Sustaining Power Plant Life Through Rehabilitation as a Part of Life Cycle Management Program r02

7/23/2019 Sustaining Power Plant Life Through Rehabilitation as a Part of Life Cycle Management Program r02

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Sustaining Power Plant Life Through

Rehabilitation as A Part of Life Cycle

Management Program

Mr. Herdiyanto SoekonoHead of Engineering Division

Arief Mustaqim

Staff of Engineering DivisionPT. Indonesia Power

National Conference On Electricity Business & Technology

Jakarta, 1-2 October 2014

Case Study of Kamojang Geothermal Power Plant (KGPP)

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Outline :

Background

Life Cycle Management of KGPP

Feasibility Study for Rehabilitation

The Compliance of Performance Standards on

Environmental and Social Sustainability

Conclusion

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Background

KGPP- is the first geothermal plant in Indonesia with the totalinstalled capacity 140 MW, almost 30 years in operation and theexistence still needed by the grid.

KGPP is Owned & operated by PT. Indonesia Power subsidiary of PLNwhile steam supplied by Pertamina Geothermal Energy

Several references stated, EPRI experiences, rotating part of thepower plant shall be replaced after 200.000 hrs operation orrefurbished due to integrity inspection results, another referencestated the life time of power plant can be achieved 65 years with theschedule of rehabilitation at 25 years and 45 years and after 65 yearsold demolition shall be considered.

The need to sustaining KGPP life to prolong its existence as perworldwide references

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Business Impact vs Phase of Asset life.

Source: adapted from several references4


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Deployment of LCM

LCM has been developed by considering :

Technical evaluation of system structure component,

Identification and evaluation of life cycle alternative plan

Life cycle cost analysis for the justified life cycle alternative

plan

Selection of optimum life cycle plan

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O&M Strategy Program

Maintenance Strategy Program

EAF > 90%

Corrective

Preventive

& ProActive

Predictive

Turbinerepairement

Generatorrewinding

RetainningRing

replacement

CoolingTower part

replacement

coolingsystem and

some part ofsteam pipeinstalation

repairment and refurbishment activities

as a part of Life Management

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Life Assessments Program

Life Assessments Program of KGPP scenario considering several issues as

follows :

Operation &

maintenance historicalrecords

Examination analysisboth NDE / DE

Life prediction withrobust model which give

high confidence levelusually comes from

research organization

statistical review fromsister plant

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Life Assessments Program

Turbine & Steam

Blade

Rotor

Diaphragm

Turbine Valve

Receiving header

Demister

Final separator

Pipeline system

I&C

Plant DAS to DCS

Turbine COntrol

BOP Main Motor

Main cooling waterpump

Cooling tower fanmotor

Cooling Tower

Civil Structure

Cooling Element

Generator & Trafo

Rotor

Stator

Transformerwinding

The equipment list of geothermal power plant as a concern of lifeassessment program as follows:

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Results:

The result of material inspection such as NDT and Microstructure

investigation found some defect as well micro cracks and predicted the

life time of HIP turbine on the near end of life. Other defect found in

hot and pressured steam piping such as degradation of wall thickness

and also predicted the life time on the near end of life phase. (thestatement from several references confirmed)

Beside the life time to be extended, the turbines efficiency will plant to

be increased by applied new design of turbine blade as well as the new

material and digital control system.

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The result of financial analysis show an optimistic result from

financial indicator with the assumption of steam contract from PGE

to be establish at least for the next 15 years. (Several studies

confirmed Kamojang Geothermal field predicted exist for the next

20 to 25 years from 2005)

Due to significant budget needed to execute the program and

regulation of the company, in Order to get financing for the

rehabilitation program the plant should comply IFC to meet the

requirement of world wide financing organization.


Results:

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Tentative Illustration

Rehabilitation Scope of Work

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AVR

DCIS


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The Performance Standards on Environmental and Social Sustainability

used in the Feasibility Study is IFC (International Finance Corporation)

The IFC guideline consists of 8 performance standard to comply;

Assessment and Management of Environmental and Social Risks and Impacts

Labour and Working Conditions

Resource Efficiency and Pollution Prevention

Community Health, Safety, and Security

Land Acquisition and Involuntary Resettlement

Biodiversity Conservation and Sustainable Management of Living Natural

Resources

Indigenous Peoples

Cultural Heritage

The Environmental and Social Assessment in accordance IFC performance standard

results KGPP life extension project planning meet majority performance standard

required

The Compliance of Performance Standards

on Environmental and Social Sustainability

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Conclusion:

Life assessment program for main equipment as an input of life

cycle management program conducted partially and scheduled with

outage time of the plant. Based on the life assessment results

selected life cycle program for KGPP justified.

The feasibility study results the life extension program to be

feasible both from technical, financial and risk identification point

of view including the predicted steam availability for the next 20

years.

The Environmental and Social Assessment in accordance IFC

performance standard results KGPP life extension project planning

meet majority performance standard required.

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Terima KasihJl. Jend. Gatot Subroto Kav. 18

Jakarta Selatan 12950

www.indonesiapower.co.id

[email protected]

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Sustaining Power Plant Life Through Rehabilitation as a Part of Life Cycle Management Program r02