ULUMUDIN, AHYA' (2020) PERANCANGAN LOGIC PROGRAM DCS UNTUK COAL BURNER STARTUP/SHUT DOWN SEQUENCE GUNA OPTIMISASI KONSUMSI BBM PADA UNIT 5-7 PLTU SURALAYA. S1 thesis, Universitas Mercu Buana.
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Abstract
Suralaya Power Plant is one of thermal power plant which use pulverized coal as its main fuel. Beside pulverized coal, diesel fuel was used in the startup and shut down process of coal burners. The use of diesel fuel in the startup and shut down process of coal burners at the Suralaya power plant basically can run automatically through the logic program in the DCS (Distributed Control System), but several process changes have been made by the operator manually for diesel fuel consumption saving in the process. In its implementation there are inconsistencies in the use of diesel fuel so as to provide a gap to optimize diesel consumption by finding the best method of operation. Identification of the operating method is carried out to find the most efficient operating pattern in the consumption of diesel fuel at the start up and shut down coal burner process. The design of the DCS logic program modification is done to apply the best pattern so that it runs automatically to reduce the inconsistency of the results in the process of startup and shut down coal burner. The design of the process modification is based on the recommendation of NFPA 85 (National Fire Protection Academy), best practices that have been carried out as well as technical recommendations from the manufacturing of installed boilers. The program design created provides opportunities for efficiency in processing time and savings in the cost of using diesel fuel of around 17.38% and 8.5% for each process of startup and shut down coal burner. The total potential cost savings obtained from these modifications to the DCS Suralaya power plant unit 5-7 is worth Rp. 35,941,799.16 per month. Keywords : Coal burner startup/shut down sequence, Logic Program DCIS, Units 5-7 Suralaya Power Plant, Modification, Optimizations, Diesel Fuel. PLTU Suralaya merupakan salah satu pusat pembangkit listrik thermal tenaga uap yang menggunakan batu bara halus (pulverizerd coal) sebagai bahan bakar utamanya. Selain memakai bahan bakar batu bara, PLTU Suralaya juga menggunakan bahan bakar solar pada sebagian proses produksinya. Salah satu proses yang menggunakan bahan bakar solar adalah proses startup dan shut down coal burner. Kedua proses tersebut pada dasarnya dapat berjalan secara otomatis melalui logic program yang ada pada DCS (Distributed Control System), namun telah dilakukan beberapa perubahan proses oleh operator secara manual guna menghemat konsumsi bahan bakar solar pada proses tersebut. Dalam pelaksanaannya terdapat inkonsistensi pemakaian solar pada setiap proses startup dan shut down coal burner. Hal ini memberi celah untuk optimisasi konsumsi solar dengan mencari metode terbaik dalam pengoperasiannya. Identifikasi metode pengoperasian dilakukan untuk menemukan pola operasi yang paling efisien dalam konsumsi bahan bakar solar pada proses startup dan shut down coal burner. Perancangan modifikasi logic program DCS dilakukan untuk mengaplikasikan pola terbaik tersebut agar berjalan secara otomatis guna mengurangi inkonsistensi hasil pada proses startup dan shut down coal burner. Perancangan modifikasi proses adalah berdasarkan rekomendasi NFPA 85 (National Fire Protection Academy), best practice yang sudah dilakukan serta rekomendasi teknis dari manufaktur boiler yang terpasang. Rancangan program yang dibuat memberikan peluang efisiensi waktu proses serta penghematan biaya pemakaian solar sekitar 17,38% dan 8,5% untuk masing masing proses startup dan shut down coal burner. Total potensi penghematan biaya yang didapatkan dari modifikasi tersebut pada DCS PLTU Suralaya unit 5-7 adalah senilai Rp. 35.941.799,16 perbulan. Kata Kunci : Coal burner startup/shut down sequence, Logic Program DCIS, PLTU Suralaya Unit 5-7, Modifikasi, Optimisasi, Solar.
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