| Title | 110 MW Geothermal Steam Turbine Rotor Replacement |
|---|---|
| Authors | Amri ZEIN, Wahyu MULYANA, Heribertus DWIYUDHA |
| Year | 2015 |
| Conference | World Geothermal Congress |
| Keywords | Wayang Windu, geothermal, turn around, turbine rotor, power plant, reliability, availability |
| Abstract | Unit 1 steam turbine of Wayang Windu geothermal power plant with capacity 110 MW has been operated since plant commissioning in 2000. Periodic Turn Around (TA) program such as turbine inspection and overhaul was conducted in every 3 years interval. On 2006 turbine inspection program, it was found erosion damage defect on the rotor body between each of the reaction stages. Several of “J” seal strips in these sections have been peeled off through the erosion from parent metal surrounding the caulking groove. The erosion damage become worse during turbine inspection in inspection 2009 program. As a result, there was a high potential for the seal strip caulking being dislodged in the future after the rotor was returned to service with its current condition and resulted in major consequential potential catastrophic damage to turbine. Star Energy Geothermal Wayang Windu Ltd. (SEGWWL) conducted an engineering study and decided to replace the existing turbine rotor with new turbine rotor with the aim to avoid major problem and to provide long reliability operation which would minimize cost and shutdown time also if site repair was conducted. The new turbine rotor replacement was conducted in Unit 1 TA 2012 with planned shutdown schedule was 16 days. In order to achieve the target, the planning and preparation work of TA team was very essential and should be conducted with qualified team. TA team started the preparation work 1.5 years before work execution by preparing budget proposal, detailed work package & specification, detailed work schedule, regular Safety Health and Environment (SHE) & coordination meeting etc. This huge effort gave significant impact to completion of this TA program whereas the actual Unit 1 shutdown schedule was 12 days (4 days ahead schedule), within budget and No LTA by providing high plant availability and reliability for long term plant operation. |