THE PREPARATORY SURVEY ON TONSEALAMA HYDROPOWER … · The Preparatory Survey on Tonsealama Hydropower Station Rehabilitation Project (2) Chapter 1 Outline of Additional Survey 1

THE REPUBLIC OF INDONESIA MINISTRY OF ENERGY AND MINERAL RESOURCES

THE PREPARATORY SURVEY ON

TONSEALAMA HYDROPOWER STATION REHABILITATION PROJECT

IN THE REPUBLIC OF INDONESIA

PREPARATORY SURVEY REPORT (2)

OCTOBER 2014

JAPAN INTERNATIONAL COOPERATION AGENCY (JICA)

NIPPON KOEI CO., LTD. IL

JR

14- 114

THE REPUBLIC OF INDONESIA MINISTRY OF ENERGY AND MINERAL RESOURCES

THE PREPARATORY SURVEY ON

TONSEALAMA HYDROPOWER STATION REHABILITATION PROJECT

IN THE REPUBLIC OF INDONESIA

PREPARATORY SURVEY REPORT (2)

OCTOBER 2014

JAPAN INTERNATIONAL COOPERATION AGENCY (JICA)

NIPPON KOEI CO., LTD.

The Preparatory Survey on Tonsealama Hydropower Station Rehabilitation Project Preparatory Survey Report (2) OCTOBER 2014

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ContentsPreface

Contents

Location Map/Perspective

List of Figures & Tables

Abbreviations

CHAPTER 1 OUTLINE OF ADDITIONAL SURVEY 1-1 Background of Additional Survey .............................................................................................. 1-1

1-2 Purpose of Additional Survey ..................................................................................................... 1-1

1-3 Recalculation Result of Project Cost ........................................................................................... 1-1

1-4 Equipment to be Excluded from the Content of the Project........................................................ 1-1

1-5 Summary of Change in Rehabilitation Plan ................................................................................ 1-2

1-6 Status of This Preparatory Survey Report ................................................................................... 1-3

CHAPTER 2 REVISED CONTENTS OF THE PROJECT 2-1 Overall Plan ................................................................................................................................. 2-1

2-2 Equipment Plan ........................................................................................................................... 2-4

2-3 Spare Parts ................................................................................................................................... 2-8

2-4 Outline Design Drawings ............................................................................................................ 2-9

2-5 Implementation Policy ................................................................................................................ 2-10

2-6 Scope of Works ........................................................................................................................... 2-13

2-7 Implementation Schedule ............................................................................................................ 2-14

2-8 Initial Cost Estimation................................................................................................................. 2-15

CHAPTER 3 OTHER POINTS OF CONCERN 3-1 Present Status of Tonsealama Power Station .............................................................................. 3-1

3-2 Consideration for Making Schedule of Complete Shutdown of All Units .................................. 3-1

[Appendices] 1. Member List of the Survey Team

2. Survey Schedule

3. List of Parties Concerned in the Recipient Country

4. Minutes of Discussions（M/D）

[Drawings] 1. TSL-E-001 Minahasa-Gorontalo Network System Diagram

2. TSL-E-002 Tonsealama Hydropower Station Single Line Diagram for Existing Facilities

3. TSL-E-003 Tonsealama Hydropower Station Single Line Diagram for New Unit 1

4. TSL-E-004 Development of Hydropower Stations on Tondano River

5. TSL-C-101 (R) Layout of Existing Intake

6. TSL-C-102 (R) Layout of New Intake

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7. TSL-C-201 Layout of Existing Penstock

8. TSL-C-202 (R) Layout of New Penstock

9. TSL-C-301 Floor Plan of Existing Powerhouse for Unit 1

10. TSL-C-302 Section of Existing Powerhouse for Unit 1

11. TSL-C-303 Floor Plan of New Powerhouse for Unit 1

12. TSL-C-304 Section of New Powerhouse for Unit 1

13. TSL-M-101 (R) Arrangement of Sand Flush Gate (For Reference)

Location Map

Molinggapoto

Boroko

Maelang

Imandi

Molibagu

NuanganKotamobagu

Modoinding

Belang

Tomohon Tondano

Kawangkoan

Inobonto

Tanawangko

BITUNGMANADO

Likupang

Amurang

Tumpaan

Limboto

GORONTALO

LEGEND

Major City

Town/City

Road

River

Lake

a6861

タイプライターテキスト

PERSPECTIVE

a6861


a6861


a6861


a6861


a6861


Abbreviations - i

Abbreviations

A/A : Agent Agreement

A/P : Authorization to Pay

B/A : Banking Arrangement

BDA : Blanket Disbursement Authorization

G/A : Grant Agreement

JICA : Japan International Cooperation Agency

kV : Kilovolt

kVA : Kilovolt-ampere

MEMR : Ministry of Energy and Mineral Resources

MVA : Megavolt-ampere

MW : Megawatt

PLN : Perusahaan Listrik Negara (State Electricity Company)

rpm : Revolution per minute

SSG : Speed signal generator

PLN : Perusahaan Listrik Negara (State Electricity Company)

List of Figures & Tables - i

List of Figures & Tables

＜Figure＞

Figure 2-1 Project Implementation System ............................................................................................ 2-11

＜Table＞

Table 1-1 Change in Rehabilitation Plan .............................................................................................. 1-3

Table 1-2 Correlation between Previous Survey Report and This Survey Report ................................ 1-3

Table 2-1 Revised Rehabilitation Plan .................................................................................................. 2-1

Table 2-2 Revised Equipment Plan ....................................................................................................... 2-4

Table 2-3 Revised List of Spare Parts to be Supplied for Project ......................................................... 2-8

Table 2-4 Revised Outline Design Drawings ........................................................................................ 2-10

Table 2-5 Major Undertakings by Each Government Concerned ......................................................... 2-13

Table 2-6 Revised General Implementation Schedule .......................................................................... 2-15

Table 2-7 Direct Cost Borne by the Indonesian Side ............................................................................ 2-15

The Preparatory Survey on Tonsealama Hydropower Station Rehabilitation Project (2) Chapter 1 Outline of Additional Survey

1 - 1

CHAPTER 1 OUTLINE OF ADDITIONAL SURVEY

1-1 Background of Additional Survey

The Tonsealama Hydropower Station is located in the upper reach of the Tondano River, which flows out from Lake Tondano situated in North Sulawesi Province. It consists of three generating units and has a total installed capacity of 15 MW. The Tonsealama Hydropower Station is a comparatively small-scale power plant but becomes one of the major power plants in supplying electricity to the North Sulawesi Province so far.

The existing turbine, generator, and penstock for the Tonsealama Unit 1 were manufactured in 1917 and originally installed in 1920 in the Yamura Hydropower Station in Yamanashi Prefecture, Japan, then subsequently relocated to its present location in 1943. Unit 1 has been operational for 63 years since its commissioning in 1950. However, all items of equipment for Unit 1 have significantly aged, deteriorated, and degraded as a whole, in terms of unit output, security and reliability, and therefore their operating conditions cannot be recovered through partial rehabilitation work.

Under these circumstances, the Government of Indonesia requested a grant aid from the Government of Japan for the renewal of the existing equipment and facilities for Unit 1 of the Tonsealama Hydropower Station.

In response to the request from the Government of Indonesia, JICA conducted the Preparatory Survey on Tonsealama Hydropower Station Rehabilitation Project in JFY 2012 (hereinafter referred to as "Previous Survey"). At this Previous Survey, the basic design and cost estimation of the Project were executed on assumption that the procurement of goods and services will be made under the general type grant aid scheme. Based on the Previous Survey, the contents and cost of the Project were approved by the Government of Japan in February 2013.

In February 2014, however, the Government of Indonesia requested the Government of Japan to change the grant aid scheme from general type to agent type. In response to the request from the Government of Indonesia, the Government of Japan decided to conduct the Additional Survey to review the result of the Previous Survey.

1-2 Purpose of Additional Survey

This Additional Survey aims to recalculate the project cost for changing the grant aid scheme to agent type, and to re-examine the contents of the Project in case the recalculated project cost exceeds the amount agreed by the Government of Japan.

1-3 Recalculation Result of Project Cost

The project cost was recalculated not only by adding the agent cost but also by updating foreign currency exchange rate, labor cost, airfare, etc. As a result, it was found that the recalculated project cost exceeds the amount agreed by the Government of Japan.

Accordingly, it is required to exclude some items of equipment from the contents of the Project in order to reduce the project cost to within the amount agreed by the Government of Japan.

1-4 Equipment to be Excluded from the Content of the Project

The items to be excluded from the contents of the Project is selected from the equipment which will not spoil the relevance and desired effect of the Project. After the technical validity has been verified, it was determined to exclude the following two equipment from the contents of the Project.


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(1) Sand Flush Gate

The sand flush gate is provided to flush away the sediment accumulated in the intake weir. Because the existing sand flush gate is broken and out of operation, its renewal was planned in the previous survey.

According to further hearing investigation at this additional survey, the following were informed by PLN Sektor Minahasa:

(a) The existing sand flush gate is broken and out of operation for more than 30 years. Despite this, the sediment has never flowed into the turbines.

(b) In fact, no sediment was observed in front of the intake screen when PLN conducted a detailed inspection of the intake screen in 2013.

Judging from these facts, the sediment in the intake weir seems very small and therefore renewal of the sand flush gate is not an urgent issue for continuous operation of the Tonsealama Power Station. That is why it is decided to exclude the sand flush gate from the rehabilitation plan of this Project.

By the way, the Previous Survey suggested that the new sand flush gate should be installed at the downstream side of the existing one as shown in Drawing No. TSL-M-101 (R) attached herewith. Therefore, it will be possible to install the new sand flush gate without shutting down the operation of the Tonsealama Power Station even after completion of the Project.

(2) Backup Valve of Penstock Valve for Unit 1

The penstock valve is provided at the upper end of the penstock to facilitate inspection and maintenance of the penstock and the inlet valve.

In the Previous Survey, the new penstock valve was designed for double-valve construction to provide a practical convenience to its maintenance work, in a similar way to the existing penstock valve for Unit 2 and 3.

According to a common design practice, however, penstock valves are usually designed with single-valve construction because this construction is functionally sufficient for opening and closing operations.

By the way, the penstock valve is normally kept open but will be closed only when the major overhaul of the penstock and inlet valve which is scheduled at every 5 years. The overhaul of the penstock valve will be required at every 10 years. Although the overhaul of the penstock valve requires a complete shutdown of the Tonsealama Power Station, it will not significantly interfere with the operation of the Tonsealama Power Station because it can be carried out in the dry season when the river flow is reduced.

1-5 Summary of Change in Rehabilitation Plan

The rehabilitation plan revised by the review of the contents of the Project is summarized as shown in Table 1-1:


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Table 1-1 Change in Rehabilitation Plan

Rehabilitation Plan of Previous Survey Change Revised Plan by Additional Survey Equipment/Work Scheme Equipment/Work Scheme

Unit 1 Unit 1 Turbine Renewal Turbine Renewal Generator Renewal Generator Renewal Main transformer Renewal Main transformer Renewal Switchgear Renewal No Change Switchgear Renewal DC supply equipment Addition DC supply equipment Addition Control and relay panel Renewal Control and relay panel Renewal Penstock Renewal Penstock Renewal Penstock valve Renewal

(Dual valve) Change of

Specification Penstock valve Renewal

(Single valve)

Station-Service Supply System Station-Service Supply System Power transformers Renewal No Change Power Transformers Renewal Switchgear Renewal Switchgear Renewal

Intake Facilities Intake Facilities Intake screen panel Renewal

No Change Intake screen panel Renewal

Raking equipment Renewal Raking equipment Renewal Intake stoplog Renewal Cancel from

Grant Aid Intake stoplog Renewal

Sand flush gate Renewal

Civil and Building Works Civil and Building Works Unit 1 powerhouse Modification Unit 1 powerhouse Modification Equipment foundations Renewal No Change Equipment foundations Renewal Intake structure Widening Intake structure Widening Unit 1 valve house Renewal Unit 1 valve house Renewal (Prepared by the Survey Team)

1-6 Status of This Preparatory Survey Report

This Preparatory Survey Report is linked with the Preparatory Survey Report which was prepared by the Previous Survey. This Preparatory Survey Report deals in the contents of the Project which are revised by this Additional Survey. The correlation between the Previous Survey Report and this Preparatory Survey Report is as shown in Table 1-2.

Table 1-2 Correlation between Previous Survey Report and This Survey Report

Previous Survey Report This Survey Report Clause Title Change Clause and Title

Chapter 1 Background of Project 1-1 Background of Project No (Refer to the Previous Survey Report) 1-2 Natural Conditions No (Refer to the Previous Survey Report) 1-3 Environmental and Social Considerations No (Refer to the Previous Survey Report) 1-4 Present Status of Tonsealama Unit 2 and

Unit 3 No (Refer to the Previous Survey Report)

Chapter 2 Contents of the Project 2-1 Basic Concept of the Project No (Refer to the Previous Survey Report) 2-2 Outline Design of the Japanese Assistance 2-2-1 Design Policy No (Refer to the Previous Survey Report) 2-2-2 Basic Plan 2-2-2-1 Overall Plan Yes 2-1 Overall Plan 2-2-2-2 Technical Considerations for Basic Plan No (Refer to the Previous Survey Report)


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Previous Survey Report This Survey Report Clause Title Change Clause and Title

2-2-2-3 Arrangement of Schematic Procedures for Rehabilitation Works

No (Refer to the Previous Survey Report)

2-2-2-4 Equipment Plan Yes 2-2 Equipment Plan 2-2-2-5 Spare Parts Yes 2-3 Spare Parts 2-2-3 Outline Design Drawings Yes 2-4 Outline Design Drawings 2-2-4 Implementation Plan 2-2-4-1 Implementation Policy Yes 2-5 Implementation Policy 2-2-4-2 Implementation Conditions No (Refer to the Previous Survey Report) 2-2-4-3 Scope of Works Yes 2-6 Scope of Works 2-2-4-4 Consultant Supervision No (Refer to the Previous Survey Report) 2-2-4-5 Quality Control Plan No (Refer to the Previous Survey Report) 2-2-4-6 Procurement Plan No (Refer to the Previous Survey Report) 2-2-4-7 Operational Guidance Plan No (Refer to the Previous Survey Report) 2-2-4-8 Soft Component (Technical Assistance)

Plan No (Refer to the Previous Survey Report)

2-2-4-9 Implementation Schedule Yes 2-7 Implementation Schedule 2-3 Obligations of Recipient Country No (Refer to the Previous Survey Report) 2-4 Project Operation Plan No (Refer to the Previous Survey Report) 2-5 Project Cost Estimation 2-5-1 Initial Cost Estimation Yes 2-8 Initial Cost Estimation 2-5-2 Operation and Maintenance Cost No (Refer to the Previous Survey Report) Chapter 3 Project Evaluation 3-1 Preconditions No (Refer to the Previous Survey Report) 3-2 Necessary Inputs by Recipient Country No (Refer to the Previous Survey Report) 3-3 Project Evaluation 3-3-1 Relevance No (Refer to the Previous Survey Report) 3-3-2 Effectiveness No (Refer to the Previous Survey Report) (Prepared by the Survey Team)

The Preparatory Survey on Tonsealama Hydropower Rehabilitation Project (2) Chapter 2 Revised Contents of the Project

2 - 1

CHAPTER 2 REVISED CONTENTS OF THE PROJECT

2-1 Overall Plan

By the review of the contents of the Project, there are the following two major revisions in the rehabilitation plan:

(a) To exclude the sand flush gate from the rehabilitation plan (b) To change the type of a new penstock valve from double-valve type to singe-valve type

Therefore, the overall rehabilitation plan of this Project is revised as shown in Table 2-1.

Table 2-1 Revised Rehabilitation Plan

Equipment/Facilities Results of Site Survey Rehabilitation Plan

1. Unit 1 Turbine

1) Turbine main parts Damaged by corrosion, erosion and cavitation.

Turbine efficiency is too low. Grease leakage from guide vane

operating mechanism.

Renewal of the whole turbine including runner.

Reuse of the embedded parts of the existing draft tube liner.

2) Inlet valve Inlet valve is installed at the vertical section of penstock.

There is a 90 elbow pipe between turbine and inlet valve. This may cause a big loss.

Inlet valve is of hand-operated type and is not designed for automatic start and stop operations.

Change of layout of the penstock Renewal of the inlet valve

3) Governor Renewal of the governor, because of the replacement of turbine.

4) Turbine control panel Renewal of the turbine control panel, because of the replacement of turbine and generator.

5) Cooling water supply system

Renewal of the cooling water supply system, because of the replacement of turbine and generator.

2. Unit 1 Generator

1) Generator main parts Loose stator windings. Deterioration, moisture absorption

and lower insulation resistance of stator windings.

Renewal of the whole generator. Change of the structural design of

generator. Change of the generator voltage.

2) Excitation equipment Deterioration due to aging, as a whole.

Increased frequency of faults and troubles.

Renewal of the excitation equipment, because of the replacement of generator

3) Neutral grounding equipment

No neutral grounding equipment is provided.

Additional installation of neutral grounding equipment.


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3. Unit 1 Main Transformer Deterioration of insulation materials in the transformer.

Deterioration of insulating oil.

Renewal of the main transformer. Change of the transformer ratio to

30/6.3 kV, because of the change of generator voltage.

4. 16.5/0.23 kV Station- Service Transformer

Heavily deteriorated due to aging. Renewal of the station-service transformer.

Change of the transformer ratio to 6.3/0.4-0.23 kV, because of the change of generator voltage.

5. 20-15/0.38 kV Station-Service Transformer

Heavily deteriorated due to aging. Renewal of the station-service transformer

Change of transformer ratio to 20/0.4-0.23 kV

6. 15/0.23 kV Pole-Mounted Transformer

Heavily deteriorated due to aging. Renewal of the pole-mounted transformer.

Change of the transformer ratio to 6.3/0.4-0.23 kV, because of the change of generator voltage.

7. 30 kV Switchgear There are no circuit breaker and current transformers for protection of Unit 1 main transformer.

Additional installation of 30 kV circuit breaker and current transformers.

8. 20 kV Switchgear 20 kV circuit breaker and current transformers for 20-15/0.38 kV station-service transformer are out of service.

Renewal of 20 kV circuit breaker and current transformers.

9. 15 kV Switchgear Heavily deteriorated due to aging. Replacement of 15 kV switchgear by 6.3 kV switchgear, because of the change of generator voltage.

10. Low Voltage Switchgear Heavily deteriorated due to aging. Renewal of the low voltage switchgear.

Restructuring of station-service supply system.

11. DC Power Supply System Additional installation of DC power supply system for exclusive use of Unit 1 to employ DC motor-driven servomotors for guide vanes and inlet valve.

12. Control Panels Heavily deteriorated due to aging. Renewal of the local control panel for Unit 1, because of the replacement of turbine and generator.

Renewal of the local control panel for station-service circuits, because of restructuring of station-service supply system.

Additional installation of a remote control panel to control the Unit 1 and station-service circuits from the existing control room.


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13. Electrical Protective Relays Heavily deteriorated due to aging. Renewal of the electrical protective relays for Unit 1, because of the replacement of generator and main transformer.

Renewal of the electrical protective relays for station-service circuits, because of the restructuring of station-service supply system.

14. No. 1 Overhead Traveling Crane

Hand-operated type. Removal and disposal of No. 1 overhead traveling crane.

Extension of crane rails and conductors to enable use of the existing No. 2 overhead crane for Unit 1.

15. Unit 1 Penstock

1) Penstock valve Penstock valve cannot be operated due to malfunction of bypass valve.

Deterioration due to aging of the whole penstock valve including the operating unit.

Renewal of the penstock valve.

2) Penstock Lack of strength due to plate thickness reduction.

Water leakage from rivet joints. Water leakage from flange

connections. Water leakage from expansion

joints.

Renewal of the penstock.

16. Intake Facilities

1) Intake screen High water velocity at the intake screen

Observation of vortex in front of the intake screen.

Deformation of the intake screen.

Widening of intake structure. Renewal of the intake screen.

2) Intake stoplog Renewal of the stop log and monorail hoist, because of the widening of intake

3) Intake raking equipment

Deterioration due to aging of electric motor and reducer.

Deterioration due to aging of control panel and wiring.

Renewal of the intake raking equipment, because of the change of width of intake screen.

17. Civil Works

1) Unit 1 powerhouse The powerhouse substructure is still stable enough for reuse.

Modification of the powerhouse, in line with the replacement of the turbine and generator for Unit 1.

Re-design of foundation for the renewed generator.

2) Concrete foundation for Unit 1 main transformer

Reconstruction of concrete foundation for the renewed main transformer.

Construction of additional oil sump tank.


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3) Concrete foundation for 30 kV switchgear

Construction of additional concrete foundation for the new 30 kV switchgear.

4) Concrete foundation for 20 kV switchgear

Reconstruction of concrete foundation for the renewed 20 kV switchgear.

5) Concrete foundation for Unit 1 penstock

Reconstruction of concrete foundations for the renewed penstock.

6) Intake structure Widening of intake structure.

18. Building Work

1) Unit 1 powerhouse Reconstruction of the powerhouse superstructure after removal of the existing generator floor.

Reuse of the existing wooden building, after temporary destruction and reconstruction.

2) Unit 2 powerhouse Removal of the concrete wall of Unit 2 powerhouse superstructure at Unit 1 side, so that No. 2 overhead crane can be used to handle Unit 1 equipment.

3) Valve house for No. 1 penstock valve

Reconstruction of the valve house for the renewed penstock valve.

(Prepared by the Survey Team)

2-2 Equipment Plan

Due to the change of the overall rehabilitation plan as described in Sub-Clause 2-1, the equipment plan is revised as shown in Table 2-2.

Table 2-2 Revised Equipment Plan

No. Equipment Specifications Q’ty

1. Unit 1 Turbine

1.1 Turbine main parts Type: Vertical-shaft, Francis turbine Rated head: 89.5 m Rated discharge: 6.5 m3/s Rated output: 5,100 kW Rated speed: 500 rpm Servomotor: DC motor-driven type Shaft: Turbine shaft + intermediate shaft

1 set

1.2 Inlet valve Type: Through-flow type butterfly valve Diameter: 1.2 m Servomotor: DC motor-driven type

1 set

1.3 Governor Type: Electric governor Speed regulation: Digital PID computation Speed sensing: Speed signal generator (SSG)

1 set


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1.4 Turbine control panel Operation: Selector, control and operation switches Measurement: Guide vane opening, speed, water pressure, temperature Indication: Operating status, faults

1 set

1.5 Cooling water supply system

Water supply method: Water supply from penstock Components: Automatic valve, main strainers (2 sets), shaft seal strainer (2 sets) and flow meters

1 lot

1.6 Drainage pump Type: Portable, submergible pump Pumping head: 15 m Discharge volume: 1.0 m3/min

1 set

2. Unit 1 Generator

2.1 Generator main parts Type: Vertical-shaft, synchronous generator Construction: Suspended type Cooling method: Totally enclosed, water-cooled air coolers Rated output: 5,440 kVA Rated voltage: 6.3 kV Rated power factor: 0.9 Rated speed: 500 rpm Brake: Electro-magnetic brake

1 set

2.2 Excitation system Type: Brushless excitation system with AC exciter 1 set

2.3 Neutral grounding system

Grounding method: 100 A resistor Grounding resistor: 36.4 , 30 seconds rating Installation method: Enclosed in a cubicle

1 set

3. Power Transformers

3.1 Unit 1 main transformer

Type: Three-phase, two-winding, oil immersed, generator transformer Cooling method: Natural oil circulation natural air cooling (ONAN) Rated power: 6,000 kVA Transformer ratio: 6.3/30 kV

1 set

3.2 No. 1 station-service transformer

Type: Three-phase, two-winding, cast-resin mold, dry type power transformer Cooling method: Natural air cooling (AN) Rated power: 300 kVA Transformer ratio: 6.3/0.4-0.23 kV

1 set

3.3 No. 2 station-service transformer

Type: Three-phase, two-winding, oil immersed type power transformer Cooling method: Natural oil circulation natural air cooling (ONAN) Rated power: 300 kVA Transformer ratio: 20/0.4-0.23 kV

1 set

3.4 Local-service transformer (for intake facilities)

Type: Three-phase, two-winding, oil immersed, pole-mounted transformer Cooling method: Natural oil circulation natural air cooling (ONAN) Rated power: 50 kVA Transformer ratio: 6.3/0.4-0.23 kV Accessories: Supporting structures, Surge arresters (for three phases)

1 set


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4. Switchgear

4.1 30 kV outdoor use metal-enclosed switchgear

Use: Unit 1 main transformer circuit Components: Vacuum circuit breaker (VCB) x 1, Current transformer (CT) x 3 VCB: 36 kV, 630 A, 12.5 kA CT: 36 kV, 150/5 A

1 set

4.2 20 kV circuit breaker Use: No. 2 station-service transformer circuit Type: Outdoor use, three-phase vacuum circuit breaker (VCB) with supporting structure Rating: 24 kV, 400 A, 8 kA

1 set

4.3 20 kV current transformer

Use: No. 2 station-service transformer circuit Type: Outdoor use, single-phase, protective current transformers with supporting structure Rating： 24 kV, 50/5 A, 5P20

3 sets

4.4 6.3 kV metal-enclosed switchgear -1

Use: Generator circuit Components: Vacuum circuit breaker (VCB) x 1, current transformer (CT) x 9 VCB: 7.2 kV, 1250 A, 12.5 kA CT: 7.2 kV, 750/5 A

1 set


Use: Generator circuit Components: Disconnector (DS) x 1, Surge absorber (SA) x 3 DS: DC motor-driven, 7.2 kV, 1250 A, 12.5 kA SA: Single-phase, 7.2 kV

1 set


Use: Generator circuit Components: Voltage transformer (VT) x 9, grounding voltage transformer (GVT) x 3 VT: 6.3/3//0.11/3 kV GVT: 6.3/3//0.11/3//0.11/3 kV

1 set


Use: No. 1 station-service transformer circuit/ Local-service transformer circuit Components: Vacuum circuit breaker (VCB) x 1, current transformer (CT) x 3 VCB: 7.2 kV, 630 A, 12.5 kA CT: 7.2 kV, 50/5 A

2 sets

4.8 Low voltage metal-enclosed switchgear -1

Use: No. 1 station-service transformer circuit/ No. 2 station-service transformer circuit Components: Air circuit breaker (ACB) x 1, current transformer (CT) x 3, voltage transformer (VT) x 3 ACB: 600 V, 800 A, 12.5 kA CT: 600 V, 600/5 A VT: 600 V, 0.4/3//0.11/3 kV

2 sets

4.9 Low voltage metal-enclosed switchgear -2

Use: Station loads for Unit 1/ Station loads for Unit 2/ Station loads for Unit 3 Components: Molded case circuit breaker x 20

3 sets


2 - 7


5. DC Power Supply Equipment

5.1 Stationary batteries with steel rack

Type: Valve regulated type lead-acid battery designed for long life Nominal voltage: 2.0 V/cell Capacity: 300 AH at 10-hour discharge rate Number of cells: 54 cells

1 set

5.2 Battery charger Type: Transistor rectifier type Rated input: AC, 3-phase 3-wire system, 400 V, 50 Hz Nominal output voltage: DC 110 V Rated output current: 75 A

1 set

5.3 DC distribution panel Type: Metal-enclosed cubicle Components: DC molded case circuit breaker x 20

1 set

6. Control and Relay Panels

6.1 Local control panel -1 Use: Unit 1 Type: Floor-standing, metal enclosed panel Control circuits: Programmable logic controller Control and indication device: Electronic visual display (touch screen) Other device: Automatic synchronizing device

1 set

6.2 Local control panel -2 Use: Station-service circuit Type of panel: Floor-standing, metal enclosed panel Control circuits: Programmable logic controller Control and indication device: Electronic visual display (touch screen)

1 set

6.3 Relay panel -1 with electrical protective relays

Use: Unit 1 generator, Unit 1 main transformer Components: Electrical protective relays for generator, electrical protective relays for main transformer, lockout relays Type of panel: Floor-standing, metal enclosed panel Type of relays: Digital relays

1 set

6.4 Relay panel -2 with electrical protective relays

Use: Station-service circuits Type of panel: Floor-standing, metal enclosed panel Type of relays: Digital relays

1 set

6.5 Remote control panel Use: Remote control of Unit 1 and station- service circuits from the exiting control room Type: Desk-top computer with touch screen

1 set

7. Intake Facilities

7.1 Intake screen panel Width: 4.0 m Vertical height: Approximately 4.4 m Mounting angle: 80Bar pitch: 30 mm Material: Stainless steel Design velocity: 1.0 m/s

2 sets

7.2 Raking equipment Type: Traveling type with conveyor system Horizontal conveyor: Approximately 12 m Inclined conveyor: Approximately 10 m

2 sets


2 - 8


7.3 Intake stoplog gate leaf and guide frame

Clear span: 4.0 m Clear height: 4.3 m Type: Steel made stoplog (3 blocks per one gate) Design depth: 4.2 m

2 sets

7.4 Intake stoplog monorail hoist

Driving method: Electric-motor driven Length of rail: Approximately 15 m

1 set

8. Unit 1 Penstock Valve

8.1 Main valve Diameter: 1600 mm Type: Butterfly valve Driving method: Hydraulic cylinder/counterweight Other device: Over-velocity tripping device

1 set

8.2 Bypass valve Bypass valve: Hand-operated type Diameter: 300 mm

1 set

9. Unit 1 Penstock

9.1 Penstock Diameter: 1.6 m - 1.2 m Total length: Approximately 164 m Plate thickness: 10 mm - 14 mm

1 lot

(Prepared by the Survey Team)

2-3 Spare Parts

In association with the change of the equipment plan as described in Sub-Clause 2-2, the list of spare parts to be supplied for the Project is revised as shown in Table 2-3.

Table 2-3 Revised List of Spare Parts to be Supplied for Project

Spare Parts Quantity

1. Turbine (including inlet valve, governor and cooling water supply system)

(1) Turbine guide bearing pad for one unit 1 set

(2) Shear pins with failure detectors for one unit 1 set

(3) Carbon brushes for electric motors of servomotors for one unit

2 sets

(4) Gaskets, packing and sealing materials used for one unit 1 set

(5) Complete set of sensors for speed signal generator 1 set

(6) Indicating lamps of each type used 50% of actual use

(7) Fuses of each type and rating used 100% of actual use

2. Generator (including excitation system and neutral grounding equipment)

(1) Thrust bearing pads for one unit 1 set

(2) Upper guide bearing pads for one unit 1 set

(3) Lower guide bearing pads for one unit 1 set

(4) Brake shoes for one unit 1 set


2 - 9

Spare Parts Quantity

(5) Gaskets, packing and sealing materials used for one unit 1 set

(6) Current limiting fuses for thyristor protection for one unit 1 set



3. Main transformer

(1) Gaskets used for one unit 1 set

(2) Bursting plate with gasket for pressure relief device 1 piece

(3) Moisture absorbent used for one unit 1 piece

4. Switchgear

(1) Closing coils for each circuit breaker 3 pieces

(2) Tripping coils for each circuit breaker 3 pieces



5. DC supply equipment



6. Control and Relay Panels



7. Raking equipment

(1) Chute rubber 100% of actual use

8. Intake stoplog

(1) Seal rubber 100% of actual use

9. Penstock

(1) Gaskets, packing and sealing materials 100% of actual use

10. Penstock valve

(1) Seal rubber 100% of actual use (Prepared by the Survey Team)

2-4 Outline Design Drawings

Some outline design drawings are modified to reflect the changes in the overall rehabilitation plan, as shown in Table 2-4.

A preliminary design drawing for the new sand flush gate, which is excluded from the scope of work for this Project, remains attached to this report just for reference.


2 - 10

Table 2-4 Revised Outline Design Drawings

No. Drawing No. Drawing Title

1 TSL-E-001 Minahasa-Gorontalo Network System Diagram 2 TSL-E-002 Tonsealama Hydropower Station Single Line Diagram for Existing

Facilities 3 TSL-E-003 Tonsealama Hydropower Station Single Line Diagram for New Unit 1 4 TSL-E-004 Development of Hydropower Stations on Tondano River 5 TSL-C-101 (R) Layout of Existing Intake 6 TSL-C-102 (R) Layout of New Intake 7 TSL-C-201 Layout of Existing Penstock 8 TSL-C-202 (R) Layout of New Penstock 9 TSL-C-301 Floor Plan of Existing Powerhouse for Unit 1 10 TSL-C-302 Section of Existing Powerhouse for Unit 1 11 TSL-C-303 Floor Plan of Existing Powerhouse for Unit 1 12 TSL-C-304 Section of New Powerhouse for Unit 1

For Reference 13 TSL-M-101 (R) Arrangement of Sand Flush Gate

Note: (R) means the drawings revised under this Additional Survey (Prepared by the Survey Team)

2-5 Implementation Policy

This Project aims at renewal of all the equipment for Unit 1 including station service power supply system, penstock, and intake facilities. Demolition and removal of the existing equipment and associated civil and building works are also included in the scope of work for this Project.

The implementation schedule will be formulated to substantially complete all the Works within 18 months on the assumption that every site work can be executed smoothly and efficiently by using the most appropriate method and procedure.

Due to the change of the grant aid scheme from general type to agent type, the basic concept and focal points for the implementation of the Project are changed as follows:

(1) Project Implementation System

The Government of Indonesia will enter into an agreement with the procurement agent to implement the procurement of a consultant and contractors for the Project. Each of the consultant and contractors will make a contract with the procurement agent to carry out the duties and works specified.

The implementation system of this Project is shown in Figure 2-1.

(2) Executive Agency of Indonesian Side

The Directorate General of Electricity, Ministry of Energy and Mineral Resources (MEMR) is the responsible and implementing organization of the Project.

PT. PLN (Persero) (PLN) is the cooperating organization in charge of the site rehabilitation works.

After completion of the Project, all the Facilities provided by this Project will be taken over from MEMR to PLN in order for PLN to execute their operation and maintenance.


2 - 11

(Source: Minutes of Discussion on 10 June 2014, Annex-3)

Figure 2-1 Project Implementation System

For the implementation of the Project, the Indonesian side is requested to pay careful attention to the following two items, and to assign the person in-charge of the Project for its smooth execution.

(a) Coordination and arrangements for unit shutdown during the rehabilitation works

In the implementation of this Project, it will be requested to stop operations of Unit 2 and Unit 3 for a total of six months. The operation of other power plant should be arranged so that the shutdown of Unit 2 and Unit 3 will not interfere with the electric power supply to the North Sulawesi Region.

PLN Sektor Minahasa is requested to make necessary coordination with the Load Dispatching Center in time to stop Unit 2 and Unit 3 for the successful and smooth implementation of the Project.

(b) Preparation of budget and assignment of personnel for proper execution of the works allocated to the Indonesian side

The Indonesian side is requested to take a share in the site rehabilitation works. The works shared to the Indonesian side should be carried out timely in close coordination with the implementation schedule of the Project. Necessary budget and personnel should be allocated for smooth and efficient execution of the shared works.

The Indonesian side should be responsible for the following works:

i) Shutdown of Unit 2 and Unit 3 during the implementation of this Project;

ii) Reinforcement of the existing bridge on the main access road to the Tonsealama Power Station;

iii) Relocation or rerouting of 20 kV distribution lines and communication cables, which will interfere with the rehabilitation work for penstock and penstock valve for Unit 1;

iv) Relocation of the existing 160 kVA transformer, 380 V and 220 V distribution circuit breakers for temporary power supply to Unit 2 and Unit 3; and

Supervision

Government of Indonesia

Government of Japan

JICA JICA Indonesia Office

ExchangeNote (E/N)

ImplementationSupervision

Contractor

Contract for Procurement/ Construction

ConsultativeCommittee

GrantAgreement

Contract for Detailed Design and Supervision

PLN

Agent Agreement (A/A)

Procurement Agent

MEMR

Detailed Design/Supervision Consultant


2 - 12

v) Disposal of unnecessary and waste articles of the removed old facilities, equipment, and materials.

(3) Procurement Agent

In accordance with the Agent Agreement (A/A) with the Government of Indonesia, the procurement agent will process the procurement related works for the Project on behalf of the Government of Indonesia, under the terms of the Exchange of Notes (E/N) and the Grant Agreement (G/A). The duty of the procurement agent covers procurement of consultant services, preparation of tender documents, tendering, tender evaluation, contract signing with the contractors, payment to the consultant and the contractor under the A/A, management of project fund, etc.

In order to manage the project smoothly, a consultative committee will be organized by the representatives of both Indonesian and Japanese Governments. The consultative committee will be chaired by MEMR and will be convened upon request from either the Indonesian or Japanese Government. The procurement agent will be responsible for the adviser of the committee as necessary.

(3) Consultant

At detailed design stage, the consultant will review and finalize the technical parts of the tender documents, based on the results of the preparatory survey and the discussions with the Indonesian Besides, the consultant will assist the procurement agent in tender announcement, preparation of addenda, answers to queries, tender opening, tender evaluation and contract negotiation.

At project implementation stage, the consult will conduct kick-off meeting, approval of contractor's design drawings, pre-shipment inspection of the procurement equipment, supervision of the site rehabilitation work, preparation of progress report during a period of site work, issuance of payment certificate, witnessing of site tests. After completion of the Project, the consultant will conduct issuance of a completion certificate of the Works, necessary procedure for taking over of the Project, preparation of a completion report and final inspection of all the facilities before expiry of the defect liability period.

During the site implementation period, the consultant will periodically report the progress of the Works to the Government of Indonesia and the procurement agent as well.

(4) Contractors

This rehabilitation project involves construction of virtually new equipment and facilities for Unit 1 at the same site as the existing ones. It is planned to complete a series of site works for demolition of the existing equipment, modification of civil and building structures, installation of new equipment and site tests within 18 months.

In order to complete all the works within 18 months, various works will inevitably be carried out simultaneously. Since various works are related to each other, proper coordination is essentially required among all the works.

Since the implementation of the various works is covered under one contract package, the contractor’s organization will include a turbine manufacturer, a generator manufacturer, a penstock manufacturer, and a construction company. In addition, the contractor will employ a system coordinator to secure the closest coordination among all the works and a site project manager to manage overall implementation of the Project, progress control, and security at the site.

The contractor is requested to design, execute, and complete the works in accordance with the specifications prepared by the consultant. When completed, the works will be inspected for proper installation, and the equipment will be tested to demonstrate their performances. All site tests will be completed before Taking Over. The contractor is requested to carry out transfer of technology to


2 - 13

the PLN’s personnel during the period of site tests.

(4) Necessity to Dispatch Specialists

Site installation works will require practical skills and extensive and special knowledge about performance, function, and structure of the equipment and facilities. Therefore, a number of experienced and qualified supervisors will be assigned to provide technical instructions, quality control, and progress control of the site installation works. In addition, experienced testing engineers will also be required for carrying out the required tests on completion.

On the other hand, the disassembling and assembling works for the turbine and generator will require professional skills and work performance with first class quality. Therefore, qualified professional technicians will be assigned for their assembling works.

This Project will deal with almost all components of Unit 1, station service supply system and intake facilities that are extended to various special fields. Accordingly, the following specialists are planned to be dispatched to the site for the successful and smooth execution of the Project:

(a) Supervisor: Turbine, governor, generator, excitation system, power transformer, control panel, penstock, penstock valve, intake screen, raking equipment and intake stoplog.

(b) Testing engineer: Turbine, governor, generator, excitation system, power transformer, control panel, electrical protective relay, scour gate, other electrical equipment

(c) Technicians: Turbine, generator, cable termination work

2-6 Scope of Works

The major undertakings by each Government of Japan and Indonesia are as listed in Table 2-5 below:

Table 2-5 Major Undertakings by Each Government Concerned

No. Item To be covered by Grant Aid

To be covered by Recipient Side

1 To secure land necessary for the implementation of the Project and to clear the site

●

2 To construct the following facilities 1) The building ●

2) The gates and fences in and around the site ●

3) The parking lot ●

4) The road within the site ●

5) The road outside the site ●

3 To provide facilities for distribution of electricity, water supply and drainage and other incidental facilities necessary for the implementation of the Project outside the site

1) Electricity a. The power distribution line ●

b. The drop wiring and internal wiring within the site ●

c. The main circuit breaker and transformer ●

2) Water Supply a. The city water distribution main to the site ●

b. The supply system within the site (receiving and elevated tanks)

●


2 - 14

No. Item To be covered by Grant Aid

To be covered by Recipient Side

3) Drainage a. The city drainage main (for storm sewer and others to

the site) ●

b. The drainage system (for toilet sewer, common waste, storm drainage and others)

●

4) Gas Supply N/A N/A 5) Telephone System a. The telephone trunk line to the main distribution

frame/panel (MDF) of the building ●

b. The MDF and the extension after the frame/panel ●

6) Furniture and Equipment a. General furniture ●

b. Project equipment ●

4 To ensure prompt unloading and customs clearance of the products at ports of disembarkation in Indonesia and to assist internal transportation of the products

a. Marine (Air) transportation of the Products from Japan to Indonesia

●

b. Tax exemption and customs clearance of the Products at the port of disembarkation

●

c. Internal transportation from the port of disembarkation to the project site

●

5 To ensure that customs duties, internal taxes and other fiscal levies which may be imposed in Indonesia with respect to the purchase of the products and the services be exempted

●

6 To accord Japanese nationals whose services may be required in connection with the supply of the products and the services such facilities as may be necessary for their entry into Indonesia and stay therein for the performance of their work

●

7 To ensure that the Facilities and the products be maintained and used properly and effectively for the implementation of the Project

●

8 To bear all the expenses, other than those covered by the Grant, necessary for the implementation of the Project

●

9 To bear the following commissions paid to the Japanese bank for banking service based upon B/A

1) Payment commission ●

10 To give due environmental and social consideration in the implementation of the Project

●

*1: B/A: Banking Arrangement, A/P: Authorization to pay *2: If the environmental screening category is C, No.10 is unnecessary

(Source: Minutes of Discussion on 10 June 2014, Annex-5)

2-7 Implementation Schedule

Due to the change of the grant aid scheme from general type to agent type, the implementation schedule is revised so that the Project will be completed in 23 months after the grant aid agreement has been concluded. The substantial time for completion of the rehabilitation work is estimated at 18.5 months after the contract signing.

The general implementation schedule is revised as shown in Table 2-6 below.


2 - 15

Table 2-6 Revised General Implementation Schedule

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 251) Grant Aid

Agreement 2) Selection of

Consultant 3) Detailed Design Home Work 4) Bidding Field Work 5) Contract Signing 6) Modification of

Intake Structure 7) Removal of

Existing Equipment8) Modification of

Powerhouse 9) Manufacturing of

New Equipment 10) Installation of New

Equipment 11) Pre-commissioning

Tests 12) Commissioning

Tests (Prepared by the Survey Team)

2-8 Initial Cost Estimation

By updating the foreign exchange rate, direct cost of this Project borne by the Indonesian side is estimated at Indonesian Rupiah (IDR) 958.7 million, as shown in Table 2-7.

Table 2-7 Direct Cost Borne by the Indonesian Side

Item Estimated Amount (IDR in million)

1 Reinforcement of the existing bridge on the main access road to the Tonsealama Power Station

108.1

2 Relocation or rerouting of 20 kV distribution lines and communication cables near surge tank

206.9

3 Relocation of the existing 160 kVA transformer, 380 V and 220 V distribution circuit breakers for temporary power supply to Unit 2 and Unit 3

206.9

4 Disposal of unnecessary and waste articles of the removed old facilities, equipment, and materials

206.9

5 Payment of bank commission 229.9

Total (1+2+3+4+5) 958.7

(a) Time of estimation: April 2014 (b) Foreign exchange rate: IDR 1.0 = JPY 0.0087

The Preparatory Survey on Tonsealama Hydropower Rehabilitation Project (2) Chapter 3 Other Points of Concern

3 - 1

CHAPTER 3 OTHER POINTS OF CONCERN

3-1 Present Status of Tonsealama Power Station

According to the additional survey of the present status of the Tonsealama Unit 1 and the intake facilities, there are some problems on the following equipment:

(1) Unit 1 Turbine

The Unit 1 turbine is still operational in seemingly good condition. However, the maximum producible output is decreased to 3.5 MW although the rated output is 4.4 MW.

The linkage of the turbine regulating mechanism has come loose and this looseness often interferes with speed/load adjustments of the turbine. As a result, it takes a long time for the generator to get synchronized to the network system. In normal case, starting-up time of the generating unit is just 5 - 6 minutes up to synchronizing. In case of the Tonsealama Unit 1, however, it will take 5 - 6 hours up to synchronizing.

Even in such situation, the Unit 1 turbine is not allowed to stop its operation for a long time for convenience of power supply management to cope with a shortage of power generation in North Sulawesi Province. Besides, every part of the Unit 1 turbine is getting old and obsolete and therefore its spare part is not available any longer. For these reasons, the Unit 1 turbine didn't have any overhaul or annual inspection since 2006.

(2) Unit 1 Penstock

The Unit 1 penstock has corroded further by deterioration due to aging and the number of water leakage has increased due to local thickness reduction of the steel plates. Although the water leakage parts are sealed by weld repair, the Unit 1 penstock was not longer restored by these local remedial works.

Therefore, it is highly desirable that the Unit 1 penstock should be renewed as soon as possible before it is too late.

(3) Intake Screen

The detailed inspection of the intake screen was carried out by PLN in 2013. According to the inspection results, the intake screen has been corroded and deformed as a whole and part of that is considerably damaged and bored. In this regard, it is considered that the deformation of the intake screen is caused by high water flow velocity at the intake screen.

Therefore, it is highly desirable that the intake screen should be renewed and widened as suggested in the Previous Survey.

On the other hand, a plenty of rubbish with plastic litter are conveyed along the river to the intake weir and their amount sometimes exceeds the capacity of the existing raking equipment which is provided in front of the intake screen. Therefore, it is also desirable that the raking equipment should be replaced with a new one with a sufficient rubbish removal capacity.

3-2 Consideration for Making Schedule of Complete Shutdown of All Units

PLN fully understand that complete shutdown of all units of the Tonsealama Power Station is required during the period of modification of the intake structure, and that the complete shutdown period will be six months.

The Preparatory Survey on Tonsealama Hydropower Rehabilitation Project (2) Chapter 3 Other Points of Concern

3 - 2

In this regard, the following comments are given by PLN Wilayah Suluttenggo who is a management authority responsible for the North Sulawesi Network System.

(1) Due to complete shutdown of the Tonsealama Power Station, the power supply capacity of the North Sulawesi System will have a deficit of 11,000 kW. Although supply and demand of electricity is very tight, power development in the North Sulawesi System is behind the schedule and there are no additional power plant to be completed in 2014 and 2015.

(2) The majority of the residents of North Sulawesi Province is Christian and Christmas is the most important season for them. Therefore, the complete shutdown of the Tonsealama Power Station should be scheduled to avoid a period between the beginning of December and the beginning of January.

(3) Rubbish with plastic litter in the river water is one of serious problem for the Tonsealama Power Station. Such rubbish is removed by the raking equipment provided in front of the intake screen. When all the units of the Tonsealama Power Station are shut down, the rubbish will be diverted to the Tanggari-I Power Station which is located downstream the Tonsealama. However, the raking equipment at the Tanggari-I intake has no sufficient capacity to remove such large amount of rubbish. Therefore, it is deeply concerned that the rubbish diverted from the Tonsealama will interfere with continuous operation of the Tanggari-I.

In order to address this problem, it is suggested that the complete shutdown of the Tonsealama should be conducted in the dry season when the generating output of the Tanggari-I is reduced. By the way, the dry season is from June to November.

A1 - 1

Appendix 1 - Member List of the Study Team

1. Leader Yuki ARATSU Senior Representative JICA Indonesia Office

2. Grant Aid Kenichi KOBAYASHI Deputy Director, Management Grant Aid Project Management Division 1,

Financing Cooperation Implementation Department, JICA

3. Cooperation Kenji OGASAHARA Deputy Director, Planning Energy and Mining Division 1, Industrial Development and Public Policy Department, JICA

4. Chief Consultant/ Naoji NAKATO Nippon Koei Co., Ltd. Hydropower/ Operation and

Maintenance

5. Procurement Kazumasa YAZAWA Nippon Koei Co., Ltd. Planning/ Cost Estimate

A2 - 1

Appendix 2 - Survey Schedule

Date Day Place JICA Consultant

1 June 2 Mon Jakarta International Travel: Tokyo - Jakarta 2 June 3 Tue Manado Courtesy Call to JICA Jakarta Office

Discussion with PLN Head Office Domestic Travel: Jakarta - Manado

3 June 4 Wed Manado Discussion with PLN Sektor Minahasa Additional Survey at Tonsealama Power Station

4 June 5 Thu Manado Discussion with PLN Wilayah Suluttenggo Additional Survey at Tonsealama Power Station

5 June 6 Fri Jakarta Domestic Travel: Manado - Jakarta 6 June 7 Sat Jakarta Filing of Survey Results 7 June 8 Sun Jakarta International Travel:

Tokyo - Jakarta Filing of Survey Results

8 June 9 Mon Jakarta Discussion with PLN Head Office and Wilayah Suluttenggo 9 June 10 Tue Jakarta Discussion with Ministry of Energy and Mineral Resources (MEMR)

International Travel: Jakarta - Tokyo 10 June 11 Wed Arrival at Tokyo

A3 - 1

Appendix 3 - List of Parties Concerned in the Recipient Country

1. Ministry of Energy and Mineral Resources

Name Post Remarks

1 Mr. Hasril Nuzahar Director of Electricity Program Supervision

2. PT. PLN (Persero) Head Office

Name Post Remarks

1 Ms. Syofvi F. Roekman Head of Strategic Corporate Planning Division, Head Office

2 Ms. Novi Tria Susanti Strategic Corporate Planning Division, Head Office

3 Mr. Sutiyo Siswanto Senior Manager of Hydro Energy, New and Renewable Energy Division, Head Office

4 Mr. Dedi Khairunas Assistant Engineer of Hydro Energy, New and Renewable Energy Division, Head Office

3. PT. PLN (Persero) Wilayah Suluttenggo

Name Post Remarks

1 Mr. Muchtar Djafar Deputy Manager of System Planning Division, Wilayah Suluttenggo

2 Mr. Marthen D. Karundeng Deputy Manager of Power Plant Construction Division, Wilayah Suluttenggo

3 Mr. Idaman ST Manager of Sector Minahasa, Wilayah Suluttenggo

4 Mr. Rudy Wola Manager of Tonsealama Hydropower Station, Sector Minahasa, Wilayah Suluttenggo

Appendix 4

Appendix 4

Appendix 4

Appendix 4

Appendix 4

Appendix 4

Appendix 4

Appendix 4

Appendix 4

Appendix 4

Appendix 4

Appe

ndix 4

Appe

ndix 4

Appendix 4

Appendix 4

Appendix 4

Appe

ndix 4

Appe

ndix 4

Appendix 4

Appendix 4

Appe

ndix 4

List of Drawings

No. Drawing No. Title

1 TSL-E-001 Minahasa-Gorontalo Network System Diagram 2 TSL-E-002 Tonsealama Hydropower Station Single Line Diagram for Existing

Facilities 3 TSL-E-003 Tonsealama Hydropower Station Single Line Diagram for New Unit 1 4 TSL-E-004 Development of Hydropower Stations on Tondano River 5 TSL-C-101 (R) Layout of Existing Intake 6 TSL-C-102 (R) Layout of New Intake 7 TSL-C-201 Layout of Existing Penstock 8 TSL-C-202 (R) Layout of New Penstock 9 TSL-C-301 Floor Plan of Existing Powerhouse for Unit 1 10 TSL-C-302 Section of Existing Powerhouse for Unit 1 11 TSL-C-303 Floor Plan of New Powerhouse for Unit 1 12 TSL-C-304 Section of New Powerhouse for Unit 1

For Reference 13 TSL-M-101 (R) Arrangement of Sand Flush Gate

Note: (R) means the drawings revised under this Additional Survey

SU3.2

SU3.1

SU3.3

SU3.6

SU2.3

SU2.1

SU2.4

SU2.2

SU2.5

SI3.9

SU 1

SU 2

SU 3SU 4

SI3.10

SI3.6

SI2.1

SI3.3

SI3.2

SI3.4

SI3.5

SI3.1

SI3.8 SI3.7

SI2.6

SI2.5

SI2.3

SI2.4

SI 5

SI2.2

SI 1

SI 2

SI 3SI 4

A

BP3.2

BP3.1

BP3.3

BP2.1

BP3.5

BP3.4

MR2.1

MR3.3

MR3.1

MR3.2

MR 1

MR 2MR 3

MR 4

MR 5

IS3.2

IS3.1

IS3.4

IS3.5

IS3.6

IS3.7

IS3.3

IS2.1

IS 1

IS 2IS 3

IS 4

A

BO3.2

BO3.1

BO3.4

BO3.5

BO3.3

BO2.1

S 1

S 2

S 3S 4

AAA

A

A A

AA A

AAA A

A

A

LO3.2

LO3.1

LO3.4

LO3.5

SLO3.3

SLO2.1

OG 1OG 2

OG 3

OG 4

SO3.2

SO3.1

SO3.4

SO3.5

SO3.3

SO2.1

SO 1

SO 2SO 3

SO 4

SP3.2

SP3.1

SP3.4

SP3.5

SP3.10

SP2.5

SP2.6

SP2.7

SP2.8

SP2.2

SP2.3

SP2.4

SP2.9

SP3

SP2

SP4

SP2.1

LP4.4

LP4.3

LP4.5

LP4.6SPARE

SP3.8

SP3.9

SP3.3

SP3.7

SP3.6

PU3.2

PU3.1

PU3.5

PU3.3

PU3.6

PU4.2

PU4.1

PU3.4

SK3.2

SK3.1

SK3.3

SK3.4

SK3.5

SK2.1

SK 2

SK 3

SK 4

SE3.2

SE3.1

SE3.4

SE3.5

SE3.3

SE3.6

SE4.2

SE4.1

SH3.2

SH3.1

SH3.4

SH3.5

SH3.6

SH3.3

SH4.1

SH4.2

SH3.7

SA 1

SA 2SA 3

SA 4

SA2.1

SA3.3

SA3.2

SA3.1

SM3.8

SM3.9

SM3.13

SM3.3

SM2.1

SM2.3

SM 1

SM2.2

SM 2

SM 3SM 4

SM3.1

SM3.2

SM3.14

SM3.15

SM3.11

SM3.5

SM3.4

SM3.7

SM3.6

SM3.10

SM3.12

SL3.7

SL2.4

SL2.3

SL2.1

SL3.6

SL3.5

SL2.2

SL3.4

SL3.3

SL3.2

SL3.1

SL 1

SL 4SL 5

SL 2

SL 6

SL 7

SL 3

SR3.1

SR3.2

SR3.4

SR3.5

SR3.8

SR3.3

SR3.6

SR2.4

SR2.1

SR2.3

SR2.2

SR 1

SR 2SR 4

SR 5

SR 3

SR 6SR 7

SR3.7

SW3.7

SW3.8

SW3.5

SW3.6

SW3.11

SW3.12

SW3.10

SW3.13

SW3.4

SW3.3

SW3.2

SW3.1

SW2.1

SW2.2

SW 1SW 2

SW 3

SW3.9

SD3.3

SD3.1

SD3.4

SD3.2

SS3.1

SS3.2

SS3.7

SS3.6

SS3.5

SS2.1

SS3.8

SS3.3

SS3.9

SS3.4

SS 1SS 2

SS 3

SG4.1

SG4.2

20 MVA 10 MVA

20 MVA

20 MVA

20 MVA20 MVA20 MVA

SL3.9

SL3.8

SL3.10

20 MVA

20 MVA

20 MVA

20 MVA

10 MVA

20 MVA

10 MVA

10 MVA

20 MVA

30 MVA

16 MVA 22 MVA

15 MVA 15 MVA

25 MVA30 MVA25 MVA25 MVA

10 MVA

60 MVA

31 MVA

10 MVA

4 MVA

10 MVA 6 MVA 12 MVA

10 MVA

4.5 MW 5.44 MW 4.44 MW

2x25 MW2x10 MW

20 MW20 MW20 MW20 MW

20 MW

42 MVA

2x20 MVA 10 MW

ST4.7

ST4.12

ST48

G G G G

G G

G G

G

G G

G G

GI.LIKUPANG

10 MW Sewa110 MW Sewa3

GI.BITUNG

GI.BOTUPINGGE

GI.MARISA

GI.ISIMU

PLTD TELAGAPLTU MOLOTABU

GI.BOROKO

PLTA TONSEALAMA

GI.LOLAK

PLTD SEWA&MFO

PLTU 2 SULUTPLTD KPMPLTD LOPANA

GI.KAWANGKOANGI.LOPANA

GI.OTAM

PLTA TANGGARIⅡ

GI.TONSEALAMA

PLTD BITUNG

PLTP

GI.TASIK RIA

5 MW

GHSARIOSEWAMANADO GI.TOMOHON

GI.TELINGGIS.TELING

GI.RANOMUT GI.SAWANGAN

PLTD SEWA

LAHENDONGⅠ&Ⅱ

PLTPLAHENDONGⅢ&Ⅳ

PLTA TANGGARIⅠ

GI:Substation

PLTA:Hydro Power Station

PLTD:Diesel Power Station

PLTU:Cool Thermal Power Station

PLTP:Geo Thermal Power Station

ZZ

SM 5 SM

MINAHASA GORONTALO

(Interconnected on Oct. 27,2011)

A

G1 G3 G2

kWh

kWh

kWh

ke SS 3.4ke SS 3.9

LALA

150/300/5/530/60 VA

300/5/530/30 VA

BUSBARⅠ30 KV

BUSBARⅡ30 KV

PS KLM.P.SAMPAH

380 V20 KV

SS.4 GI.T.LAMA

20kV SS.1 GI.T.LAMA

PS.INTAKE

50/5/530/30 VA

120/6/5/510/15/30 VA

33000/100V 33000/100V

33KV100V

150/5/5 A

150/5/5 A

150/5/530/30VA

220 V

33KV/16KV-

100V-100V

6000 kVASIEMEMS

6.3/16.5-33 KVYd5

6800 kVABBC

6.3/33 KVYNd5

6000kVAENERGOIN VEST

15/30 kVYd5

PV 36285,6000 KVABROWN BOVERI

6 kV,600 rpmpf 0.75

AW 588695,6800 KVA,ANDRITZ ESCHER WYSS

6.3 kV,600 rpmpf 0.8

ATB 12,5550 KVA,GENERAL ELECTRIC

15 kV,500 rpm,pf 0.8

6000/110/100V

6000/110/100V

6000/110/100V

6300/110/100V

50 kVAUNINDO

15 KV/110-220V

600/545VA

600/545VA

700/5/5/545/60/30VA

15000/100V2φ

75VA

100-200

545VA

100-200

545VA

15000/100V75VA

15000/100V75VA

UNINDO 160kVA15-20kV/231/400V

16.5 kVA/230VAEG 200kVA

Y/Z 5

6300/√3

100V

700/5220VA

600/545VA

100-200/5

3φ

1φ

LA

500/5/5

15 KV

CO

CO

380 V

220V

New Work Shop

Crane 25/5 ton

Rectifier 110V unit Ⅲ

Rectifier 48V unit Ⅲ

Rectifier 110V unit Ⅰ

,Ⅱ

Pom pa air

Old Work Shop

Lighting for Premises

PS Intake TanggariⅠ

PS Governor unitⅠ

PS Governor unitⅡ

Raw water pump turbin Ⅲ

Lighting for Premises

Clean Water Pump

Keterangan :

G

CircuitBreaker(Closed)

DisconectingSwitch

LightningArrester

Transformer

Change OverSwitch

Generator

Earth GroundResistance

DS DS

DS

ST 4.7CB

ST 4.12CB

DS DS DS DS

DS

DSDSDS

DS

DS

DS

DSDS

DSDS

DS

DS

DSDSDS

DS

DS

DS

DS

DS

DS

DSDS

DS

DS

DS

DS

ST 4.6CB

ST 4.4CB

ST 4.14CB

ST 4.1CB

kWh kWh kWh kWh

ST 4.3CB

ST 4.2CB

kWh

1 2 3 4 5 6 7 8 9 10 11 12 13

30 KV

20 KV

15 KV

15 / 20 KV

6 KV

380 V

220 V

DRAWING TITLE

REHABILITATION PROJECT IN

THE PREPARATORY SURVEY ON DRAW. NO.

NIPPON KOEI CO., LTD.THE REPUBLIC OF INDONEAIA

TONSEALAMA HYDROPOWER STATIONPREPARED BY

CHECKED BY

APPROVED BY

DATE

Single Line Diagram for New Unit 1Tonsealama Hydropower Station

July, 2014RE

VIS

ION

TONDANOLAKE TONDANO RIVER

PLTATANGGARI-Ⅰ

18 MW

PLTATANGGARI-Ⅱ

19 MW

PLTASAWANGAN(Future)

17.5 MW

PLTASAWANGAN(Future)

PLTATANGGARI-Ⅱ

PLTATANGGARI-Ⅰ

PLTATONSEALAMA5.1 KM

PLTATONSEALAMA

683

683

14.4 MW

589

458

330

250

800

700

600

500

400

300

200

PLAN OF INTAKESCALE A

PROFILE OF INTAKE (SECTION A-A)SCALE A

A

A

B

B

SECTION B-BSCALE A

SECTION C-CSCALE A

C

C

PROFILE OF SCORINGWAYSCALE A

D

D

PLAN OF INTAKESCALE A

PROFILE OF INTAKESCALE A

A

A

B

B

SECTION B-BSCALE A

SECTION C-CSCALE A

C

C

PROFILE OF SCORINGWAYSCALE A

PROFILE OF PENSTOCKSCALE A

KEY PROFILESCALE B

PLAN OF ANCHOR BLOCK NO.1SCALE A



TYPICAL PLAN OF SADDLESCALE A

PROFILE OF PENSTOCKSCALE A

KEY PROFILESCALE B



PLAN OF ANCHOR BLOCK NO.3 AND NO.4SCALE A

TYPICAL PLAN OF RING GIRDERSCALE A

A

A

B B

A

A

B B

A

A

B B

TURBINE FLOOR (at GL-EL.6.300m)SCALE A

GROUND FLOOR (at GL+0.000m)SCALE A GENERATOR FLOOR (at GL+EL.5.000m)

SCALE A

TRANSVERSE SECTION A-ASCALE A

LONGITUDINAL SECTION B-BSCALE A

A

A

B B

A

B

A

B

A

A

B B

TURBINE FLOOR (at GL-EL.6.300m)SCALE A

GENERATOR FLOOR (at GL+0.000m)SCALE A

UPPER PART OF GENERATOR FLOOR (at GL+EL.5.000m)SCALE A

TRANSVERSE SECTION A-ASCALE A

LONGITUDINAL SECTION B-BSCALE A

MAX. Water Level WL.683.700

MIN. Water Level WL.681.600

Rated Water Level WL.682.630

Clear Height 800

11001500 1100

2000Clear Span 2500

Clear Span 2500

Datum Line

PLANS=1:80

ELEVATIONS=1:80

PROFILES=1:80

※ ※

※

5300

800

4500

5300

1550

3100

3550

2100

Spindle Hoist

Spindle Support

※ Datum Line

EL.683.800

FLOW

EL.683.800

Spindle Supports

Wedge Plates

EL.678.500(EL.688.500)

EL.678.500(EL.688.500)

(WL.691.600)

(WL.692.630)

(WL.693.700)

(EL.693.800)(EL.693.800)

Additional Slab

Additional Slab

EL.679.500(EL.689.500)

Existing gate is to be removed

150

Ladder

Ladder

Additional Slab

4300

Clear Height 800

Datum Line

FLOW

※

※

DETAIL OF SEALINGS=1:15

300

500

EL.678.500(EL.688.500)

300

290

Wedge Plates

200

FLOW

Clear Span 2500250

※ ※

200

315

285

800

DETAIL OF SLOTS=1:15

Datum Line

Wedge Plate

ARRANGEMENT OF SAND FLUSH GATE

Upstream

0.3 m/min. +/- 10%

Quantity 1 set

Hoisting Height Not less than 0.900 m / Maximum 1.400 m

Operation Speed

Downstream

Downstream

4 Edges Rubber Seal at Upstream Face

Upstream

Motor Drive Twin Spindle Hoist

EL 678.500 m

Water Level

Lowering

Sealing Method

Sill Elevation

Hoist Type

Raising

Water Level

Clear Height

Clear Span

0.800 m

2.500 m

Steel Made Fixed Wheel GateGate Type

DESIGN DATA

Upstream

Downstream

Sedimentary Level Upstream

Operation

：EL.678.500 m

：EL.683.700 m

：EL.679.500 m

：EL.683.700 m

：EL.678.500 m

：EL.683.700 m

：EL.678.500 m

Skin-plate, Side beams, Main wheelsMain MaterialsSide rollers

SUS304Exposed guide frame, etc.

Documents

THE PREPARATORY SURVEY ON TONSEALAMA HYDROPOWER … · The Preparatory Survey on Tonsealama Hydropower Station Rehabilitation Project (2) Chapter 1 Outline of Additional Survey 1