Case Study

risk asset management

Yudan Whulanza
Departemen Teknik Mesin Fakultas Teknik
Universitas Indonesia
2024
 Assets:
• 1. Cooling tower • 10. Steam governor valve • 19. Superheater
• 2. Cooling water pump • 11. High pressure turbine • 20. Forced draught fan
• 3. Transmission line (3-phase) • 12. Deaerator • 21. Reheater
• 4. Unit transformer (3-phase) • 13. Feed heater • 22. Air intake
• 5. Electric generator (3-phase) • 14. Coal conveyor • 23. Economiser
• 6. Low pressure turbine • 15. Coal hopper • 24. Air preheater
• 7. Boiler feed pump • 16. Pulverised fuel mill • 25. Precipitator
• 8. Condensor • 17. Boiler drum • 26. Induced draught fan
• 9. Intermediate pressure turbine • 18. Ash hopper • 27. Chimney Stack
 No Unit Fungsi
1 Menghantarkan batu bara dari tempat penyimpanan di gudang dan di
Coal conveyor

PEMAHAMAN UNIT 2
Forced draught fan
daratan menuju pulverized mill
Melakukan pencampuran udara yang telah dipanasi terlebih dahulu
(preheat) menjadi campuran bahan bakar panas hot air-fuel mixture
dan mengalirkan ke boiler
3 Boiler Merubah fase air liquid menjadi uap
4 Meninggikan temperatus dan pans dari boiler drum menjadi sekitar
Superheater
200 bar dan 570o C
5 High pressure Stage pertama dari rangkaian proses turbin uap sehingga suhu dan
turbine temperature menjadi turun
6 Memanaskan kembali fluida dari high pressure turbin untuk menjadi
Boiler reheater
umpak ke intermediate pressure turbine
7 Intermediate Stage kedua dari rangkaian turbin uap dan mengalirkan fluida
pressure turbin langsung ke low pressure turbin
8 Low pressure turbin Stage terakhir dari rangkaian turbin uap
9 Melakukan penukaran kalor antara uap keluar dari low pressure
Condenser turbine dengan air dingin (dari cooling tower) sehingga fase berubah
menjadi air dengan fasa liquid
10 Deareator unit pengaliran air fase liquid dari condenser
11 Feed heater sistem untuk melakukan pemanasan awal (prewarmed)
12 System untuk menaikan suhu fluida cair sebelum kembali ke boiler
economizer
drum
13 Induced draft fan Menarik sisa gas dari boiler untuk dikeluarkan melalui chimney
Description A typical coal-fired thermal power plant

• 1. Coal is conveyed (14) from an external stack and ground to a very fine powder by large metal
spheres in the pulverized fuel mill (16).
• 2. There it is mixed with preheated air (24) driven by the forced draught fan (20).
• 3. The hot air-fuel mixture is forced at high pressure into the boiler where it rapidly ignites.
• 4. Water of a high purity flows vertically up the tube-lined walls of the boiler, where it turns into
steam, and is passed to the boiler drum, where steam is separated from any remaining water.
• 5. The steam passes through a manifold in the roof of the drum into the pendant superheater (19)
where its temperature and pressure increase rapidly to around 200 bar and 570°C, sufficient to
make the tube walls glow a dull red.
• 6. The steam is piped to the high-pressure turbine (11), the first of a three-stage turbine process.
• 7. A steam governor valve (10) allows for both manual control of the turbine and automatic set
point following.
• 8. The steam is exhausted from the high-pressure turbine, and reduced in both pressure and
temperature, is returned to the boiler reheater (21).
• 9. The reheated steam is then passed to the intermediate pressure turbine (9), and from there passed
directly to the low pressure turbine set (6).
• 10. The exiting steam, now a little above its boiling point, is brought into thermal contact with cold water
(pumped in from the cooling tower) in the condensor (8), where it condenses rapidly back into water,
creating near vacuum-like conditions inside the condensor chest.
• 11. The condensed water is then passed by a feed pump (7) through a deaerator (12), and prewarmed, First
in a feed heater (13) powered by steam drawn from The high pressure set, and then In the economizer (23),
Before being returned To the boiler drum.
• 12. The cooling water from the condensor is sprayed inside a cooling tower (1), creating a highly visible
plume of water vapor, before being pumped back to the condensor (8) in cooling water cycle.
• 13. The three turbine sets are coupled on the same shaft as the three-phase electrical generator (5) which
generates an intermediate level voltage (typically 20-25 kV).
• 14. This is stepped up by the unit transformer (4) to a voltage more suitable for transmission (typically 250-
500 kV) and is sent out onto the three-phase transmission system (3).
• 15. Exhaust gas from the boiler is drawn by the induced draft fan (26) through an electrostatic precipitator
(25) and is then vented through the chimney stack (27).
Case study: industri penghasil daya
• https://www.youtube.com/watch?v=k76MJAgP6OA&ab_channel=PTI
ndonesiaPowerOfficialPTIndonesiaPowerOfficial
• https://www.youtube.com/watch?v=Vnb22QVfXDs&ab_channel=PJBS
CHANNELPJBSCHANNEL
• Anatomi PLTU Batubara, Agung Subagio, naskah kuliah DTM FTUI
2012.
Tugas 1: Competency 1
• Able to breakdown the
organization’s asset per
required standard
• Find the best practice for
breakdown asset at power
plant industry
• Do the screening analysis
(static/rotating/instrument)
• Formulate function block
diagram(s) of this facility
Tugas 2: Competency 2
• Able to identify FMEA worksheet for organizations’ assets
• Find FMEA worksheet that the most suitable and/or has complete information
• Identify F, FF, FM, FE
• Put in the FMEA worksheet for corresponding assets
Tugas 3: Competency 3
• Able to identify risk registry based on the FMEA method
Screening asset example: Power Plant

POWER
PLANT

UNIT 1 UNIT 2 UNIT 3

N01 N02 N03

WASTE
BOILER SYSTEM
FUEL
N02B N02N N02F

FLY ASH BED ASH

N02NA N02NB
Example: Air Compressor

INGERSOLL
RAND
COMPRESSOR

SYSTEM PRESSURIZATION SYSTEM

1A SYSTEM 1B 1C

SUBSYSTEM SUBSYSTEM AIR PUMP SUBSYSTEM

1B1 1B2 ASSY 1B3 1B4

MOTOR COMPR CHK VALVE AIR FILTER PRESSURE

1B3A 1B3B 1B3C 1B3D REG 1B3E
 C UNIT AUXILIARY TRANSFORMER (UAT) A I SEALING AIR FAN A
Transformer Oil Fan Bearing
Transformer Insulator Motor (Rotor, Stator & Bearing)
Fan Lubrication Sys
D BOILER WATER CIRCULATING PUMP (BWCP) A
Switchgear, Bus Duct, Relay Panel, DCS Pane
Motor (rotor, stator & Bearing) J INDUCED DRAFT FAN (IDF) A
Switchgears Panel

HINTS A
Fan Bearing
E BOILER FEED PUMP TURBINE (BFPT) A Motor (Rotor, Stator & Bearing)
Fan Lubrication Sys
Pump Bearing Switchgear, Bus Duct, Relay Panel, DCS Pane
Pump Lubrication Sys K FORCED DRAFT FAN (FDF) A
F CONDESATE EXTRACTION PUMP (CEP) A Fan Bearing
Motor (Rotor, Stator & Bearing)
Pump Bearing
Fan Lubrication Sys
Motor (Rotor, Stator & Bearing) Switchgear, Bus Duct, Relay Panel, DCS Pane
Pump Lubrication Sys L PRIMARY AIR FAN (PAF) A
Switchgear, Bus Duct, Relay Panel, DCS Panel Fan Bearing
Motor (Rotor, Stator & Bearing)
G BOILER FEED SUPPLY PUMP (BFSP) Fan Lubrication Sys
Pump Bearing Switchgear, Bus Duct, Relay Panel, DCS Pane
A TURBIN - GENERATOR Motor (Rotor, Stator & Bearing) M AIR PREHEATER A (APH A)
Turbine Bearing AH Bearing
H VACUUM PUMP A
Generator (Rotor, Stator & Bearing) Motor (Rotor, Stator & Bearing)
Generator Insulation Pump Bearing AH Lubrication Sys
Turbine Lubrication Sys Motor (Rotor, Stator & Bearing) AH Duct Insulation
Switchgear, Bus Duct, Relay Panel, DCS Panel I SEALING AIR FAN A N PULVERIZER A
Mill Bearing
Main Steam Insulation Fan Bearing Motor (Rotor, Stator & Bearing)
B GENERATOR TRANSFORMER (GT) Motor (Rotor, Stator & Bearing) Mill Lubrication Sys
Transformer Oil Fan Lubrication Sys O COAL FEEDER A
Transformer Insulator Switchgear, Bus Duct, Relay Panel, DCS Panel Motor (rotor, stator & Bearing)
C UNIT AUXILIARY TRANSFORMER (UAT) A MCC Panel
J INDUCED DRAFT FAN (IDF) A P CIRCULALTING WATER PUMP (CWP) A
Transformer Oil
Transformer Insulator
Fan Bearing Pump Bearing
Motor (Rotor, Stator & Bearing) Motor (Rotor, Stator & Bearing)
D BOILER WATER CIRCULATING PUMP (BWCP) A Pump Lubrication Sys
Motor (rotor, stator & Bearing) Fan Lubrication Sys
Switchgear, Bus Duct, Relay Panel, DCS Pane
Switchgears Panel Switchgear, Bus Duct, Relay Panel, DCS Panel Q SEA WATER PUMP A
E BOILER FEED PUMP TURBINE (BFPT) A K FORCED DRAFT FAN (FDF) A Pump Bearing
Pump Bearing Fan Bearing Motor (Rotor, Stator & Bearing)
Pump Lubrication Sys Pump Lubrication Sys
Motor (Rotor, Stator & Bearing) Switchgear, Bus Duct, Relay Panel, DCS Pane
F CONDESATE EXTRACTION PUMP (CEP) A Fan Lubrication Sys R SUBMERGED SCRAPPER CONVEYOR
Pump Bearing Switchgear, Bus Duct, Relay Panel, DCS Panel Motor (rotor, stator & Bearing)
Motor (Rotor, Stator & Bearing) Hydarulic Tension Device
L PRIMARY AIR FAN (PAF) A
Pump Lubrication Sys MCC Panel (Control Cabinet)
Switchgear, Bus Duct, Relay Panel, DCS Panel Fan Bearing S BOTTOM ASH CRUSHER
G BOILER FEED SUPPLY PUMP (BFSP) Motor (Rotor, Stator & Bearing) Motor (rotor, stator & Bearing)
Fan Lubrication Sys Gearbox & Blower Bearings
Pump Bearing
MCC Panel
Motor (Rotor, Stator & Bearing) Switchgear, Bus Duct, Relay Panel, DCS Panel
H VACUUM PUMP A M AIR PREHEATER A (APH A)
Pump Bearing AH Bearing
Motor (Rotor, Stator & Bearing) Motor (Rotor, Stator & Bearing)
I SEALING AIR FAN A
HINT B
HINT B-cont
 Tabel 3.5.3 Economic Parameter
FMEA FME
poin Occurence Severity Detection

1 1 0 Tangible (Mudah dirasakan

panca indra)
2 2 <10 JT
3 3 10-50 JT Measurable (Bisa diukur)
4 4 50-100 JT
5 5 100-200 JT Online monitoring (DCS)
6 6 200-500 JT
7 7 500-1000 JT No monitor (tanpa monitor)
8 8 1-5 M
9 9 5-10 M Hidden (tersembunyi)
10 10 >10 M
 Tabel 3.5.4 Health&safety parameter

FMEA poin Occurence Severity

health & safety parameter
Detection

1 1 No injury Tangible (Mudah dirasakan panca

indra)
2 2 Slight injury (luka gores)

3 3 Measurable (Bisa diukur)

4 4 Minor injury (luka yg harus
dijahit)
5 5 Midle injury (luka dengan Online monitoring (DCS)
jahitan >5 )
6 6 Major injury (amputasi, luka
bakar, tindakan operasi, patah
tulang)
7 7 No monitor (tanpa monitor)
8 8 Single fatality
9 9 Hidden (tersembunyi)
10 10 Multiple fatalities
 Tabel 3.5.5 Environment Parameter

FMEA poin Occurence Severity

Environment parameter
Detection
1 1 No effect Tangible (Mudah dirasakan panca indra)
2 2 Slight effect (mudah
dibersihkan)
3 3 Measurable (Bisa diukur)
4 4 Minor effect
5 5 Online monitoring (DCS)
6 6 Local effect (dampak
hanya sekitar unit)
7 7 No monitor (tanpa monitor)
8 8 Major effect (melanggar
UU lingkungan)
9 9 Hidden (tersembunyi)
10 10 Massive effect
(kebakaran, pencemaran
lingkungan ada efek
kesehatan, melanggar
UU lingkungan)
Format pelaporan
• Dalam naskah tulisan (word file) – halaman tidak dibatasi, font
Palatino linotype, ukuran 10, spasi single.
• File tipe lain bisa di-embed dalam file utama
• Dikerjakan berkelompok-max 3 orang (akan ditentukan scr. terpisah)
• Memuat: objective, method (cara pengerjaan), result (hasil/output
pengerjaan) dan conclusion
• Mencantumkan credit team (kontribusi setiap anggota dalam
pekerjaan)
• Mencantumkan referensi yang digunakan