En 18-20206 Aerodyn. Meas., Installation, Commissioning Extern

TLT-Turbo GmbH
Measurement engineering &

commissioning
Distribution PLTU Mr. Kukuh, Mr. Rendra

list: Trinity Media Prima Mrs. Sinta Triani, Mr. Budi Prastowo
TLT-Turbo GmbH Mr. Hohmann, Mr. Roeder
Commissioning & Measurement
Engineering
Aerodyn. Measurement
Installation
Commissioning
PLTU Pangkalan Susu
ID fan 1A, 1B, 2A
Machine type: G158/225

Machine No.: 713007164, --, --
Order No.: 1030647

SAP file No.: 939955
Report No.: 18-20206
Rev.: Created by: Reason for revision: Checked by: Approved:

Digitally signed by Sven
Hoffmann
DN: cn=Sven Hoffmann, c=DE,
/ o=TLT Turbo GmbH, ou=S FS
COM, email=s.hoffmann@tlt-
turbo.com
Date: 2018.12.20 11:49:40
+01'00'
Aerodyn. measurement, installation, Report No.: 18-20206
commissioning SAP file No.: 939955
PLTU Pangkalan Susu (IDN) Place: Pangkalan S.
ID fan 1A, 1B, 2A Date: 12/19/2018
TLT-Turbo GmbH G158/225 Page: 2 of 25
Table of contents:
1. Purpose of the work carried out.............................................................. 3
2. Work carried out ....................................................................................... 4
3. Measurement results................................................................................ 5
3.1. Investigation of trends Unit 1............................................................ 5

3.2. Aerodynamic measurement IDF2A (SBW fan)................................. 6
3.2.1. Measurement protocol ......................................................................... 7
3.2.2. Evaluation operation point ................................................................... 8
3.2.3. Performance diagram .......................................................................... 9
3.3. Installation IDF1A........................................................................... 10
3.3.1. Alignment .......................................................................................... 10
3.3.2. Blade gap .......................................................................................... 11
3.3.3. IVC and auma ................................................................................... 12
3.3.4. Impeller bump test ............................................................................. 13
3.4. Commissioning IDF1A ................................................................... 14
3.4.1. Pressure transmitter IDF1A and IDF1B ............................................. 14
3.4.2. Inlet Vane Controller (IVC) ................................................................. 16
3.4.3. Vibration measurement VC 1100 ....................................................... 17
3.4.4. Cooling air fan ................................................................................... 18
3.5. Test run IDF1A and hot operation .................................................. 19
3.5.1. Test run ............................................................................................. 19
4. Next steps ............................................................................................... 22
4.1. Final meeting with IP 12/18/2018 ................................................... 23
5. Inspected fan .......................................................................................... 24
6. Attendees at site ..................................................................................... 24
6.1. Customer ....................................................................................... 24

6.2. Trinity Media .................................................................................. 24
6.3. TLT Turbo GmbH ........................................................................... 24
7. Used measuring instruments ................................................................ 25
8. Attachments ............................................................................................ 25
ID fan 1A, 1B, 2A Date: 12/19/2018
1. Purpose of the work carried out
PLTU Pangkalan Susu has 4 Units. Unit 1 & 2 are in operation, Unit 3 & 4 are under
construction. Unit 1 & 2 are equipped with 4 ID fans, 2 per Unit. All ID fans had
originally been delievered by SBW. The customer (Indonesia Power) wanted to
replace the ID fans of Unit 1 by TLT fans (IDF1A & IDF1B). In a first step IDF1A had
been replaced, after that IDF1B should be replaced. The power plant startet
operation of Unit 1 on 31st of October around 6:00 am (setup of Unit 1 at that time:
IDF1A – TLT fan, IDF1B – SBW fan). During start up of boiler IDF1A got damaged –
that happened 3rd of November around 3:00 am. Up to that moment the boiler had
no load, the boiler was still in start up condition.
IDF2A damaged 15th of November around 2:00 pm – boiler load at that time 130 MW
– 150 MW. The disassembled SBW fan of Unit 1 (IDF1A in the past) had been
installed to get the Unit in service as fast as possible. During assembly of the fan
measurement positions for performing an aerodynamic measurement had been
installed.
Because of the damage of IDF1A from 3rd of November aerodynamic measurements

had been performed to get detailed knowledge about the operation point of the
installed fans. The measurement was performed at the prepared IDF2A (SBW fan).
During the same time the second delivered fan of TLT had been installed by SMM
(Mr. Tony + team) to replace the damaged IDF1A (TLT fan).
Fig. 1: Situation Unit 1&2

ID fan 1A, 1B, 2A Date: 12/19/2018
2. Work carried out
12/06/2018: arrival and short site visit
12/07/2018: collecting trends and discussion about fan operation, preparation of

aerodynamic measurement at IDF2A
Interuption
12/12/2018: preparation + perform of aerodynamic measurement of IDF2A,

evaluation of measurement result
12/13/2018: installation of IDF1A, meeting with IP (Mr. Kukuh, Mr. Radnar), Trinity
Media Prima (Budi Prastowo), TLT Turbo GmbH (Sven Hoffmann)
12/14/2018: installation of IDF1A
12/15/2018: commissioning of IDF1A
12/16/2018: test run IDF1A and start of boiler Unit 1
12/17/2018: hot operation Unit 1
12/18/2018: hot operation Unit 1, final meeting with IP, departure of TLT personnel
ID fan 1A, 1B, 2A Date: 12/19/2018
3. Measurement results
3.1. Investigation of trends Unit 1

Trends from the past of IDF1A and IDF1B had been collected to investigate the
behavior of the fans before the damage (see att. 1).
Trend 1 shows that even during standstill of Unit 1 and the fans there is a positive
pressure rise on the discharge side of the ID fans. The customer has no explanation
for this situation. This pressure rise also happended during operation.
It could be possible that the pressure rise is caused by condensate in the
measurement pipe from the measurement position to the pressure transmitter (see
chapter 3.4.1.).
Trend 1 and 2 show, that all dampers (9 dampers – 4 dampers before air preheater,
5 dampers after ESP) had been opened during start up of the boiler.
Fig. 2: dampers in the ID fan system
Trend 3 shows operation of IDF1A and IDF1B after the installation of the TLT fan.
From the beginning the TLT fan had a higher current comparing to the current of the
SBW fan. The reason was a wrong setting of the IVC of the TLT fan (see chapter 4).
Trend 4 shows that the the behavior of the parallel operating fans IDF1A and IDF1B
had been nearly equal before the replacement by TLT fan.
Trend 5 shows similar behavior of IDF1A and IDF1B after installation and
commissioning of the 2nd TLT fan (see chapter 4).
ID fan 1A, 1B, 2A Date: 12/19/2018
3.2. Aerodynamic measurement IDF2A (SBW fan)

The measurements had been performed according VDI2044, acceptance and
performance tests on fans.
Therefore 3 measurement planes had been defined (see fig. 3):
plane measured values

1 – inlet box temperature
dynamic pressure
static pressure
2 – before impeller static pressure
3 – outlet diffuser static pressure
+ ambient pressure outside
Table 1: measurement planes
Fig. 3: overview measurement planes
The aerodynamic measurements at the fan had been taken out according to VDI
2044, Acceptance and performance tests on fans, November 2002.
The suction box of IDF2A, was distributed in 27 measuring points according to the
Log-Tchebycheff method.
To calculate the volume flow, the arithmetical mean of the dynamic pressure in the
measuring plane of the inlet box was taken.
ID fan 1A, 1B, 2A Date: 12/19/2018
3.2.1. Measurement protocol
Plant: PLTU Pangkalan Susu

Mach.-type: G158/225
Mach.no.: IDF2A
Speed: [1/min] 995
Ambient pres.: 1009,3
IVC pos.: 80%
DCS DCS DCS

1/2
Meas. p1dyn (p1dyn) p 1stat p 2stat p 3stat t1 t3 p 1stat p 2stat p 3stat
No. [m bar] [m bar] [m bar] [m bar] [m bar] [°C] [°C] [m bar] [m bar] [m bar]
1 7,03 2,65 --- -37,90 3,00 158,00 166,00
2 8,95 2,99 ---
3 9,55 3,09 ---
4 5,66 2,38 -25,40 -38,00 3,00
5 6,78 2,60 -26,20
6 10,27 3,20 -24,60
7 4,08 2,02 -25,60 -38,10 3,10
8 5,32 2,31 -26,10
9 4,24 2,06 -33,00
10 6,09 2,47 -25,40 -38,00 3,20
11 6,98 2,64 -26,80
12 7,24 2,69 -30,60
13 6,27 2,50 -26,30 -37,80 3,40
14 7,51 2,74 -26,80
15 10,85 3,29 -30,40
16 0,90 0,95 --- -38,00 3,20
17 1,00 1,00 ---
18 1,10 1,05 ---
19 1,30 1,14 --- -37,60 3,20
20 1,22 1,10 ---
21 1,00 1,00 ---
22 0,90 0,95 ---
23 1,10 1,05 ---
24 1,00 1,00 ---
25 1,31 1,14 ---
26 1,40 1,18 ---
27 1,26 1,12 --- 158,00 166,00
Mittelwert4,46 1,94 -27,27 -37,91 3,16 158,00 166,00
Min. 0,90 0,95 -33,0 -38,1 3,0 158,0 166,00
Max. 10,85 3,29 -24,6 -37,6 3,4 158,0 166,00
Fig. 4: measurement protocol
ID fan 1A, 1B, 2A Date: 12/19/2018
3.2.2. Evaluation operation point
Anlage: PLTU Pangkalan Susu

Ventilator: IDF2A r Norm Luft R Luft A1 A2 A3
Masch. Typ: G158/225 [kg/m³] [Nm/kgK] [m2] [m2] [m2]
Masch. Nr.: --- 1,29 287,2 7,150 --- 5,524
plane 1 plane 2 plane 3

1
b =
2
æ A2 ö
1 - çç ÷
÷
è A1 ø
input field
evaluation field
Fan --- SBW IDF2A

Date --- 12.12.2018
Time --- 18:20-18:55
Meas. Point --- 1
Boiler load [MW]
IVC pos. [%] 80
Ambient pres. [mbar] 1009,40
p1stat [mbar] -27,50
p2stat [mbar] ---
p3stat [mbar] 3,20
p1dyn [mbar] 4,46
a x b ( n.TLT) --- 1,0000
b --- 1,0000
a --- 1,0000
K-Faktor (n.KK&K) --- ---
nMeas. [min-1] /
t1 [°C] 158,0
t2 [°C] ---
t3 [°C] 166,0
r1 [kg/m³] 0,793
r2 [kg/m³] ---
r3 [kg/m³] 0,803
V1 operation [m³/s] 239,8 => volume flow in m³/s
V1 Nm ³ [Nm³/h] 530.728,4 => operation volume flow in Nm³/h
V2 [m³/s] ---
V3 [m³/s] 236,8
m 1=m 2=m 3 [kg/s] 190,2
p1dyn [mbar] 4,46
p3dyn [mbar] 7,38
p1ges [mbar] -23,04
p3ges [mbar] 10,58
Dp1,3ges [Pa] 3362
Yad(Mess.) [Nm/kg] 4185,1
Nab (Vent.) [kW] 795,9
Fig. 5: evaluation of operation point
ID fan 1A, 1B, 2A Date: 12/19/2018
3.2.3. Performance diagram

The operation point of IDF2A is shown in the performance diagram.
Fig. 6: performance diagram
The performance diagram shows that the fan had been operated in an uncritical
zone to the moment of the measurement.
ID fan 1A, 1B, 2A Date: 12/19/2018
3.3. Installation IDF1A

The installation was nearly finished when TLT arrived on site. The installation had
been done by an installation team ordered by Trinity Media Prima (SMM – Mr. Tony).
The alignment had been checked and the IVC and it’s drive had to be installed and
commissioned. All signals were connected (bearing temperatures, vibrations,
pressure measurements).
3.3.1. Alignment
The alignment was done by the installation team of SMM – Mr. Tony. The measured
values are between the tolerances of the coupling.
Fig. 7: alignment
ID fan 1A, 1B, 2A Date: 12/19/2018
3.3.2. Blade gap

The blade gap had been measured by IP on 9 o’clock position with view in flow
direction.
Fig. 8: blade gap

ID fan 1A, 1B, 2A Date: 12/19/2018
3.3.3. IVC and auma

The position of the support of the auma had to be changed. It is placed closer to the
fan to get a vertical working direction of the lever (less forces on the drive) and the
auma was turned on the support to ensure that the electronic is not to close to the
hot ID fan housing. Pictures show the difference between drawings and final setup.
Fig. 9: IVC drive acc. drawing
Fig. 10: new position Fig. 11: new position (view against flow direction)
ID fan 1A, 1B, 2A Date: 12/19/2018
3.3.4. Impeller bump test

A bump test of 3 blades was done to see the natural frequency of the blades.
Fig. 12: bump test
Fig 13 – 15: sample of measurement result of bump test
Fig. 16: results

ID fan 1A, 1B, 2A Date: 12/19/2018
3.4. Commissioning IDF1A
3.4.1. Pressure transmitter IDF1A and IDF1B

The signal of the pressure transmitters of the customer had been checked to ensure
that the correct value is shown in the DCS. Therefore a defined pressure was given
to the transmitter and measured parallel with a portable precision manometer. The
value of the portable precision manometer and the DCS had been compared to each
other. The test confirmed that all 4 measurements show the correct measurement
value in the DCS.
Fig. 17: pressure measurements IDF1A + IDF1B
By disconnecting the pipe of the pressure measurement from the transmitter on the
discharge side a change of the measurement value could be monitored. Blowing in
the pipe showed that there seemed to be dirt or condensate in the pipe. To make
sure this happens not again TLT recommends to change the design of the
measurement pipe (continous decline) and installation of a condensate separator on
the deepest point of the pipe.
Fig. 18: example for design of measurement pipe discharge side

ID fan 1A, 1B, 2A Date: 12/19/2018
Fig. 19: 1st deep point close to Fig. 20: 2nd deep point in horizontal direction
transmitter
Fig. 20: vertical pipe to position at diffuser

ID fan 1A, 1B, 2A Date: 12/19/2018
3.4.2. Inlet Vane Controller (IVC)

The range of the IVC was set similar to the settings of the IVC of IDF1B. This was
done to ensure that both fans (IDF1A: TLT, IDF1B: SBW) have nearly the same
behavior during parallel operation.
The design of the IVC of the TLT fan has a bigger range acc. The performance
diagram. If the SBW fan will be replaced by a TLT fan in future, the IVC should
be adjusted to the full range.
Settings IVC
SBW TLT
0 % position
 closed position with a gap of  closed position with a gap of

approx. 8 cm approx. 8 cm
100 % position
 straight open, no “Gegendrall” –  straight open, no “Gegendrall” –

means air flow against rotation of means air flow against rotation
impeller of impeller
Table 2: settings IVC IDF1A
The IVC was successfully opened and closed in the remote mode by the control
room (see fig. 21 next page).
ID fan 1A, 1B, 2A Date: 12/19/2018
Fig. 21: open and close of IVC by operator
3.4.3. Vibration measurement VC 1100

The setup parameters of the vibration measurement system were checked. There is
a deviation of the settings on site to the settings which were originally made.
The relay configuration N10, N11 and N12 should be “YES” according
documentation and was set on “NO” by the customer.
These settings are depending on the control system of the customer. The customer
changed the settings to ensure the connectivity to the control system. With the
settings of the documentation the alarms had been active all the time.
The OK monitoring configuration O01 and O02 should be “YES” according

documentation and was set on “NO” by the customer.
These settings are necessary to monitore the condition of each channel. If the status
of a channel is not ok, the evaluation unit of the VC 1100 will give a feedback to the
control room.
The customer is informed about the situation.
Settings dated from 12/17/2018 see att. 2.

ID fan 1A, 1B, 2A Date: 12/19/2018
3.4.4. Cooling air fan

The power consumption of the motor of both fans is too high. The cooling air fans
cannot be operated due to a trip by motor protection. Acc. the label on the motors
the nominal current is max. 6.1 A. The current with full load of each fan is around
7.5 A. Different tests have been done:
- Check of power supply – power supply is between 360V and 370V

- Connection to power supply – the wiring is correct
- Removing of filter on suction side – current increases
- Throttle on discharge side – current decreases.
More tests couldn’t be done due to hot operation of the fan. The manual damper on
the discharge side is setted to appr. 40 % open so that the cooling air fan is running
with appr. 5.9 A.
Fig. 22 – 24: cooling air fan plate, motor plate, wire terminal
In the control system a switch over to the 2nd standby cooling air fan is implemented.
This is physically not possible due to the manual dampers in the duct of the cooling
air system (see fig. 25).
The manual dampers have to be replaced by a damper which allows an automatic

switch over to the standby fan (e.g. check valve, …).
Fig. 25: manual damper

ID fan 1A, 1B, 2A Date: 12/19/2018
3.5. Test run IDF1A and hot operation
3.5.1. Test run

The test run started 12/16/2018 at 8:40 pm an ended 12/17/2018 at 2:45 am. The
fan behavior was without any abnormalities. The fan was running in good conditions
– the vibrations had been within Zone A acc. DIN ISO 10816 – 3, support class rigid
(vrms < 2.3 mm/s).
Definition of Zone A:
The vibration of newly commissioned machines would normally fall within this zone.
Fig. 26: portable measurement Vibrotest 80 Fig. 27: vib. monitoring system at fan
Channel A: inner bearing, horizontal direction

Channel B: outer bearing, horizontal direction
B A
Fig. 28: measurement position for vibration

ID fan 1A, 1B, 2A Date: 12/19/2018
Trend test run
Fig. 29: trend test run
Trend hot operation
Fig. 30: trend hot operation

ID fan 1A, 1B, 2A Date: 12/19/2018
Screenshot control room hot operation
Fig. 31: screenshot control room

ID fan 1A, 1B, 2A Date: 12/19/2018
4. Next steps
The fan can be operated in continuous operation without limitation acc. the manual.
In parallel operation IDF1A (TLT fan) and IDF1B (SBW fan) have similar behavior
(IVC pos., current, pressure).
The aerodynamic measurement of IDF2A showed normal behavior in hot boiler

operation. There is no indication for any stall condition during operation.
The IVC of the first TLT fan was setted wrong. The blades of the IVC had been
turned 180 - that was not necessary and leads to turbulent flow. Also the direction
of opening the blades was wrong. The IVC opened with “Gegendrall” – airflow
guided against rotation direction of impeller – which caused the high current of the
fan compared to the parallel IDF1B. Also the frequency analysis of the test run of the
first TLT fan was “noisy” – the reason seemed to be the wrong setting of the IVC. It
cannot be excluded that this wrong setting caused the damage at IDF1A.
The wrong settings of the IVC could be part of the reason why the auma stopped
due to high torque during last commissioning. The max. torque is 60 Nm, the auma
could not open the IVC during operation. The position of the auma of the IVC was
also not suitable. To minimize torque on the auma the position was changed (see
chapter 3.3.3. and 3.4.2.). After changing the position and taking out the correct
settings of the IVC the auma opened with a maximum torque of 26 Nm during test
run.
Due to the fact that IDF1A damaged after 3 days during start up of the boiler, the
operator should take care that the fan is operated acc. the manual. This means the
operator has to make sure that all needed dampers are open and the resistance of
the system is not too high. Especially during start up of the plant it is important to
take care on the pressure conditions of the fan. During operation with small opening
of the IVC (< 25 % - see extract of performance diagram) the distance to the stall line
is small. Any sudden pressure rise could cause the fan running in stall condition
which causes high forces on the machine and could destroy it.
Fig. 32: extract performance diagram

ID fan 1A, 1B, 2A Date: 12/19/2018
Additional information “Gegendrall”:
It is part of the characteristic of some fans to open the IVC more than 90°. This
means the fan will be operated with “Gegendrall” – the airflow is guided against the
rotation direction of the impeller. This leads to higher performance of the fan and is a
wish of the fan designer => in this situation “Gegendrall” has a positive effect. Also
the delivered TLT fans could be run with this setting. This will be done if two TLT
fans are installed for parallel operation. As long as there is a setup with one TLT fan
and one SBW fan the IVC should be setted similar to the SBW fan.
4.1. Final meeting with IP 12/18/2018

TLT Turbo GmbH sent an official letter to IP on 12/17/2018 in which the results of
the investigation are written (see att. 3).
In the final meeting with IP (Mr. Kukuh, Mr. Rendra), Trinity Media Prima (Mr. Budi
Pratsowo) and TLT Turbo GmbH (Mr. Sven Hoffmann) the results of the
investigations had been discussed.
Output of the meeting are the following questions:
1. Which parts can be used again, which parts have to be replaced? Can the
shaft be used again?
2. There is a planned standstill of Unit 2 in 01/27/2019 for 60 days. Will all spare
parts be delievered to that time?
3. A solution for the high motor current of the cooling air fan is awaited latest to
the delivery of the spare parts – at least a bigger motor for each cooling air
fan should be delievered that it doesn’t trip anymore.
ID fan 1A, 1B, 2A Date: 12/19/2018
5. Inspected fan
Machine type: G158/225

Machine No.: 713007164
Speed: 995 min-1
Rotary frequency: 16,58 Hz
Assembly: inflexible
Number of blades 19
Blade passing frequency: 315 Hz
6. Attendees at site
6.1. Customer
Phone: ---
Mr. Kukuh
Mobile: ---
Plant manager
E-mail: ---
Phone: ---
Mr. Rendra
Mobile: ---
Responsible for fans
E-mail: ---
6.2. Trinity Media

Phone: ---
Budi Prastowo
Mobile: ---
E-mail: trinitymedia102@gmail.com
6.3. TLT Turbo GmbH
Phone: +49 6237 97983 – 06

Sven Hoffmann
Mobile: +49 152 226 502 64
Field Service Int.
E-mail: s.hoffmann@tlt-turbo.com
Phone: ---
Patrick Grimm
Mobile: +49 173 515 05 77
Installation FS Int.
E-mail: p.grimm@tlt-turbo.com
ID fan 1A, 1B, 2A Date: 12/19/2018
7. Used measuring instruments
The subsequently listed measuring instruments were used for measuring:
Name Type Ident.-No.: Annotations:

Portable vibration supported by
SKF ---
measurement IP
Portable vibration supported by
Bruel&Kjaer ---
measurement IP
Digital barometer DPI 500649 none
Precision manometer
Thommen 500664 none
0…100 mbar
Precision manometer
Huber 500395 none
0…70 mbar
Temperatur measurement Fluke 500291 none
Thermocouple type K Conatex 500633 none
Prandt’l tube TLT --- none
8. Attachments
The subsequently listed logs have been attached to this report:
Attachment 1, page 1 - 6 Trends of Unit 1

Attachment 2, page 7 - 9
Settings VC 1100 Vibration monitoring
Attachment 3, page 10 - 12
Official letter from TLT Turbo GmbH
Aerodyn. measurement, installation, Report no.: 18-20206
commissioning SAP file no.: 939955
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
- Attachments - Page: 1 of 12
Attachment 1
Trends of Unit 1
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
Trend 1: positive pressure rise in the duct during standstill and dampers position before air
preheater during fan operation
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
Trend 2: dampers position behind ESP during fan operation

ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
Trend 3: higher current of IDF1A compared to IDF1B with nearly same IVC position
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
Trend 4: same behavior of IDF1A and IDF1B before installation of TLT fan
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
Trend 5: same behavior of IDF1A and IDF1B after installation of 2nd TLT fan
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
Attachment 2
Settings VC1100
Vibration monitoring
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
Attachment 3
Official letter from TLT Turbo

GmbH
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH
ID fan 1A, 1B, 2A
Date: 12/19/2018
G158/225
TLT-Turbo GmbH

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TLT-Turbo GmbH

Measurement engineering &

Distribution PLTU Mr. Kukuh, Mr. Rendra

PLTU Pangkalan Susu

ID fan 1A, 1B, 2A

Machine type: G158/225

Order No.: 1030647

Rev.: Created by: Reason for revision: Checked by: Approved:

2. Work carried out ....................................................................................... 4

3.1. Investigation of trends Unit 1............................................................ 5

4. Next steps ............................................................................................... 22

4.1. Final meeting with IP 12/18/2018 ................................................... 23

5. Inspected fan .......................................................................................... 24

6. Attendees at site ..................................................................................... 24

6.1. Customer ....................................................................................... 24

7. Used measuring instruments ................................................................ 25

1. Purpose of the work carried out

Because of the damage of IDF1A from 3rd of November aerodynamic measurements

Fig. 1: Situation Unit 1&2

2. Work carried out

12/06/2018: arrival and short site visit

12/07/2018: collecting trends and discussion about fan operation, preparation of

12/12/2018: preparation + perform of aerodynamic measurement of IDF2A,

12/14/2018: installation of IDF1A

12/15/2018: commissioning of IDF1A

12/16/2018: test run IDF1A and start of boiler Unit 1

12/17/2018: hot operation Unit 1

3.1. Investigation of trends Unit 1

Fig. 2: dampers in the ID fan system

3.2. Aerodynamic measurement IDF2A (SBW fan)

plane measured values

Table 1: measurement planes

Fig. 3: overview measurement planes

3.2.1. Measurement protocol

Plant: PLTU Pangkalan Susu

DCS DCS DCS

3.2.2. Evaluation operation point

Anlage: PLTU Pangkalan Susu

plane 1 plane 2 plane 3

Fan --- SBW IDF2A

3.2.3. Performance diagram

Fig. 6: performance diagram

3.3. Installation IDF1A

3.3.2. Blade gap

Fig. 8: blade gap

3.3.3. IVC and auma

Fig. 9: IVC drive acc. drawing

3.3.4. Impeller bump test

Fig. 12: bump test

Fig 13 – 15: sample of measurement result of bump test

Fig. 16: results

3.4. Commissioning IDF1A

3.4.1. Pressure transmitter IDF1A and IDF1B

Fig. 17: pressure measurements IDF1A + IDF1B

Fig. 18: example for design of measurement pipe discharge side

Fig. 20: vertical pipe to position at diffuser

3.4.2. Inlet Vane Controller (IVC)

 closed position with a gap of  closed position with a gap of

 straight open, no “Gegendrall” –  straight open, no “Gegendrall” –

Fig. 21: open and close of IVC by operator

3.4.3. Vibration measurement VC 1100

The OK monitoring configuration O01 and O02 should be “YES” according

The customer is informed about the situation.