Tugas Khusus FIX Insya Allah PDF

Laporan Tugas Khusus Kerja Praktek
PT. PERTAMINA (Persero) Refinery Unit V Balikpapan

September Oktober 2016
CHAPTER I
INTRODUCTION
1.1 Background
One of the processing units that are owned PT.PERTAMINA is RU V
Balikpapan, where the crude oil processing refinery with a capacity of 60 design
MBSD in Balikpapan processing unit I and 200 MBSD in Balikpapan II
processing units. Distillation and Wax (DisWax) is a processing unit at the
refinery in Balikpapan I which have a main unit that is Crude Distilation Unit
(CDU) V and High Vacuum Unit (HVU) III.
Unit (HVU) III is a unit that is used to separate components components of
the long residue from the bottom of the product on the CDU vacuum pressure of
V on 12.75 mmHg or equal to 0.016314 kg/cm2 (design). Decoy long residue
CDU V flow goes into a vacuum feed surge drum (C-202-01) before flowing to
preheat (heat exchanger) to get the initial warming, after that lures streamed to
vacuum heater to raise the temperature until it reaches the bait range 391-394 c
(design), then streamed to the vacuum column C-202-01 for rengkah into specific
products. Furnace design can use fuel fuel gas and fuel oil. Furnace is the highest
cost heater, where about 60-80% of the total cost of production of the refinery
used to fuel consumption of the furnace. So it needs to be kept operating with
furnace performance evaluation based on calculation efficiency furnace F-202-
01.
I.2. Scope of the Problem
Presented the scope of the implementation of specific tasks are:
Muthiah Nur Fadlilah (D500130037)

Program Studi Teknik Kimia Fakultas Teknik
Universitas Muhammadiyah Surakarta
1. Writing the report specifically focused to calculate the efficiency of a furnace

F-202-01.
2. Data Base using data of operational conditions of the period September 2016
I.3. Objectives
The purpose of the implementation of this particular task, among others, are:
1. As a condition for the fulfillment of the Field work practice courses.
2. Knowing the principles and process of work on the furnace F-202-01 unit
HVU III.
3. Know the performance of the furnace F-202-01 unit HVU III by evaluating
and calculating the efficiency of the furnace.
I.4. Method of Approach
The method of approach were used to complete this special report through
approaches:
1. Studi literature.
2. Datasheet of furnace F-202-01.
3. Data analisys of laboratory.
3. Data of Pi.
4. Other Supporting Data (PFD dan P&ID).

CHAPTER II
LITERATURE REVIEW
2.1 High Vacuum Unit III (HVU III)

High Vacuum Unit (HVU III) is a unit that is designed to process Crude from
Reduced Crude Distillation Unit (CDU V) or Reduced Crude Export Fuel Oil
tanks of the existing vacuum pressure made of 12.75 mmHg or equal to 0.016314
kg/cm2 (design). Products resulting from this form of unit off gas, Light Vacuum
Gas Oil (LVGO), Paraffinic Oil Distillate (POD), High Vacuum Gas Oil
(HVGO), slop wax (no longer produced) and Short residue.
The process unit HVU III system is divided into the feed charge and sexy
preheat. On the system feed charge, a process that happens to be seen based on
the operation of hot charge (normal operating) and operating cold charge. The
process that occurs in the operation of hot charge i.e. reduced crude from CDU V
fed into a vacuum feed surge drum C-202-02, with the condition of feed in the
form of Mixed Crude which has a capacity of design (100% capacity) and the
temperature MBSD 25 160 C, as well as feed in the form of Minas Crude which
has a capacity of 25 MBSD and tenperatur of 170 C.
The process that occurs during operation cold charge i.e. long residue from
the tank to the existing Fuel Oil Exports (01 and 02) located in offsite area, fed
into a vacuum feed surge drum C-202-02, at the time the CDU V shutdown. To
maintain the operating condition of vacuum feed surge drum it takes pressure of
1.7 kg/cm2G guarded by using pressure controller, which works on the basis of
the split range. In addition to high liquid in vacuum feed surge drum is
maintained by using the level controller, which will drain the reduced crude

export fuel oil tank from the existing (O1 and O2) into the vacuum feed surge
drum. As well as the temperature is maintained by way of a siphon into the steam
coil LLP in the drum bottom, operated manually.
On the system reduced crude preheat section of vacuum feed surge drum C-
202-02, pumped by using reduced crude pumps G-202-01 A/B to the vacuum
column C-202-01. Before entering the vacuum column C-202-01, reduced crude
is heated up to the temperature required for separation in vacuum heater F-202-
01, after the first in a series of heated in heat exchanger in section preheat.
First Ejector First Condensor Second Ejector Third Ejector Non Condensate Gas
Second Condensor
Third Condensor
Vacuum Column
Light Vacuum Slop
Eo-202-01
G-202-02A/B
Water
Vacuum Column
Overhead Accumulation
G-202-08A/B G-202-06A/B
Eo-202-05
Furnace LVGO
G-202-07A/B
G-202-03A/B POD
Eo-202-06
Eo202-02
HVGO
G-202-04A/B Eo-202-03
Vacuum Residue
E-202-08
Eo-202-04
E-202-11
C-202-05
E-202-10
G-202-05A/B
E-202-07 C-202-04
E-20209
Reduced Vacuum Feed Surge
Crude Drum E-202-03
from G-202-01A/B E-202-01
CDU V E-202-02
E-202-12
Figure 1.3 Process Flowchart HVU III

2.2 Furnace
In the industry of petroleum and other chemical industry often require the
process with high temperature conditions, so need equipment that can drain the
heat. The tool is the furnace. In the petroleum industry, furnace used for heating a

fluid flow before entering the reactor, before entering the fluid flow heaters
fraksinator heaters for craking black oil and other functions that require warming.
Furnace has a function to move the heat generated from the combustion of fuel in
combustion chamber of liquid that will be heated (Hanifa, 2012). The fluid flows
through the pipe around the vessel that was in the combustion chamber.
Figure 2.2 Charts Furnace
Convection section is an area where entry of liquids will be separated. In this

section, the liquids are heated by convection flow with combustion exhaust. The
liquid is then channelled to the radiation where the liquid will be heated by the
fuel burned. Radiant section is also called the combustion box, because the
process of burning fuel there is in this section. Heat of combustion of the fuel is
transferred to the liquid in the process of radiation.

For combustion, fuels furnace fuel oil is usually used, fuel gas, or both are
used together, the fuel selection depending on a lot of calories in the form of heat
produced or keekonomisannya. The amount of heat that will be given to the
liquid that will be heated will depend from the amount of feed and inlet and
outlet temperature difference to be achieved.
2.3 Classification of Furnace
Furnace can be classified from the incoming air and its classification as follows:
a. Natural Draught
On natural draught, the air goes into the furnace is naturally due to the
pressure difference between the furnace with air in the atmosphere. Tekanna in
lower furnace so that air can enter into the furnace. Natural draught has several
characteristics :
Requires no Warming Water
Resistance to small exhaust gas flow
Have a high enough stack
b. Forced Draught
The air goes into the furnace due to the pressure difference created by the
blower. Forced draught has several characteristics:
Have a low stack
Resistance to small exhaust gas flow
c. Induced Draught
The incoming air to the furnace with the help of a blower that is on the end of
the stack. This is because the withdrawal of the blower in the furnace pressure
lower than atmospheric pressure, so the air outside the entrance furnace.

Based on the mechanical design, there are several types of furnace based on the
mechanical design, namely:
1. Cylindrical Vertical Furnace
This is commonly used in furnace heat hot oil and process laian which are
usually small in size. This heater is probably the most commonly used to heat up
to about 150 MBtu/HR. On the type of cylinder, upright tube in section of
radiation are installed in vertical in a round circle of stove. Burner located under
dilantai, so that it is aligned with the flame tube. This type was applied:
Fluid heaters are commonly used as bait reactor
A heat Load ranges between 10-200 Gj/h
Used for heating a fluid which has the distinction of sushu between inlet and
outlet are not too big or about 200OF (90OC)
Figure 2.3 Cylindrical Vertical Furnace

The advantage of using vertical cylindrical furnace:
The simple Construction, so the price is relatively cheap

The surface area of the pipe can be arranged so that the thermal efficiency is
greater height
Area required is relatively small
Economically to fuel about 60-80 MMBTU/hour
The loss of usage of vertical cylindrical furnace:
The relatively small feed Capacity

Pilot area is minimal and the operation needs to be more carefully
2. Box Furnace
This type of shaped box with heat transfer convection and radiation are
separated by one or more of the wall called the bridge wall. This type has a large
capacity and usually wear fire box double radiation section. This type was
applied:
Process used for large capacity
Commonly used fuel is fuel oil
Used the old installation, sometimes used in new installations which have a
supply of fuel with high levels of grey
A heat Load ranges between 60-80 MMBTU/hour or more

Figure 2.4 Box Furnace
The advantage of using box furnace :

A heat flux Distribution evenly around the pipe
Economically to wear on the load a heat above 60-80 MBTU/h
Loss of use box furnace :
Relatively expensive Price

Require a wider area
When one of the fluid flow is stopped, then the whole opersi kitchen also must
be stopped to prevent rupture of the pipe
Can not be used for fluid cooled for high temperature fluid flow and short
3. Cabin furnace
This type does not have a bridge wall. Berad convection section at the top of
daput. Vessel in the area of radiation generally are mounted horizontally, but
there are also mounted in vertical. The burner is mounted in the bottom of the

fire that has perpendicular to the vessel, so that the direction of the fire glow
mupun exhaust gas perpendicular to the arrangement of the pipeline.
Figure 2.5 Horizontal Tube Cabin Heater
The advantage of wearing carbin furnace :

Form a compact construction and have a high thermal efficiency.
Heat Load approximately 20-300 MMBTU/hour.

2.4 Furnace Parts
Figure 2.6 Furnace Parts
In general the furnace has several sections as follows :
a. Wall of Furnace
Serves as an insulator to keep the combustion heat is not lost to the outside of
the circle.
b. Stack
Function to remove the exhaust gases of combustion result from the kitchen
out to the outside environment.

c. Stack damper
Function to set the smoke is lost in the stack. If the opening of the pereedam
decreases, the amount of heat lost in the stack will be reduced, but if the opening
is too small, the pressure will increase.
d. Window Watcher
Function to see the fire in the kitchen walls.
e. Air Registers
The air handler is used to regulate the amount of air that goes into the kitchen.
Air registers are composed of two parts: primary and secondary.
f. Tubes
Made of material resistant to corrosion and have a pretty strong force
(usually made of chromium). The pipeline serves to remove heat from liquid fuel
combustion yng terkndung in the tubes.
g. Burner
Serves to keep the airflow settings in hetaer used by fuel gas to get the fuel
mixing with the air either.
h. Soot blower
Function to remove the soot that sticks to pipe the vessels in this part of
the convection by spraying fluids such as air, water, or steam.
2.5 Triangle Fire

Triangle Fire or better known as the Fire Triangle is three basic
elements that are interlinked between one element with other elements. The fire
was the result of rapid oxidation at high temperatures is accompanied by the
appearance of the product gas heat and radiation emissions are visible as well as
invisible. The fire is visible or invisible. Oxidation generally occurs in the form

of rust on metal, but in arson fire, which creates the oxidation takes place very
quickly.
Figure 2.7 Triangle Fire
The elements of the triangle fire is :
a. Fuel: solid, liquid, or a gas when heated issue the flammable vapor. E.g.
paper, wood. Cardboard, oil, paint, acetylene, etc.
b. Heat: critical Temperature should be reached in order for the ignition
occurred, but after the fire have formed the fire usually will retain the heat
themselves. Heat can arise intentionally, or may not be intentional. For
example, the heater placed too close to furniture, overloaded electrical circuits
on a spot, and the personal computer are covered with Office paper.
c. Oxygen: Gas chemical elements that are colorless, odorless, tasteless and not
that filling 20% of the air we breathe.

The fire will not be created when one of the components of the fire triangle is
missing. The fire will not be able to continue to blaze in one of the components
of the tetrahedron is lost. In addition to the creation of fire also in influence by
the flash point and the composition of the concentration. When the temperature
on the flash point exceeding the minimum then the less chance for the formation
of the fire. Also in the composition of the concentration on one of the
components of the fire triangle is not enough then there will be formed a fire.
2.6 Combustion Process
The combustion process is a process of bereaksinya of fuel, air, and heat until
the occurrence of fire. Following things are associated with the combustion
process:
a. Air
The number of air dipetlukan on burning depending on the type and amount
of fuel gas, tools as well as steam reformer tube operating conditions. At
pembkaran, too much air will produce excessive heat, so the gas much heat
that is perfect which later can lead to the formation of carbon on the tube.
Comparison of the air with fuel gas is important so that the efisiennya
maintained a determined optimal.
b. Mixing Fuel Gas with Air
The entire air should be mixed with the fuel gas, since each particle that can
terbakarharus can really contact with oxygen in the air before combustion
occurs. If the mixing distribution and uneven, it will happen to the excess air,
and then going on a torrent of burning. So in the combustion process must
take place mixing the fuel and air is perfect.

c. Combustion Time
The mixing of air and fuel gas as well as temperature largely determined by
the speed of oxidation reactions in combustion. It takes time for the perfection
of the process. When the equipment is operating at high speed so that the time
to perfect combustion is not enough, then the fuel gas does not burn
completely.
The theory of combustion or chemical reaction between a fuel with air or oxygen
produces energy heat and gas-gas combustion results can be grouped into:
Perfect Combustion
Perfect combustion the combustion is where all the carbon reacts with oxygen
to form karbonbdioksida (CO2) and hydrogen reacts with oxygen to form water
(H2O), used no Oxygen left. Examples of reactions :
C3H8 + 5O2 3CO2 + 4H2O + Energi
Combustion reaction is actually only exists on the theoretical combustion,
while in a State of actual inside never happened.
Not Perfect Combustion
Imperfect combustion is a combustion in which oxygen is used for
combustion reactions are insufficient in number, so on combustion produces
carbon monoxide. Examples of reactions :
C2H6 + 3O2 CO2 + CO + 3H2O + Energi
Other Combustion
On the burning of fuel gas or fuel oil, not only consists of hydrocarbons, then
some other combustion reactions that may occur are :
2H2S + 3O2 2SO2 + 2H2O
2CO + O2 2CO2

The formation of oxides of sulfur is not desired inside the volcano, because of
the presence of water vapour in the exhaust gas will be possible vitriol. While the
rest of the carbon is not burned will produce a blackish red colour on the flame.
2.7 Gas Burner

The principle of mixing air with gas fuel for the combustion process is done in
two stages. The first stage, mixing with primary air namely mixing prior to
combustion. Mixing occurs along the burner, from the orifice until spinder.
The second stage, i.e. secondary air mixing with mixing fuel gas with air
during the combustion process that goes to mnyempurnakan the course of
combustion process in a fired heater. Mixing occurs in the radiant section.
If the air in the mix is less, then the flame redness and sometimes fuming. It's
best if the air in the mixture too much, then the flame is blue, not smoky, some
distance from the flame limits spinder, and at any time can be extinguished.
When the air for the combustion process less or more, then the kitchen is not
working effectively. When the lack of air, the combustion process less than
perfect so that the fuel gas which does not burn out as the black smoke. When
excessive hot air, partly a result stack. Visually, the lack of air can be known
when :
a. The flame Red
b. The base of fire inherent in spinder
c. Sometimes happened back fire


CHAPTER III
METHODOLOGY
3.1 Implementation of Specific Tasks

As a whole the methodology undertaken for carrying out specific tasks are as
follows :
1. Studi literature and field
2. Data collection
3. Data processing
3.2 Studi Literature and Field
The study of the literature and field aims to study the things pertaining to the
specific job. The study of the literature was conducted to find out the process
which deals in plant of High Vacuum Unit (HVU) and furnace by studying the
processes that occur in plant HVU, usefulness of the furnace for the plant, the
principle ketja HVU furnace and energy balance calculations in the furnace.
The literature used is textbooks, slides, process diagram, flowsheet and internet
website. Field studies conducted include a performance monitoring tool directly
at the refinery and a discussion with officers of the Court, the clerk, and the
control room supervisor.
3.3 Data Collection
The data used in the calculation to complete specific tasks were obtained from
a number of sources i.e. primary data as well as secondary data. Primary data
obtained from actual data that occurs in the process or operating conditions.
The data is taken in the calculations this time are data on September 29, 2016,
both from the data control panel as well as the data field. Data capture on

September 29, 2016 due on that date furnace F-202-01 has been dicleaning. So
it can be known how the overall performance of the preheat furnace especially
F-202-01. As for the secondary data, obtained from the data sheet or the design
that are already specified in the initial design.
3.4 Data Processing
Calculation of the heat used in the furnace can be reviewed from the use of
fuel gas coming out of the chimney. Methods that can be used is with the
method of heat release. On a method of heat release, heat the fluid absorbed is
calculated based on the difference between the incoming heat with the heat lost
through the fuel gas out of the chimney.
3.5 Heat Calculation Measures Used
Heat calculation measures used can be known through two stages, namely by
calculating the heat enters the furnace and the second step by calculating the
heat out furnace :
3.5.1 Calculation Of Incoming Heat Furnace

I. Heat Sensibel Fuel oil ( Q1 )
- Determine slope correction and middle fuel oil boiling point of attachment,
then determine the price of middle boiling point of slope.
- Calculate the value of KUOP from fuel oil with following formula
- (Nelson, 1968)
Calculate heat type (Cp) of the fuel oil with the help of graphs on the
attachment and on the basis of a price correction factors can be determined
KUOP Cp based on the graph at Appendix 3.
- Fuel oil Consumption can be calculated with the formula :
M=V

Where : M = Mass of fuel oil, lb/hr
V = Volume of fuel oil, ft3/hr
= Density of fuel oil, ft3/lb
- Heat-sensible fuel oil can be calculated with the formula :

Q1 = M Cp (Tin Tout)
Cp = Heat type of fuel oil, Btu/lb oF
Tin = Temperature of fuel oil masuk furnace, oF
Tout = Temperature calculation base, oF
II. Heat Combustion of Fuel Oil ( Q2 )
Q2 = M NHV
NHV= Net Heating Value, Btu/lb
III. Heat of Steam Atomizing ( Q3 )

Pressure and temperature of steam atomizing steam enthalpy obtained
with the aid of tables in Appendix 9 page 8. The amount of atomizing steam
consumption can be known with the help of graphs on the attachment 4 page
4 where necessary for fuel oil pressure data to determine the amount of
discharging steam atomizing. Hot steam atomizing can be calculated with
the formula:

Q3 = M H
Where : M = Mass of steam, lb/jam
H = Comparison of enthalphy steam, Btu/lb
IV. Sensible Heat Fuel Gas ( Q4 )

a. Fuel gas is assumed as the ideal gas
b. Determine the heat type (Cp) of each component of the fuel gas.
c. Calculate SG fuel gas in the following way (Burcik, 1979):
d. The sensible heat of the fuel gas can be calculated with the formula:
Q4= M Cp (Tin- Tout)
Where : M = Mass of fuel gas, lb/jam
Cp = Heat type of fuel gas, Btu/lb oF
Tin = Temperature of fuel gas furnace, oF
Tout = Calculate Temperature base, oF
V. Heat Combustion of Fuel Gas ( Q5 )

Q5 = M NHV
Where : M = Mass of fuel gas, lb/jam
NHV = Net Heating Value, Btu/lb
VI. Sensible Heat of Combustion Air ( Q6 )

Discharging the air = flow rate of air

a. Determine the hot type (Cp) from the air upon the temperature
b. Heat combustion air Sensible (Q6) can be calculated with the formula:
Where : M = Mass of Combustion Air, lb/hr
Cp = Heat capacity of air combustion, Btu/lb oF
Tin = Temperature of incoming air in furnace, oF
Tout= Temperature of calculation base, oF
3.5.2 Calculation Of Heat Out Furnace
I. The Heat Brought of Flue Gas ( Q7 )

a. Calculation of% heavy H and C contained in fuel oil by using equation
(Perry's, 1997):
% H = 26 ( 15 S )
% C= 100 % - (% H + % S + % H2O + % Abu)
Where : S = SG fuel oil
%H =%Hydrogen in fuel oil
%S = %Sulphure Weight in fuel oil
%H2O = %Water Wight in fuel oil
%Ash =% Ash Weight in fuel oil
b. Calculate the weight of each component contained in fuel oil and fuel gas.
c. Calculate the theoretical air needs (Wa) with a base of 1 kg/h fuel, the
formula used

( )
Where : Wa = The theoretical air needs, kg air/hr
C = The weight of the carbon in the fuel, kg/hr
H = The weight of the hydrogen in the fuel, kg/hr
O = Weight of oxygen in the fuel, kg/hr
S = The weight of the sulphur in the fuel, kg/jam
d. Calculate the actual air used for combustion with 1 kg of fuel. The
theoretical air needs can be deduced from the following chemical
equation :
- Reaction for carbon :
C + O2 CO2
1 mole + 1 mole 1 mole

12g + 32 kg = 44 kg
1kg + 8/3 kg = 11/3 kg
- Reaction for hydrogen:

2H2 + O2 2H2O
1mole + 1 mole 2 mole

1kg + 8 kg = 9 kg
- Reaction for sulphure :

S + O2 SO2
1 mol e + 1 mole 1 mole

32 kg + 32 kg = 64 kg
1 kg + 1 kg = 2 kg
Of these reactions can be said that for the reaction of burning 1 kg of fuel
containing the elements carbon, hydrogen, and sulfur in order to burn
perfectly requires oxygen rate :
For technical calculations, data-the data needed are :
- Volumetric Composition:
N2 = 79% Vol
O2 = 21% Vol
- Weight Composition :
N2 = 77% Weight
O2 = 23% Weight
- Molecular Weight of Air = 29

- Comparison of Mole = 79/21
Thus the theoretical air needs (Wa) can be calculated using the following
equation :
Or can be expressed :
( )

( )
Calculate the actual air requirements, which should be known i.e. the
weight of the air is actually unions needed heavy fuel known as "Air Fuel
Ratio" (AFR). In reality the actual air requirements (WA) is greater than the
theoretical air needs (Wa), because the theoretical air only combustion will
not last. Selisish between the needs of the actual air with theoretical air
usually referred to with the excess water. Excess water is expressed in the
form of the following equation :
( )
Where : x = Excess air, %
WA= The amount of air required is actually, kg udara/hr
Wa = The theoretical amount of air needed, kg udara/hr
If the magnitude of the excess water is known, then the actual amount
of air that is required can be calculated using the following equation :
( )
Calculate the content of water vapour contained in the combustion air with
the equation :
Where : Pvapour = Water vapor pressure, psia

Pstandart = The pressure is 1 atmosphere, psia
RH = Relatif Humidity, %

BMwater = The weight of the water molecule, lb/lbmol
BMair = The weight of the air molecules, lb/lbmol
The weight of the flue gas (Gas Combustion) is influenced by several

factors, including the magnitude of the fuel components and excess water
used. Fuel contains the elements carbon, hydrogen, oxygen, and water
(water), whereas the air contains oxygen and nitrogen and water vapor (Ma).
While flue gas produced consists of SO2, CO2, H2O, O2, and N2. Based on
combustion reactions already mentioned before, then the magnitude of flue
gas produced can be written in the form of the equation as follows :
WFG = 11/3 C + 2S + 9H2 + 0.77Wa + 0.0023 X Wa
Where : WFG = weight of flue gas, kg/kg fuel
Wa = the theoretical air, kg air/hr
W = water content, kg vapour/hr
Ma = water vapor in air, kg vapour/kg air
WA = the actual air, kg air/hr
The heat brought on flue gas (Q7) can be calculated by :

Where : M = Mass of flue gas, lb/hr
Cp = Heat Capacity of flue gas, Btu/lb oF
Tin = Temperature of flue gas, oF
Tout = Temperature of calculation base, oF

II. The Heat Lost Through Walls and The Base of The Furnace (Q8)
a. Calculate the area of the wall and the base of the furnace on the section
of radiation and convection
b. Determine the heat transfer coefficient of convection and radiation, as
well as wall and slope correction factor the basic furnace.
c. The heat lost through walls and the base of the furnace (Q8) can be
calculated with the formula :
Q8 = A hi (Td Tu)
Where : A = Area of the wall and the base of the furnace, ft2
Hi = The coefficient of heat transfer, Btu/ft2 oF hr
Td = Wall surface temperature/basic furnace, oF
Tu = The temperature of the outside air, oF

CHAPTER IV
RESULT AND DISCUSSION
4.1 Result and Discussion of Furnace F-202-01
4.1.1 Composition of Fuel Oil and Fuel Gas
Using data analysis and operating conditions dated 29 September 2016 where
CDU unit V operating at a capacity of 62 MBSD and unit capacity of 25 MBSD
HVU III, obtained results calculation and discussion of the following:
Tabel 4.1 Composition of fuel oil
Contents Unit Value

Spec.Garavity at 60/60 F - 0.95
Density 15C kg/L 0.95
API Gravity at 60F API 18.10
Pour Point F 100
Flash Point Visc. F 318
Kinematic at 140F Cst 598.30
Ash Content % wt 0.04
CCR % wt 8.90
Sulphur Content % wt 0.39
Water Content % Volume 0.10
*Analisys Data of Fuel Oil Lab. RU V - 29 September 2016

Tabel 4.2 Composition of fuel gas
Fuel Composition BM % Mol

CH4 16.04 82.69
C2H6 30.08 4,.9
C3H8 44.1 3.05
i-C4H10 58.12 0.68
n-C4H10 58.12 0.81
i-C5H12 72.15 0.31
n- C5H12 72.15 0.24
C6H14 86.18 0.60
N2 28.01 0.05
CO2 44.01 6.97
TOTAL 100.00
*Analisys Data from datasheet F-202-01
Calculation of the oAPI using formulas (Nelson, 1968).
So the value of oAPI are obtained in the following ways :
Deg. API = 18.1
Data from the API Technical Data Book It 14-2
o
API C/H ratio
25.0 7.17
30.0 6.79
Then, with the oAPI 18.1 obtained C/H of 6.27

C/H ratio = 6.27
C = 6.27 H
C + H = 100 (% S + % Ash + % Water)
(6.27 H) + H = 100 (0.39 + 0.04 + 0.1)
H = 13.69 %
C = 85.78 %
Net Heating Value Fuel Oil
NHV = 11,088 2,100 d2 + (757 d x (1 - % Air - % Ash - % S)) + 2,450 %S

585 %Water
NHV = 10,445 kcal/kg
4.2 Calculation of Heat Furnace
4.2.1 Calculation of Incoming Heat Furnace
The steps for the calculation of the efficiency of the furnace is by calculating
the balance of heat include heat system and heat out of the system. Heat system
consists of :
I. Heat Sensibel Fuel Oil (Q1)

Based on the data sheet, data is obtained as follows :
Table 4.3 Fuel Consumption Data and The Operating Condition of Furnace F-202-01
P FO Flow In Flow Out P Steam T Steam T FO

2
(kg/cm ) (m3/hr) (m3/hr) (kg/cm2) (C) (C)
4.88 0.34 0.32 14.30 357.26 123.97

Flow Fuel oil used = Flow in Flow out

= (0.34 0.32) m3/hr
= 0.02 m3/hr
T Fuel Oil = 255.146oF
T base = 60 oF
o
API Fuel Oil = 18.1
From Grafik, Obtained the data :
Cp T basis = 0.43 Btu/lb oF
Cp T Fuel Oil = 0.54 Btu/lb oF
Cp Average = 0.485 Btu/lb oF
Material ASTM slope ASTM mid boiling Correction

(general) deg/percent point (F) (F)
Gas Oil and
5.00 300-800 53-72
Reduced Crude
* W L Nelson Petroleum Refinery Engineering 4th Edition, Page 172
As in the table above, the price obtained middle boiling point fuel oil
amounting to 800-72 = 728 oF. By using these data to calculate the price of the
UNINHABITED KUOP as follows :
KUOP = 10.82
After obtained the price of the UNINHABITED KUOP, from Appendix 3

page 3 obtainable correction factors of Cp = 0.95, then rectified Cp = 0.95 x
0.485 Btu/lb oF = 0.4607 Btu/lb oF. Fuel oil consumption is calculated by the

equation :
M =
= 18.92 kg/hr x 2.2046 lb/kg
= 41.7070 lb/hr
Hot sensibel fuel oil can be calculated with the equation :
Q1 =M Cp (Tin Tout)
= 41.7070 lb/hr x 0.485 Btu/lb oF x ( 255.146 60) oF
= 3,927.05 Btu/hr x 0.25216 kcal/Btu
= 990.26 kcal/hr
So, heat sensibel fuel oil obtained of 990.26 kcal/hr.
II. Heat Combustion of Fuel Oil (Q2)

Heat of combustion of fuel oil is calculated by the equation below.
NHV values of fuel oil derived from previous calculations.
Q2 =M NHV
= 18.92 kg/hr x 10,445 kcal/kg
= 197,594.44 kcal/hr
So, the heat of burning fuel oil obtained amounted to 197, 594.44 kcal/hr.
III. Heat of Steam Atomizing (Q3)

To be able to calculate the heat of steam atomizing, first need to know
the amount of discharging steam used for atomizing. The amount of steam
consumption can be known from the graph at Appendix 4 where the fuel oil

pressure data is used to determine the amount of steam consumption for

atomizing.
Fuel oil consumption = 18.92 kg/hr
Pressure of steam atomizing = 14.3 kg/cm2 = 203.393 psia
Temperature steam atomizing = 357.26 oC = 675.068 oF
From the steam tables steam enthalpy obtained are:
H at T base = 28.06 Btu/lb
T h on steam = 746.68 Btu/lb
Pressure fuel oil =
= 4.7824 bar g
From the graph at Appendix 4 obtained atomizing steam consumption was 0.29
kg steam/kg of fuel oil.
Steam consumption = 18.92 kg/hr x 0.29 kg steam/kg fuel oil
= 5.49 kg steam/hr x 2.20462 lb/kg
= 12.10 lb steam/hr
Hot steam atomizing can be calculated with the formula:

Q3 =M H
= 12.10 lb steam/hr x (746.68 28.06) Btu/lb
= 8,691.68 Btu/hr x 0.25216 kcal/Btu
= 2,191.73 kcal/hr
So, the hot steam atomizing obtained amounted to 2, 191.73 kcal/hr.
IV. Sensible Heat of Fuel Gas (Q4)

Based on the data sheet gas fuel data is obtained as follows :

Table. 4.4 Gas fuel consumption data
Fuel Gas
Flow (NM3/hr) P (kg/cm2) Tin (oC)
1,215.50 1.20 33.38
T fuel gas = 92.084 oF

T basis = 60 oF
From the above data obtained the Cp value following :
Table 4.5 CP's average composition fuel gas
Cp Cp
Cp
pada pada
rata-
Fuel Mass % T T fuel
BM % mol rata
Composition (lb/lbmol) Berat basis gas
(Btu/lb
(Btu/lb (Btu/lb
F)
F) F)
CH 0.5315
16.04 82.6936 13.2665 63.6052 0.53 0.5362
CH 0.4180
30.08 4.5922 1.3809 6.6205 0.41 0.4271
CH 0.3978
44.10 3.0486 1.3443 6.4453 0.39 0.4078
i-CH 0.3972
58.12 0.6750 0.3923 1.8810 0.39 0.4075
n-CH 0.4016
58.12 0.8128 0.4724 2.2650 0.39 0.4092
i-CH 0.3922
72.15 0.3142 0.2267 1.0869 0.38 0.4020
n-CH 0.3970
72.15 0.2378 0.1716 0.8226 0.39 0.4073
CH 0.3963
86.18 0.6040 0.5205 2.4955 0.39 0.4062
N 0.2483
28.01 0.0496 0.0139 0.0666 0.25 0.2485

CO 0.1990
44.01 6.9722 3.0685 14.7115 0.2 01989
TOTAL 100 20.8576 100 3.71 3.8506 3.7789
Calculating the SG by using equation (Burcik, 1979) :
= 0.72
Fuel gas usage = Fuel gas usage x SG gas x air
= 1,215.50 NM3/hr x 0.72 x (1 kg/m3 x 0.94
m3/NM3)
= 821.7695 kg/hr x 2.2046 lb/kg
= 1,811.69 lb/hr
Weight (m) CH4 =
= 1,152.33 lb/hr
Sensible heat fuel gas using the following equation:
Q4 =M Cp (Tin- Tout)
QCH4 =1,152.33 lb/hr x 0.5315 Btu/lb oF x (92.084 60) oF
=19,648.67 Btu/hr
By using the same method above, then sensible heat gas components can
be calculated as follows :

Table 4.6 Hot sensibel each component
Fuel Berat Cp rata-rata

Composition (lb/hr) (Btu/lb F) T (F) Panas Sensibel (Btu/hr)
CH
1152,33 0,5315 32,084 19648,67
CH
119,94 0,4180 32,084 1608,68
CH
116,77 0,3978 32,084 1490,35
i-CH
34,08 0,3973 32,084 434,37
n-CH
41,03 0,4016 32,084 528,72
i-CH
19,69 0,3922 32,084 247,81
n-CH
14,9 0,3970 32,084 189,81
CH
45,21 0,3963 32,084 574,85
N
1,21 1,2483 32,084 9,61
CO
266,53 0,1990 32,084 1701,32
TOTAL 1811,69 3,7789 26434,19
Q4 = 26,434.19 Btu/hr x 0.25216 kcal/Btu

= 6,665.75 kcal/hr
So, sensible heat fuel gas obtained amounted to 6, 665.75 kcal/hr.
V. Heat Combustion of Fuel Gas (Q5)

In Appendix 10, page 9 will be obtained the value of Net Heating Value
(NHV) of each component of the fuel gas is as follows :

Table 4.7 NHV each component of fuel gas
Mass NHV
Fuel % % NHV
BM Proporsional Component
Composition mol berat (Btu/lb)
(lb/lbmol) (Btu/lb)
82.693 63.60
CH 16.04 13.2665 21,520.00 13687.83
6 52
6.620
CH 30.08 4.5922 1,3809 20,432.00 1352.70
5
6.445
CH 44.10 3.0486 1.3443 19,944.00 1285.45
3
1.881
i-CH 58.12 0.6750 0.3923 19,629.00 369.22
0
2.265
n-CH 58.12 0.8128 0.4724 19,680.00 445.75
0
1.086
i-CH 72.15 0.3142 0.2267 19,478.00 211.70
9
0.822
n-CH 72.15 0.2378 0.1716 19,517.00 160.54
6
2.495
CH 86.18 0.6040 0.5205 19,403.00 484.21
5
0.066
N 28.01 0.0496 0.0139 - -
6
14.71
CO 44.01 6.9722 3.0685 - -
15
TOTAL 508.9 100 20.8576 100.0 159,603.00 17,997.4

7 0 0
Calculate the heat of combustion of fuel gas using the following formula :
Q5 =M NHV
= 1,811.69 lb/hr x 17,997.40 Btu/lb
= 32,605,701.05Btu/hr
= 8,221,984.00 kcal/hr
So, the heat of combustion of fuel gas is obtained of 8,221, 984.00 kcal/hr.
VI. Sensible Heat of Air Combustion (Q6)

From page 1 of annex 1, the obtained data operating conditions as
follows:Dari lampiran 1 halaman 1, didapatkan data-data kondisi operasi
sebagai berikut:
Table 4.8 Operating conditions and the wearing of the combustion air
Combustion Air
Tin (C) P (kg/cm) Flow (NM/hr)
147.3664 79.9014 21001.3863
Air consumption (WA) = Air consumption x air
= 21001.3862 NM3/hr x 0.94 kg/NM3

= 19,741.30 kg/hr

T basis = 288.56 K
T Air = 420.37 K
Based on data obtained by T on top:
Cp T basis = 1.00561 kJ/kg oC
Cp T udara = 1.01672 kJ/kg oC
Cp Average = 1.01117 kJ/kg oC
Sensible heat of combustion air (Q6) can be calculated with the equation
Q6 =M Cp (Tin Tout)
= 19,741.30 kg/hr x 1.01117 kJ/kg oC x (147.3664 15.56) oC
= 2,631,081.77 kJ/hr
= 629,144.37 kcal/hr
So, sensible Heat combustion air obtained amounted to 629, 144.37 kcal/hr.
4.2.2 Calculation of Heat Out of Furnace
In the heat balance calculation method with reference to the method of lost
heat (heat loss method), then the heat is missing, which is the hot flue gases and
brought the heat is lost through the walls of the furnace.
I. Missing Heat Brought of flue gas (Q7)
The methods used in the calculation of the heat carried by the flue gases is by
calculating the balance of burning fuel oil and fuel gas with combustion air are
used. As for the measures undertaken are as follows :
-Calculation of the rat H and C contained in fuel oil out of the equation (Perry's,
1997):
% H = 26 - (15 SG)
= 26 (15 x 0.9459)

= 11.81%
From Equation :
% C = 100 % - ( % H + % S + % H2O + % Abu )
= 100% - (11.81% + 0.39% + 0.1% + 0.04%)
= 87.66%
Calculate the weight of H, C, N and O in the fuel gas with base 1 kgmol
Table 4.9 Percentage content of C, H, N and O in the fuel gas
Mass Berat
Fuel Berat C Berat H Berat N
Proporsio O
Composi BM % mol (kg/kg (kg/kg (kg/kg
nal (kg/kg
tion Fuel) Fuel) Fuel)
(lb/lbmol) Fuel)
82.693
CH 16.04 13.2665 0.47576 0.15859 - -
6
CH 30.08 4.5922 1.3809 0.05284 0.01321 - -
CH 44.10 3.0486 1.3443 0.05262 0.01169 - -
i-CH 58.12 0.6750 0.3923 0.01553 0.00324 - -
n
58.12 0.8128 0.4724 0.01871 0.00390 - -
-CH
i-CH 72.15 0.3142 0.2267 0.00904 0.00060 - -
n-CH 72.15 0.2378 0.1716 0.00684 0.00137 - -
CH 86.18 0.6040 0.5205 0.02085 0.00347 - -
N 28.01 0.0496 0.0139 - - 0.00067 -
CO 44.01 6.9722 3.0685 0.04011 - - 0.10697
TOTAL 508.97 100.00 20.8576 0.69230 0.19607 0.00067 0.10697

Total fuel = The amount of fuel oil + the amount of fuel gas
=18.92 kg/hr + 821.7695 kg/hr
= 840.69 kg/hr
Weight of Carbon = (87.66% x 18.92 kg/hr) + (0.69230/100 x 821.7695
kg/hr)
= 22.2723 kg/hr
Weight of Hydrogen = (11.81% x 18.92 kg/hr) + (0.19607/100 x 821.7695
kg/hr)
= 3.8457 kg/hr
Weight of Sulphure = 0.39% x 18.92 kg/hr
= 0.0738 kg/hr
Weight of Nitrogen = 0.0019% x 821.7695 kg/hr
= 0.0055 kg/hr
Weight of H2O = 0.1% x 18.92 kg/hr
= 0.01892 kg/hr
Weight of O2 = 0.10697/100 x 821.7695 kg/hr
= 0.87903 kg/hr
Weight of Ash = 0.04% x 18.92 kg/hr
= 0.0076 kg/hr
Table 4.10 % Weight of C, H, N and O
Fuel
Amount (kg/hr) % Weight
Composition
C 22.2723 82.1771
H 3.8457 14.1894
S 0.0738 0.2722

N 0.0055 0.0202
H2O 0.0189 0.0698
O 0.8790 3.2433
Ash 0.0076 0.0279
Total 27.1028 100
- The theoretical air needs (Wa) is calculated with equation (Allen, 1914)
( )
= ( )
= 15.50 kg air/kg fuel x 2,515.15 kg/hr

= 13,032.82 kg air/hr
From Equation :
( )

=
= 0.51%
- Actual air requirements for 1 kg of fuel (WA) from the equation
( )
=( )
= 15.58 kg udara/hr

- Content of moisture in the combustion air (Ma)

Air Temperature = 86.18 oF
Water vapor pressure = 0.6251 psia = 0.0439 kg/cm2
Relatif Humidity = 73% (www.balikpapan.climatemps.com/humidity)
With Equation (3.21)
= 0.02 kg vapour/kg air

The weight of the flue gas (WFG) with base 1 kg/hr fuel with the equation
WFG = 11/3 C + 2S + 9H2 + 0.77WA + 0.0023 X Wa
= (11/3 x 82.1771%) + (2 x 0.2722%) + (9 x 14.1894%) + (0.77
x15.58 ) + (0.0023 x 15.50 )
= 16.33 kg/kg fuel
WFG TOTAL =16.33 kg/kg fuel x 840.69 kg/hr
= 13,728.79 kg/hr
-Weight of the flue gas of each component
( )
CO2 =
( )
=
= 2533.13 kg/hr
= 5,584.58 lb/hr
( ( ))
H2O = * +
( ( )
=* +
= 1,349.65 kg/hr
= 2,975.46 lb/hr

SO2 =
= 4.58 kg/hr
= 10.09 lb/hr
N2 =( )
=( )
= 10,086.93 kg/hr
= 22,237.85 lb/hr
O2 =
= 15.43 kg/hr
= 34.02 lb/hr
Table 4.11 The Heat from the Flue Gas
Cp pd T Cp pd Cp rata-
flue gas
Berat T flue T basis flue gas* T basis rata Q
compos
(lb/hr) gas (F) (F) (Btu/lb (Btu/lb (Btu/lb (Btu/hr)
ition
F) F) F)
CO2 5,584.58 716.32 60.00 0.26300 0.19905 0.23102 846767.15
H2O 2,975.46 716.32 60.00 0.49050 0.44500 0.46775 913452.19
SO2 10.09 716.32 60.00 0.18560 0.14734 0.16647 1102.51
2,2237.8 3709372.1
N2 5 716.32 60.00 0.26020 0.24810 0.25415 3
O2 34.02 716.32 60.00 0.24420 0.21875 0.23148 5167.83
TOTA 5475861.8

L 0
The heat brought on flue gas (Q7) is calculated using the equation
Q7 = 5475861.80 Btu/hr x 0.25216 kcal/Btu
= 13,80815.21 kcal/hr
So, the hot flue gas brought obtained amounted to 13, 80815.21 kcal/hr.
II. Heat Lost Through the Walls and The Base of The Furnace (Q8)
Fuel gas usage = 821.77 kg/hr
Fuel oil consumption = 18.92 kg/hr
NHV fuel gas = 17,997.40 Btu/lb
= 39,677.43 Btu/kg
NHV fuel oil = 10,444.78 kcal/kg
Loss Assumption = 2.5% (Patel, 2005)
From the previous calculation can be concluded that:
Massa fuel x NHV = Heat of combustion of fuel
Q8 = (Heat combustion of fuel gas + Heat combustion of fuel gas) x Loss
= (821.77 kg/hr x 39,677.43 Btu/kg) + (18.92kg/hr x
10,444.78kcal/kg) x 2.5%
= (32605701.05 Btu/hr + 197594.44 kcal/hr) x 2.5%
= (8221984.00kcal/hr + 197594.44 kcal/hr) x 2.5%
= 210489.46 kcal/hr
So, the heat is lost through the walls and the base of the furnace is obtained of
210489.46 kcal/hr.

4.2.3 Heat Balance and Efisiensi (F-201-01)
After calculation of the heat entering and exiting from a furnace F-201-01
worked on, then it can be drawn up the balance of the heat from the furnace F-
201-01 as shown in table 4.12 :
QA (Heat used) = Incoming heat furnace Heat out furnace
= (Q1 + Q2 + Q3 + Q4 + Q5 + Q6) (Q7 + Q8)
= (990.26 + 197594.44 + 2191.73 + 6665.75 +

8221984+ 629144.37) (1380815.21 +
210489.46) kcal/hr
= 7467265.88 kcal/hr
Table 4.12 Heat Balance Furnace F-201-01
Description In (kcal/hr) Out (kcal/hr)
(Q1) Sensible Heat of Fuel Oil 990.26
(Q2) Heat Combustion of Fuel Oil 197594.44
(Q3) Heat of Steam Atomizing 2191.73
(Q4) Sensible Heat of Fuel Gas 6665.75
(Q5) Heat Combustion of Fuel Gas 8221,984
(Q6) Sensible Heat of Air Combustion 629144.37
(Q7) Heat Lost Brought of Flue Gas 1380815.21
(Q8)Heat Lost Through The Walls of

210489.46
Furnace
(QA) Heat Used 7467265.88

TOTAL 9058570.55 9058570.55
Heat balance of the above obtained
- Percentage of lost heat brought gas flue (%Q7) :
%Q7 =
= 15.24%
- Percentage of the heat lost through walls and the base of the furnace (%Q8) :
%Q8 =
= 2.32%
The efficiency of the furnace is obtained using the formula
= 82.43%
So, the efficiency of the furnace F-202-01 obtained amounted to 82.43%.

CHAPTER V
CONCLUSION AND SUGGESTION
5.1 Conclusion
Based on the results of the evaluation of the calculation of furnace F-202-01

unit HVU III for the period September 29, 2016 can be inferred:
- Computational-efficiency furnace F-202-01 of 82.43% efficiency furnace

design, and F-202-01 of 99.97%. Then it can be inferred to have occurred
where the furnace performance degradation occurs a decrease in efficiency of
8.6% over the design. The efficiency of the furnace of 82.43% still categorized
quite well.
5.2 Suggestion
Here is the things that are done to improve the performance of the furnace in
HVU III.
- Evaluate performance furnace F-202-01 HVU III continuously.
- Perform cleaning furnace F-202-01 HVU III on the occasion of the Pit Stop or
Turn Around (TA).
- Keep the furnace operating conditions F-202-01 HVU III, through the flame
settings, settings of excess O2 in the race and setting the furnace.


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Laporan Tugas Khusus Kerja Praktek

PT. PERTAMINA (Persero) Refinery Unit V Balikpapan

Muthiah Nur Fadlilah (D500130037)

1. Writing the report specifically focused to calculate the efficiency of a furnace

Muthiah Nur Fadlilah (D500130037)

2.1 High Vacuum Unit III (HVU III)

Muthiah Nur Fadlilah (D500130037)

Figure 1.3 Process Flowchart HVU III

Muthiah Nur Fadlilah (D500130037)

Figure 2.2 Charts Furnace

Convection section is an area where entry of liquids will be separated. In this

Muthiah Nur Fadlilah (D500130037)

2.3 Classification of Furnace

Muthiah Nur Fadlilah (D500130037)

Figure 2.3 Cylindrical Vertical Furnace

Muthiah Nur Fadlilah (D500130037)

The advantage of using vertical cylindrical furnace:

The simple Construction, so the price is relatively cheap

The loss of usage of vertical cylindrical furnace:

The relatively small feed Capacity

Muthiah Nur Fadlilah (D500130037)

Figure 2.4 Box Furnace

The advantage of using box furnace :

Loss of use box furnace :

Relatively expensive Price

Muthiah Nur Fadlilah (D500130037)

Figure 2.5 Horizontal Tube Cabin Heater

The advantage of wearing carbin furnace :

Muthiah Nur Fadlilah (D500130037)

2.4 Furnace Parts

Figure 2.6 Furnace Parts

In general the furnace has several sections as follows :

Muthiah Nur Fadlilah (D500130037)

2.5 Triangle Fire

Muthiah Nur Fadlilah (D500130037)

Figure 2.7 Triangle Fire

The elements of the triangle fire is :

Muthiah Nur Fadlilah (D500130037)

2.6 Combustion Process

Muthiah Nur Fadlilah (D500130037)

Muthiah Nur Fadlilah (D500130037)

2.7 Gas Burner

Muthiah Nur Fadlilah (D500130037)

Muthiah Nur Fadlilah (D500130037)

3.1 Implementation of Specific Tasks

Muthiah Nur Fadlilah (D500130037)

3.5.1 Calculation Of Incoming Heat Furnace

Muthiah Nur Fadlilah (D500130037)

Where : M = Mass of fuel oil, lb/hr

V = Volume of fuel oil, ft3/hr

= Density of fuel oil, ft3/lb

- Heat-sensible fuel oil can be calculated with the formula :

Where : M = Mass of fuel oil, lb/hr

Cp = Heat type of fuel oil, Btu/lb oF

Tin = Temperature of fuel oil masuk furnace, oF

Tout = Temperature calculation base, oF

II. Heat Combustion of Fuel Oil ( Q2 )

Where : M = Mass of fuel oil, lb/hr

NHV= Net Heating Value, Btu/lb

III. Heat of Steam Atomizing ( Q3 )

Muthiah Nur Fadlilah (D500130037)

Where : M = Mass of steam, lb/jam

H = Comparison of enthalphy steam, Btu/lb