp/Kcal 4.081.701.584 Rupiah

34 Bulan x Rp. 4.081.701.584 ,Rp

138.777.853.856

=

Rp

4.950.000.000

Jadi saving yang didapat UBP = Priok adalah

Rp

133.827.853.856

Biaya Jasa Inspection type C

Payback Periode

=

0,04

15

atau setara dengan 1 Bulan

Kesimpulan dan Rekomendasi Kesimpulan : 

Dari hasil performance test yang dilakukan setelah pelaksanaan kegiatan inspection GT – 1.1 type C, terlihat adanya kenaikan effisiensi dan juga penurunan heat rate seperti pada table berikut: Uraian Efisiensi pada Output Trafo Heat Rate pada Output Trafo

Satuan % Kcal/kWh

Sebelum 32,84 2618,43

Setelah 33,91 2535,38

Hal ini menunjukkan bahwa kegiatan C inspection yang dilakukan adalah berhasil dengan indicator meningkatnya efisiensi performance GT – 1.1 sebesar 1,07 %. 

Pada kegiatan inspection type C GT 1.1 kali ini dilakukan penggantian beberapa tula dan tule juga Heat Shield Row A Segment dengan material yang baru. Juga dilakukan pekerjaan reinsulation pada HRSG 1.1 untuk mengurangi heat loss.

Rekomendasi : Agar kondisi performance unit pembangkit GT 1.1 tetap terjaga, maka rekomendasi untuk inspection yang akan datang adalah : 1. Agar dilakukan penggantian Inlet Air Filter (IAF) GT 1.1 pada saat DP IAF mendekati 4,5 Inch H2O dengan melakukan monitoring secara intensif. 2. Untuk kegiatan inspection berikutnya type B, agar dilakukan pencucian compressor dan dimasukan dalam scope of work standard inspection. 3. Bila memungkinkan agar dilakukan proses pencucian compressor secara online (online washing compressor)

16

Tabel Correction Factor of Ambient temperature for Power Output (Tranfer from GMD 1 072 628) 0 Koreksi 5 0,9 0,98 10 15 151 20 0,991,02 25 y= y= 20 1,03 -4,5567x² 2E-05x²-0,0036x+1,0542 + 9,8339x -y= 4,277 30 -0,0072x 14 + 1,05 1,05 50 30 Tabel Faktor " Suhu Ambient" untuk Thermal Efisiensi

Created from GMD 1 072 629, Correction curve for Thermal Efficiency 1,20

η / ηo

1,10 1,00 0,90 0,80 0,70 0,60 0,50 Humidity = const. Barometric press = const. Speed n = 3000 min-1 Power factor cos phi = 0,8

0,40 0,30

compresssor intake temp.

0,20

XD ref. = XD (15 oC; 1,01325 bar; φ =0,6)

0,10 -20

-10

Load 25 % y = -1E-05x2 - 0.0018x + 0.5759 R2 = 0.9999

0

10

20

30

40

Tk1 (oC)

50

Load 50 % y = -1E-10x5 + 8E-09x4 - 5E-08x3 - 2E-05x2 - 0.0021x + 0.835 R2 = 0.9999

Load 75 % y = -1E-10x5 + 1E-08x4 - 5E-08x3 - 2E-05x2 - 0.0019x + 0.9611 R2 = 0.9999 Load 100 % y = 3E-09x4 + 1E-07x3 - 2E-05x2 - 0.0017x + 1.03 R2 = 0.9999

Load 25 % Suhu Faktor 0 0,57590 2 0,57226 4 0,56854 6 0,56474 8 0,56086 10 0,55690 12 0,55286 14 0,54874 16 0,54454 18 0,54026 20 0,53590 22 0,53146 24 0,52694 26 0,52234 28 0,51766 30 0,51290 32 0,50806 34 0,50314 36 0,49814 38 0,49306 40 0,48790 42 0,48266 44 0,47734 46 0,47194 48 0,46646 50 0,46090

Load 50 % Suhu Faktor 0 0,83500 2 0,83072 4 0,82628 6 0,82168 8 0,81692 10 0,81202 12 0,80697 14 0,80180 16 0,79649 18 0,79108 20 0,78556 22 0,77995 24 0,77425 26 0,76847 28 0,76262 30 0,75670 32 0,75071 34 0,74466 36 0,73854 38 0,73233 40 0,72604 42 0,71964 44 0,71311 46 0,70644 48 0,69958 50 0,69250

Peak Load y = 1E-08x3 - 1E-05x2 - 0.0015x + 1.0412 R2 = 0.9999

Load 75 % Suhu Faktor 0 0,96110 2 0,95722 4 0,95318 6 0,94898 8 0,94463 10 0,94014 12 0,93552 14 0,93077 16 0,92593 18 0,92099 20 0,91598 22 0,91091 24 0,90581 26 0,90068 28 0,89555 30 0,89042 32 0,88531 34 0,88023 36 0,87520 38 0,87020 40 0,86526 42 0,86036 44 0,85551 46 0,85069 48 0,84589 50 0,84110

17

Load 100 % Suhu Faktor 0 1,03000 2 1,02652 4 1,02289 6 1,01911 8 1,01518 10 1,01113 12 1,00696 14 1,00267 16 0,99829 18 0,99382 20 0,98928 22 0,98469 24 0,98006 26 0,97541 28 0,97076 30 0,96613 32 0,96154 34 0,95702 36 0,95258 38 0,94826 40 0,94408 42 0,94006 44 0,93624 46 0,93265 48 0,92930 50 0,92625

Peak Load Suhu Faktor 0 1,04120 2 1,03816 4 1,03504 6 1,03184 8 1,02857 10 1,02521 12 1,02178 14 1,01827 16 1,01468 18 1,01102 20 1,00728 22 1,00347 24 0,99958 26 0,99562 28 0,99158 30 0,98747 32 0,98329 34 0,97903 36 0,97471 38 0,97031 40 0,96584 42 0,96130 44 0,95669 46 0,95201 48 0,94727 50 0,94245

Tabel Generator Correction Factor (Tranfer from HTCM 647772-9)

0 5 0,9 10Suhu 15 Ambient" 151 20 0,991,02Power 25 y= y= 20 1,03 -4,5567x² 2E-05x²-0,0036x+1,0542 + 9,8339x -y= 4,277 30 -0,0072x 14 1,05 + 1,05 50 30 Tabel Faktor Koreksi "0,98 untuk Output Created from GMD 1 072 628, Correction curve for Power Output 1,40

P / Po

Humidity = const. Barometric press = const. Speed n = 3000 min-1 Power factor cos phi = 0,8

corr. fac power output

1,30 1,20 1,10 1,00

Peak Load

0,90 0,80

100%

0,70

75%

0,60 0,50

50%

0,40

XD ref. = XD (15 oC; 1,01325 bar; φ =0,6)

0,30 25%

0,20

compresssor intake temp.

0,10 -20

-10

Load 25 % y = 9E-08x3 - 9E-06x2 - 0.0016x + 0.2752 R2 = 0.9999

0

10

Load 50 % y = -3E-06x2 - 0.0032x + 0.5474 R2 = 0.9999

Load 100 % y = 3E-12x6 - 4E-10x5 + 7E-09x4 + 7E-07x3 - 3E-05x2 - 0.0065x + 1.1033 R2 = 0.9998

Load 25 % Suhu Faktor 0 0,27520 2 0,27196 4 0,26866 6 0,26530 8 0,26187 10 0,25839 12 0,25486 14 0,25128 16 0,24766 18 0,24401 20 0,24032 22 0,23660 24 0,23286 26 0,22910 28 0,22532 30 0,22153 32 0,21773 34 0,21393 36 0,21014 38 0,20634 40 0,20256 42 0,19879 44 0,19504 46 0,19132 48 0,18762 50 0,18395

20

Load 50 % Suhu Faktor 0 0,54740 2 0,54099 4 0,53455 6 0,52809 8 0,52161 10 0,51510 12 0,50857 14 0,50201 16 0,49543 18 0,48883 20 0,48220 22 0,47555 24 0,46887 26 0,46217 28 0,45545 30 0,44870 32 0,44193 34 0,43513 36 0,42831 38 0,42147 40 0,41460 42 0,40771 44 0,40079 46 0,39385 48 0,38689 50 0,37990

40

Tk1 (oC)

50

Load 75 % y = 1E-07x3 - 1E-05x2 - 0.0049x + 0.825 R2 = 0.9998 Peak Load y = 2E-07x3 - 2E-05x2 - 0.0066x + 1.1886 R2 = 0.9997

Load 75 % Suhu Faktor 0 0,82500 2 0,81516 4 0,80525 6 0,79526 8 0,78521 10 0,77510 12 0,76493 14 0,75471 16 0,74445 18 0,73414 20 0,72380 22 0,71342 24 0,70302 26 0,69260 28 0,68216 30 0,67170 32 0,66124 34 0,65077 36 0,64031 38 0,62985 40 0,61940 42 0,60897 44 0,59856 46 0,58817 48 0,57782 50 0,56750

18

30

Load 100 % Suhu Faktor 0 1,10330 2 1,09019 4 1,07687 6 1,06338 8 1,04975 10 1,03603 12 1,02224 14 1,00842 16 0,99458 18 0,98074 20 0,96693 22 0,95315 24 0,93941 26 0,92570 28 0,91201 30 0,89834 32 0,88466 34 0,87095 36 0,85718 38 0,84333 40 0,82935 42 0,81521 44 0,80089 46 0,78634 48 0,77152 50 0,75643

Peak Load Suhu Faktor 0 1,18860 2 1,17532 4 1,16189 6 1,14832 8 1,13462 10 1,12080 12 1,10687 14 1,09283 16 1,07870 18 1,06449 20 1,05020 22 1,03585 24 1,02144 26 1,00700 28 0,99251 30 0,97800 32 0,96347 34 0,94894 36 0,93441 38 0,91989 40 0,90540 42 0,89094 44 0,87652 46 0,86215 48 0,84784 50 0,83360

Tabel Generator Correction Factor (Tranfer from HTCM 647772-9)

Tabel Generator Correction Factor GT 13E PLTGU Created from HTCM 647772-9 Correction curve for Power Output power output 1 0,9 0,85 0,8 0,85

Cos phi

140

40

60

80

100

120

0,998875 0,999475 0,999700 1,000000 1,000600

0,998675 0,999375 0,999667 1,000000 1,000750

0,998500 0,999275 0,999625 1,000000 1,000900

0,998300 0,999150 0,999575 1,000000 1,001090

0,998100 0,999050 0,999500 1,000000 1,001260

0,997850 0,998900 0,999440 1,000000 1,001475

160

180

200

0,997600 0,998750 0,999350 1,000000 1,001735

0,997375 0,998575 0,999250 1,000000 0,000000

0,997100 0,998400 0,999150 1,000000 0,000000

Generator Correction Factor 1,003 0.7 C gen = correction factor for power factor

1,002

1,001 0.8

1,000 0.85

0,999 0.9

0,998

0,997

0,996 0

20

40

60

80

100

120

140

160

180

200

220

P = active output power of generator (MW) cos phi = 0.7 y = 3E-14x5 - 1E-11x4 + 2E-09x3 - 1E-07x2 + 1E-05x + 1.0003 R2 = 0.9997

cos phi = 0.9 y = 1E-14x5 - 8E-12x4 + 2E-09x3 - 2E-07x2 + 2E-06x + 0.9996 R2 = 0.9998

cos phi = 0.85 y = 1E-14x5 - 7E-12x4 + 2E-09x3 - 2E-07x2 + 9E-06x + 0.9996 R2 = 0.9992

cos phi = 1 y = -2E-14x5 + 1E-11x4 - 3E-09x3 + 3E-07x2 - 2E-05x + 0.9995 R2 = 0.9998

Beban

40 50 60 70 80 90 100 110 120

cos phi 1

0,99888 0,99878 0,99868 0,9986 0,9985 0,9984 0,9983 0,99818 0,9981

cos phi 0.9

0,99948 0,99943 0,99938 0,99933 0,99928 0,9992 0,99915 0,9991 0,99905

cos phi 0.85 cos phi 0.8 cos phi 0.7

0,9997 0,999683 0,999667 0,99965 0,999625 0,9996 0,999575 0,999525 0,9995

1 1 1 1 1 1 1 1 1

1,0006 1,00068 1,00075 1,00083 1,0009 1,001 1,00109 1,00115 1,00126

19

Beban

130 140 150 160 170 180 190 200 210

cos phi 1

0,99798 0,99785 0,99773 0,9976 0,9975 0,99738 0,99723 0,9971 0,99695

cos phi 0.9 cos phi 0.85 cos phi 0.8 cos phi 0.7

0,99898 0,9989 0,99883 0,99875 0,99868 0,99858 0,99848 0,9984 0,9983

0,99948 0,99944 0,9994 0,99935 0,9993 0,99925 0,9992 0,99915 0,9991

1 1 1 1 1 1 1 1 1

1,00136 1,00148 1,0016 1,00174 1,00193

Tabel Relative Frequency – Relative Power (Transfer from GMD 1 072 698)

Tabel Relative Frequency vs Relative Power Create from GMD 1 072 698 influence of Speed on Power ISO, Base Load

RelFreq RelPwr

0,950 0,9525

0,960 0,9644

0,970 0,975

0,980 0,9844

0,990 0,9925

1,000 1

1,010 1,0078

1,020 1,0125

1,030 1,0175

1,040 1,0219

1,050 1,0259

1,030 1,025 1,025938

1,020

1,02188

1,015

1,0175

Rel. Power ( RP )

1,010

1,0125

1,0078

1,005 1,000 1

0,995 0,990

0,9925

0,985 0,9844

0,980 0,975

0,975

0,970 0,965

0,9644

y = 65,50x4 - 249,8x3 + 351,8x2 - 215,4x + 48,98 R² = 0,999

0,960 0,955 0,950

0,9525

0,950

RF 0,950 0,951 0,952 0,953 0,954 0,955 0,956 0,957 0,958 0,959 0,960 0,961 0,962 0,963

RP 0,95180 0,95302 0,95423 0,95543 0,95662 0,95780 0,95897 0,96012 0,96127 0,96240 0,96352 0,96464 0,96574 0,96683

0,960

RF 0,964 0,965 0,966 0,967 0,968 0,969 0,970 0,971 0,972 0,973 0,974 0,975 0,976 0,977

0,970

RP 0,96791 0,96898 0,97004 0,97108 0,97212 0,97314 0,97416 0,97516 0,97616 0,97714 0,97811 0,97907 0,98003 0,98097

0,980

RF 0,978 0,979 0,980 0,981 0,982 0,983 0,984 0,985 0,986 0,987 0,988 0,989 0,990 0,991

0,990 1,000 Rel. Frequency (RF)

RP 0,98190 0,98282 0,98373 0,98462 0,98551 0,98639 0,98726 0,98812 0,98896 0,98980 0,99063 0,99145 0,99226 0,99305

RF 0,992 0,993 0,994 0,995 0,996 0,997 0,998 0,999 1,000 1,001 1,002 1,003 1,004 1,005

20

RP 0,99384 0,99462 0,99539 0,99615 0,99690 0,99764 0,99837 0,99909 0,99980 1,00050 1,00120 1,00188 1,00256 1,00322

1,010

RF 1,006 1,007 1,008 1,009 1,010 1,011 1,012 1,013 1,014 1,015 1,016 1,017 1,018 1,019

1,020

RP 1,00388 1,00453 1,00517 1,00580 1,00642 1,00704 1,00765 1,00824 1,00883 1,00942 1,00999 1,01056 1,01111 1,01167

1,030

RF 1,020 1,021 1,022 1,023 1,024 1,025 1,026 1,027 1,028 1,029 1,030 1,031 1,032 1,033

RP 1,01221 1,01274 1,01327 1,01379 1,01431 1,01482 1,01532 1,01581 1,01630 1,01678 1,01725 1,01772 1,01818 1,01863

1,040

RF 1,034 1,035 1,036 1,037 1,038 1,039 1,040 1,041 1,042 1,043 1,044 1,045 1,046 1,047

1,050

RP 1,01908 1,01953 1,01996 1,02040 1,02082 1,02125 1,02166 1,02207 1,02248 1,02288 1,02328 1,02367 1,02406 1,02444

Tabel Relative Frequency – RelativeEfficiency(Transfer from GMD 1 072 699)

Tabel Relative Frequency vs Relative Eficiency Create from GMD 1 072 699 influence of Speed on Efficiency ISO, Base Load

RelFreq RelPwr

0,950 0,960 0,970 0,9887 0,9918 0,9947

0,980 0,990 0,997 0,9988

1,000 1,010 1,020 1,030 1,040 1,050 1 1,0009 1,0015 1,0016 1,0013 1,0008

1,002 1,0016

1,001 1,0009

1,000

1,0013

1,0008

1,0000

0,999

Rel. Efficiency ( REff )

1,0015

0,9988

0,998 0,997

0,9970

0,996 0,995 0,9947

0,994 0,993 0,992

0,9918

0,991

y = 11,44x4 - 41,96x3 + 55,02x2 - 29,84x + 6,332 R² = 0,999

0,990 0,989

0,9887

0,988

0,950

RF 0,950 0,951 0,952 0,953 0,954 0,955 0,956 0,957 0,958 0,959 0,960 0,961 0,962 0,963

REff 0,98851 0,98885 0,98920 0,98954 0,98987 0,99020 0,99052 0,99084 0,99115 0,99146 0,99176 0,99206 0,99236 0,99264

0,960

RF 0,964 0,965 0,966 0,967 0,968 0,969 0,970 0,971 0,972 0,973 0,974 0,975 0,976 0,977

0,970

REff 0,99293 0,99320 0,99348 0,99374 0,99401 0,99427 0,99452 0,99477 0,99501 0,99525 0,99548 0,99571 0,99593 0,99615

0,980

RF 0,978 0,979 0,980 0,981 0,982 0,983 0,984 0,985 0,986 0,987 0,988 0,989 0,990 0,991

0,990 1,000 Rel. Frequency (RF)

REff 0,99637 0,99658 0,99678 0,99698 0,99718 0,99737 0,99755 0,99773 0,99791 0,99808 0,99825 0,99841 0,99857 0,99872

RF 0,992 0,993 0,994 0,995 0,996 0,997 0,998 0,999 1,000 1,001 1,002 1,003 1,004 1,005

21

REff 0,99887 0,99902 0,99915 0,99929 0,99942 0,99955 0,99967 0,99979 0,99990 1,00001 1,00011 1,00021 1,00031 1,00040

1,010

RF 1,006 1,007 1,008 1,009 1,010 1,011 1,012 1,013 1,014 1,015 1,016 1,017 1,018 1,019

1,020

REff 1,00049 1,00057 1,00065 1,00073 1,00080 1,00086 1,00093 1,00098 1,00104 1,00109 1,00114 1,00118 1,00122 1,00125

1,030

RF 1,020 1,021 1,022 1,023 1,024 1,025 1,026 1,027 1,028 1,029 1,030 1,031 1,032 1,033

REff 1,00128 1,00131 1,00133 1,00135 1,00137 1,00138 1,00139 1,00139 1,00139 1,00139 1,00139 1,00138 1,00136 1,00135

1,040

RF 1,034 1,035 1,036 1,037 1,038 1,039 1,040 1,041 1,042 1,043 1,044 1,045 1,046 1,047

1,050

REff 1,00133 1,00130 1,00128 1,00124 1,00121 1,00117 1,00113 1,00109 1,00104 1,00099 1,00094 1,00089 1,00083 1,00077

Tabel Influence of Humidity (transfer from GMD 1 072 368)

Tabel Influence of Humidity for GT 13E PLTGU Created from GMD 1 072 368 Influence of Humidity 70

T

(oC) 0.1

0.2

0.5

0.4

0.3

0.7

0.6

0.8

60

ambient air temperature

0.9 1.0

50

40 RH = 0,6 y = 18.132Ln(x) + 105.09 R2 = 0.9999

RH = 1,0 y = 17.334Ln(x) + 92.455 R2 = 0.9997

RH = 0,5 y = 18.265Ln(x) + 109.12 R2 = 0.9999

RH = 0,9 y = 17.493Ln(x) + 95.172 R2 = 0.9999

RH = 0,2 y = 18.953Ln(x) + 129.22 R2 = 0.9999

RH = 0,4 y = 18.863Ln(x) + 115.52 R2 = 0.9998

RH = 0,8 y = 17.886Ln(x) + 98.59 R2 = 0.9998

RH = 0,1 y = 20.123Ln(x) + 147.76 R2 = 0.9999

RH = 0,3 y = 18.952Ln(x) + 121.34 R2 = 0.9998

RH = 0,7 y = 17.849Ln(x) + 101.16 R2 = 0.9999

30

20

10

0 0

0,01

0,02

0,03

1,04

P / Po η / ηo

1,03

0,04 0,05 0,06 0,07 0,08 XD [kg H2O / kg air Water content of the air

0,09 dry

0,1

0,11

0,12

0,13

]

Power Out Put Thermal Efficiency

P / Po

2 + 0,520x + 0,996 y = -1,637x RH = 1,0 = 0,997 y =R² 17.334Ln(x) + 92.455 R2 = 0.9997

1,02

RH = 0,9 y = 17.493Ln(x) + 95.172 R2 = 0.9999

1,01

1

η / ηo y = -0,202x + 1,001 R² = 0,998

0,99

0,98 Water content of the air

XD [kg H2O / kg air

dry

]

0,97 0

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0,08

0,09

0,1

0,11

0,12

0,13

1,01

m / mo

XD ref. = XD (15 oC; 1,01325 bar; φ =0,6)

Suction air mass flow

1 RH = 1,0 y = 17.334Ln(x) + 92.455 R2 = 0.9997

0,99

y = -0,601x + 1,004 R² = 0,999

0,98

m / mo 0,97

Water content of the air

0,96

XD [kg H2O / kg air

dry

]

0,95 0

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0,08

0,09

22

0,1

0,11

0,12

0,13

Tabel Tranformer Efficiency GT 13E (transfer from 1 AHX 430 002)

Tabel Transformer Efficiency GT 13E PLTGU Created from 1 AHX 430 002, Transformator Efficiency Curve

MVA Cos Phi

10 0,99000 0,99000 0,99000 0,99000

1 0,9 0,8 0,7

20 0,99625 0,99570 0,99520 0,99450

50 0,99780 0,99742 0,99715 0,99660

70 0,99778 0,99740 0,99718 0,99670

100 0,99735 0,99705 0,99665 0,99630

150 0,99660 0,99620 0,99560 0,99515

200 0,99575 0,99527 0,99455 0,99400

220 0,99535 0,99480 0,99415 0,99360

250 0,99480 0,99425 0,99350 0,99300

Transformer Efficiency Curve 0,999 0,998 0,997

Efficiency Trafo (%)

0,996

1.0

0,995

0.9

0,994

0.8 0,993

0.7

0,992 0,991 0,990 0,989

0

50

100

150

200

250

S (MVA) : Apparent Power LV side

S  S (MVA) 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 100 105 110

0,7 0,9900000 0,9922500 0,9945000 0,9948500 0,9952000 0,9955500 0,9959000 0,9962500 0,9966000 0,9966250 0,9966500 0,9966750 0,9967000 0,9966333 0,9965667 0,9965000 0,9964333 0,9963000 0,9961850 0,9960700

P

actM

Correction Factor based Cos Phi 0,8 0,9 0,9900000 0,9900000 0,9853160 0,9848616 0,9952000 0,9957000 0,9955250 0,9959867 0,9958500 0,9962733 0,9961750 0,9965600 0,9965000 0,9968467 0,9968250 0,9971333 0,9971500 0,9974200 0,9971575 0,9974150 0,9971650 0,9974100 0,9971725 0,9974050 0,9971800 0,9974000 0,9970917 0,9973417 0,9970033 0,9972833 0,9969150 0,9972250 0,9968267 0,9971667 0,9966500 0,9970500 0,9965450 0,9969650 0,9964400 0,9968800

 PauxM    PractM 2

1,0 0,9900000 0,9843655 0,9962500 0,9965083 0,9967667 0,9970250 0,9972833 0,9975417 0,9978000 0,9977950 0,9977900 0,9977850 0,9977800 0,9977083 0,9976367 0,9975650 0,9974933 0,9973500 0,9972750 0,9972000

23

S (MVA) 115 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210

2  0,7 0,9959550 0,9958400 0,9957250 0,9956100 0,9954950 0,9953800 0,9952650 0,9951500 0,9950350 0,9949200 0,9948050 0,9946900 0,9945750 0,9944600 0,9943450 0,9942300 0,9941150 0,9940000 0,9939000 0,9938000

Correction Factor based Cos Phi 0,8 0,9 0,9963350 0,9967950 0,9962300 0,9967100 0,9961250 0,9966250 0,9960200 0,9965400 0,9959150 0,9964550 0,9958100 0,9963700 0,9957050 0,9962850 0,9956000 0,9962000 0,9954950 0,9961070 0,9953900 0,9960140 0,9952850 0,9959210 0,9951800 0,9958280 0,9950750 0,9957350 0,9949700 0,9956420 0,9948650 0,9955490 0,9947600 0,9954560 0,9946550 0,9953630 0,9945500 0,9952700 0,9944500 0,9951525 0,9943500 0,9950350

1,0 0,9971250 0,9970500 0,9969750 0,9969000 0,9968250 0,9967500 0,9966750 0,9966000 0,9965150 0,9964300 0,9963450 0,9962600 0,9961750 0,9960900 0,9960050 0,9959200 0,9958350 0,9957500 0,9956500 0,9955500

Tabel Expected Non Recoverable Deterioration (transfer from HTCT 71 630)

Tabel Expected Non Recoverable Deterioration of Power Output and Efficiency Vs. OH After Compressor off-line Cleaning only valid for performance test after 80 OH and for normal loading Created from HTCT 71 630, Expected Non Recoverable Deterioration of Power Output and Efficiency

0

1

2

3

4

5

6

7

8

9

0

% Multiplicative

-0,5 -1 y = -0.4987Ln(x) - 1.1928 R2 = 0.9982

-1,5

EFFICIENCY

-2 -2,5 -3 y = -0.7513Ln(x) - 1.8273 R2 = 0.9973

-3,5

POWER OUTPUT

-4 Operating Hours (OH) - (thousand)

OH 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800

Efficiency Power Output -0,390173 -0,618129 -0,735846 -1,138891 -0,938051 -1,443517 -1,081518 -1,659652 -1,192800 -1,827300 -1,283724 -1,964278 -1,360599 -2,080092 -1,427191 -2,180414 -1,485929 -2,268904 -1,538472 -2,348061 -1,586004 -2,419668 -1,629396 -2,485040 -1,669314 -2,545176 -1,706271 -2,600853

OH 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600

Efficiency Power Output -1,740678 -2,652687 -1,772863 -2,701175 -1,803097 -2,746722 -1,831602 -2,789666 -1,858565 -2,830286 -1,884145 -2,868823 -1,908477 -2,905479 -1,931676 -2,940429 -1,953844 -2,973826 -1,975069 -3,005801 -1,995427 -3,036471 -2,014986 -3,065937 -2,033807 -3,094292 -2,051944 -3,121615

24

OH 5800 6000 6200 6400 6600 6800 7000 7200 7400 7600 7800 8000

Efficiency Power Output -2,069444 -3,147979 -2,086350 -3,173449 -2,102703 -3,198084 -2,118536 -3,221937 -2,133882 -3,245055 -2,148769 -3,267484 -2,163225 -3,289262 -2,177274 -3,310427 -2,190938 -3,331012 -2,204238 -3,351048 -2,217192 -3,370563 -2,229817 -3,389584

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