IP’s Lesson Learned of Geothermal Power Plant O&M – Now & Then 6TH ITB IIGW 22nd – 23rd Mar 2017
The Outline Indonesia Power in Brief
Units Performance & Management
Unit 1 KMJ Rehabilitation Project
Layout of Unit 2-3 KMJ Life Extension Program
Ulumbu-Mataloko Geothermal Power Plant
Who Are IP? 100%
PT Perusahaan Listrik Negara (Persero) (PLN) 99,9%
PT Artha Daya Coalindo (ADC) SUBSIDIARIES
PT Cogindo Daya Bersama (CDB) PT. Indo Pusaka Berau (IPB)
UNITS
UP Suralaya
UP Semarang
UJP -SLY 8, BSR, Labuan, -Pl Ratu, Adipala, -Pangkl Susu, Baru, - Jerajang, Ulumbu
UP Perak Grati
UPJP Priok
CDB Business -Co-Generation -Energy Outsourcing -Energy Efficiency -Assessment Package
UPJP Bali
UP Saguling
UP Mrica
ADC Business - Coal Supplier & - Distributor/Transportation
UPJP Kamojang
Unit Jasa Pemeliharaan
IPB Business
- Operating 14 MWe CFPP
VISION
Sustainable and Trusted Energy Company
MISION
Engage in Environmentally Friendly Power Generation Business and O&M Services
IP Power Plants
Geothermal PP
GUNUNG SALAK GPP 180 MW
GUNUNG SALAK GPP Desa Purwabakti Kecamatan Pamijahan Kabupaten Bogor Jawa-Barat Ketinggian : 900 dpl
PLTP KAMOJANG Desa Laksana Kecamatan Ibun Kabupaten Bandung Jawa-Barat Ketinggian : 1,500 dpl
KAMOJANG GPP 140 MW
PLTP DARAJAT Desa Padaawas, Kecamatan Pasir Wangi Kabupaten Garut Jawa-Barat Ketinggian : 1,700 dpl
DARAJAT GPP 55 MW
PLTP ULUMBU (O & M) Ulumbu Nusa Tenggara Timur PLTP MATALOKO (O & M) Mataloko Nusa Tenggara Timur
Installed Capacity No.
Units
1 2
Kamojang 2 Kamojang 3 KAMOJANG GPP Gunung Salak 1 3 Gunung Salak 2 4 Gunung Salak 3 5 GUNUNG SALAK GPP Darajat 1 6 UPJP KAMOJANG
No. 1. 2. 3. 4.
Units Ulumbu ADB #1 Ulumbu ADB #2 Ulumbu APBN #1 Ulumbu APBN #2
PLTP ULUMBU
Installed Capacity (MW) 55 55 110 60 60 60 180 55
Nett (MW) 52.3 52.3 104.6 56.5 56.5 57 170 52
345
326.6
Installed Capacity (MW) 2.5 2.5 2.5 2.5
Nett (MW) 2.5 2.5 2.3 2.3
10
9.6
COD 29-Jul-87 13-Sep-87 12-Mar-94 12-Jun-94 16-Jul-97 6-Oct-94
COD 14-Jul-14 14-Jul-14 9-Jun-12 4-Jan-12
Performance Outline TOP PLTP KAMOJANG 2 & 3 UNIT
YEAR
HOUSE EAF EFOR SdOF PROD SOLD LOAD (%) (%) (kali) (MWH) (MWH) (MWH)
1,400,000 1,200,000 1,000,000
2011
97.99 0.71 1.5 951,291 908,410 42,881
PLTP 2012 KAMO 2013 JANG 2014 2&3 2015
94.33 0.18 2.0 894,261 854,826 39,435
2016
99.09 0.08 1.0 823,280 786,811 36,469
800,000 TARGET
600,000
99.16 0.14 1.0 798,697 763,840 34,857
400,000
94.23 1.10 2.0 909,508 872,546 36,962
200,000
99.42 0.17 1.00 627,332 599,778 27,554
-
Description: Data 2016 till August
REALISASI
TOP 44,75%
2011
2012
2013
2014
2015
2016
Description: Data 2016 till August
EAF in average > 94% as per NERC Standard Target TOP KMJ (as per agreement with Pertamina) – 72.23% TOP KMJ in 2011 until 2016 (August) average reach – 75.94 % Considering only two operating units in 2015, TOP KMJ can still be achieved by 74.16%, including Simple Inspection (SI) & Shutdown Total (SDT)
Process Flow Diagram
Asset Management Reliability Pertahanan Management Failure Defense Task
Pertahanan WPC Condition Base Pertahanan Management
Risk Pertahanan Management
Detect Failure
Risk Failure
Mitigation of Failure
Aging Asset Pertahanan Management
Outage Pertahanan Management
End of Life
Mitigation of Failure
Continuous Pertahanan Improvement Analysis and Opportunity
Turbine Highlight Double axial flow turbine 5 stage : 2 stage Impulse 3 stage Reaction Nominal Capacity : 55,000 KW rpm : 3000 rpm Inlet Steam Press. : 6.5 bar abs Outlet Steam Press. : 0.1 bar Critical speed : 1 st 1700 rpm 2 nd 3600 rpm
Roll-in/Roll-out strategy for every 24,000 operation hours Scaling problems : Occurs on 1st & 2nd stage in form of Silica Occasionally, Ferrous deposit was found on GSL – solved with nonoxygenated steam washing Common problems : Failed shroud & seal strips Deformation on blade’s dove tail Plugging on condensate drain system
Generator Highlight
Power Voltage Current Power Factor Frequency Speed Number of Phase Insulation Class Stator Temperature Rotor Temperature Water Cooler Temp.
: 68.750 KVA : 11,800 KV : 3364 A : 0,8 PF : 50 Hz : 3000 rpm : 3 Phase :B : 790 C : 900 C : 320 C
Inspection of generator rotor & stator in every 72,000 operation hours – scope of Major Inspection (MI). Problems : Retaining ring – due to 1980’s design was MnCr 18-5 – replaced in 2006 Rewinding of stator – due to base load position on the grid Rotor winding reinsulation – due to environment & lifetime
Other Main Equipment
Design Consideration
U1 KMJ Rehab Project CV-101 MSVL
SE 104 100%
MSVR CV-___
GVL
(100%)
GVR SE 101 60%
DM-100
SE 102 40%
SE 103 30%
1ST
MV___
STAGE ICND 100
CT-100
VP-100
1 X 100% LRVP w/ SEAL WATER SEPARATOR
VACUUM BREAKER
MCND-100 CONDENSER
M
M
M
STEAM TRAP
M
SIPHON BREAKER
GAS EXTRACTION SYSTEM
GENERATOR
VACUUM BREAKER
SP-100
S
(100%)
GEN-100
STEAM TURBINE, ST-100
DEMISTER
2ND STAGE ACND 101
CV-109
CV-____ CV-107
TO FLASH TANK
P-101 CV-106A
CV-106B
P-201
CV-111 CV-105A
MAIN COOLING WATER PUMPS (NEW 2 x 50%)
P-102 Lube Oil Coolers
P-202 CV-105B
A B
M
1V-1
PRIMARY INTERCOOLING WATER PUMPS (NEW 2 x 100%)
S
Flow Meter
FR STEAM RECEIVING HEADER
BLOWDOWN VALVE
S
A COLD WELL OVERFLOW & DRAIN
B Generator Coolers
U1 KMJ Schedule
Contract Awarded : 21 Des 2015 – Project Duration 21 months EPC Period : 25 Jan 2016 to Mar 2017 Commissioning : Starting May 2017 COD : Oct 2017
U2-3 KMJ Life Extension
Life time power plant has been operating almost 30 years with high availability > 92% Kamojang Power Plant currently supports West Java Electrical System, especially in Southern West Java Sub System Kamojang PP regarded as one Green Power Plant that participate for decreasing emission which has already awarded by GoI for the 8th times since 2008 Remaining Life Assessment (RLA) has been carried out in Kamojang PP related to main equipment which can be used as prediction and clarification of remaining life of equipment Rehabilitation Program is necessary carried out for improving reliability, efficiency and modernization in control system in order to able to easy to operate and profitable in long operation period First it was going to be funded by JBIC, but now KfW taking over the financial matter
Scope of U2-3 KMJ LEP Turbine System
Unit Assets
Generator System
Auxiliary System
Turbine Rotor & Diaphragm
Life extension – improvement of efficiency for output
Lube & Control Oil System
Reliability improvement
Journal & Thrust Bearing
Life extension
Generator Rotor
Renewal & rewinding for strategic operation
Exciter – AVR – GCB
Life extension – modernization – reliability improvement
Main Transformer 11.8/150 kV – Aux Transformer 11.8/6.3 kV
Reliability improvement – efficiency improvement
Cooling Water System
Improvement CWP, CT, Pri & Sec Pump, Main Cond, Intercooler
Gas Removing System
Improvement Ejector, Aux Cond Flash tank
Main Steam System
Improvement Rock Muffler, Separator, Demister, IAC, MUIV
Plant DEHC
Modernization – reliability improvement
Plant DCS – TSI – UPS
Modernization
Control System
Ulumbu & Mataloko
Lokasi PLTP Ulumbu di desa Wewo, Kecamatan Satarmese,Kabupaten Manggarai, Propinsi Nusa Tenggara Timur
Lokasi PLTP mataloko di desa Todabelu, Kecamatan Golewa,Kabupaten Ngada, Propinsi Nusa Tenggara Timur, berada sekitar 16 km ke arah timur dari Kota Bajawa
Cluster Ulumbu
Production Wells
The Units PLTP Ulumbu Unit 3 & 4 (APBN) 2 x 2,5 MW
PLTP Ulumbu Unit 1 & 2 (ADB) 2 x 2,5 MW
PFD of U1-2 ADB
PFD of U3-4 APBN
