IP’s Lesson Learned of Geothermal Power Plant O&M – Now & Then

6TH ITB IIGW22nd – 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?

PT Artha Daya Coalindo (ADC)

PT Cogindo Daya Bersama (CDB)

PT. Indo Pusaka Berau (IPB)

99,9%

100%

PT Perusahaan Listrik Negara (Persero)

(PLN)

SUBSIDIARIES

Unit JasaPemeliharaan

UPJPKamojang

UP MricaUP

SagulingUPJP Bali

UPJPPriok

UP Perak Grati

UP

Semarang

UP

Suralaya

UNITS

CDB Business

-Co-Generation

-Energy Outsourcing

-Energy Efficiency

-Assessment Package

ADC Business

- Coal Supplier &

- Distributor/Transportation

IPB Business

- Operating 14 MWe

CFPP

UJP

-SLY 8, BSR, Labuan,

-Pl Ratu, Adipala,

-Pangkl Susu, Baru,

- Jerajang, Ulumbu

VISION Sustainable and Trusted Energy Company

MISION Engage in Environmentally Friendly Power Generation Business and O&M Services

IP Power Plants

Geothermal PP

PLTP KAMOJANGDesa LaksanaKecamatan IbunKabupaten BandungJawa-BaratKetinggian : 1,500 dpl

GUNUNG SALAK GPPDesa PurwabaktiKecamatan PamijahanKabupaten BogorJawa-BaratKetinggian : 900 dpl

PLTP DARAJATDesa Padaawas, Kecamatan Pasir WangiKabupaten GarutJawa-BaratKetinggian : 1,700 dpl

PLTP ULUMBU (O & M)UlumbuNusa Tenggara Timur

GUNUNG SALAK GPP180 MW

KAMOJANG GPP140 MW

DARAJAT GPP55 MW

PLTP MATALOKO (O & M)MatalokoNusa Tenggara Timur

Installed Capacity

Installed Capacity Nett COD

(MW) (MW)

1 Kamojang 2 55 52.3 29-Jul-87

2 Kamojang 3 55 52.3 13-Sep-87

KAMOJANG GPP 110 104.6

3 Gunung Salak 1 60 56.5 12-Mar-94

4 Gunung Salak 2 60 56.5 12-Jun-94

5 Gunung Salak 3 60 57 16-Jul-97

GUNUNG SALAK GPP 180 170

6 Darajat 1 55 52 6-Oct-94

UPJP KAMOJANG 345 326.6

No. Units

Installed Capacity Nett

(MW) (MW)

1. Ulumbu ADB #1 2.5 2.5 14-Jul-14

2. Ulumbu ADB #2 2.5 2.5 14-Jul-14

3. Ulumbu APBN #1 2.5 2.3 9-Jun-12

4. Ulumbu APBN #2 2.5 2.3 4-Jan-12

PLTP ULUMBU 10 9.6

UnitsNo. COD

Performance Outline

UNIT YEAREAF(%)

EFOR(%)

SdOF(kali)

PROD(MWH)

SOLD(MWH)

HOUSELOAD

(MWH)

PLTP KAMOJANG2 & 3

2011 97.99 0.71 1.5 951,291 908,410 42,881

2012 94.33 0.18 2.0 894,261 854,826 39,435

2013 99.09 0.08 1.0 823,280 786,811 36,469

2014 99.16 0.14 1.0 798,697 763,840 34,857

2015 94.23 1.10 2.0 909,508 872,546 36,962

2016 99.42 0.17 1.00 627,332 599,778 27,554

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)

Description: Data 2016 till August

Description: Data 2016 till August

-

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

2011 2012 2013 2014 2015 2016

TOP PLTP KAMOJANG 2 & 3

TARGET

REALISASI

TOP44,75%

Process Flow Diagram

Asset Management

Pertahanan

Failure Defense Task

Reliability Management

Pertahanan

Detect Failure

Condition Base Management Pertahanan

Risk Failure

Risk Management

Pertahanan

Mitigation of Failure

Outage Management

Pertahanan

Mitigation of Failure

WPC

Pertahanan

End of Life

Aging Asset Management

Pertahanan

Analysis and Opportunity

Continuous Improvement

Turbine Highlight

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 non-

oxygenated steam washing Common problems :

Failed shroud & seal strips Deformation on blade’s dove tail Plugging on condensate drain system

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 rpm2 nd 3600 rpm

Generator Highlight

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

Power : 68.750 KVA

Voltage : 11,800 KV

Current : 3364 A

Power Factor : 0,8 PF

Frequency : 50 Hz

Speed : 3000 rpm

Number of Phase : 3 Phase

Insulation Class : B

Stator Temperature : 790 C

Rotor Temperature : 900 C

Water Cooler Temp. : 320 C

Other Main Equipment

Design Consideration

U1 KMJ Rehab Project

STEAM TURBINE, ST-100DM-100DEMISTER

M CT-100

M

Generator Coolers

P-201

Lube Oil Coolers

P-202

CV-105A

CV-105B

CV-106A CV-106B

MAIN COOLING WATER PUMPS(NEW 2 x 50%)

P-101

P-102

PRIMARY INTERCOOLING WATER PUMPS(NEW 2 x 100%)

GEN-100

MCND-100CONDENSER

FR STEAM RECEIVING HEADER

VP-100

TO FLASH TANK

GENERATOR

VACUUM BREAKER

VACUUM BREAKER

SIPHON BREAKER

CV-107

CV-109

MSVRMSVL

GVRGVL

SE10160%

CV-111

MV-___

CV-___

1V-1

CV-____

STEAM TRAP

S

M

M

M

CV-101

SE10240%

SE10330%

1ST

STAGEICND100

(100%)

2ND

STAGEACND101

(100%)

1 X 100% LRVP w/ SEAL WATER

SEPARATOR

SP-100

GAS EXTRACTION

SYSTEM

COLD WELL OVERFLOW& DRAIN

BLOWDOWN VALVE

SE104

100%

A

B

A

BSS

Flow Meter

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 fordecreasing emission which has already awarded by GoI for the 8th times since2008

Remaining Life Assessment (RLA) has been carried out in Kamojang PP relatedto main equipment which can be used as prediction and clarification ofremaining life of equipment

Rehabilitation Program is necessary carried out for improving reliability,efficiency and modernization in control system in order to able to easy tooperate and profitable in long operation period

First it was going to be funded by JBIC, but now KfW taking over the financialmatter

Scope of U2-3 KMJ LEPU

nit

Ass

ets

Turbine System

Turbine Rotor & DiaphragmLife extension – improvement of efficiency

for output

Lube & Control Oil System Reliability improvement

Journal & Thrust Bearing Life extension

Generator System

Generator Rotor Renewal & rewinding for strategic operation

Exciter – AVR – GCBLife extension – modernization – reliability

improvement

Main Transformer 11.8/150 kV – Aux Transformer 11.8/6.3 kV

Reliability improvement – efficiency improvement

Auxiliary System

Cooling Water SystemImprovement CWP, CT, Pri & Sec Pump, Main

Cond, Intercooler

Gas Removing System Improvement Ejector, Aux Cond Flash tank

Main Steam SystemImprovement Rock Muffler, Separator,

Demister, IAC, MUIV

Control System

Plant DEHC Modernization – reliability improvement

Plant DCS – TSI – UPS Modernization

Ulumbu & Mataloko

Lokasi PLTP mataloko di desa Todabelu,

Kecamatan Golewa,Kabupaten Ngada,

Propinsi Nusa Tenggara Timur, berada

sekitar 16 km ke arah timur dari Kota Bajawa

Lokasi PLTP Ulumbu di

desa Wewo, Kecamatan

Satarmese,Kabupaten

Manggarai, Propinsi Nusa

Tenggara Timur

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