Sunteți pe pagina 1din 7

CONSORTIUM OF :

TERM OF REFERENCE
ASSESSMENT STUDY OF UNBALANCE LIQUID LEVEL OF CENTRAL
SEPARATOR OF ULUBELU UNIT 3&4
Document No : Rev No. Contract No :

UBL3&4-G-0-G0-TOR-AA0-001R 0 798/PGE000/2014-S0

PROJECT : ULUBELU UNIT 3&4 GEOTHERMAL POWER


PROJECT

EMPLOYER : PT PERTAMINA GEOTHERMAL ENERGY (PGE)

LOCATION : ULUBELU, LAMPUNG

0 Issue for Quotation 9 Mar 2018


Rev Description Date Prepared Checked Approved

Consortium of Sumitomo Corporation and PT REKAYASA INDUSTRI


TERM OF REFERENCE
Document No : Rev No. Contract No :

UBL3&4-G-0-G0-TOR-AA0-001R 0 798/PGE000/2014-S0

REVISION HISTORICAL SHEET

Revision Date Description


0 9 Mar 2018 Issue for Quotation

Page 2 of 7
Consortium of Sumitomo Corporation and PT REKAYASA INDUSTRI
TERM OF REFERENCE
Document No : Rev No. Contract No :

UBL3&4-G-0-G0-TOR-AA0-001R 0 798/PGE000/2014-S0

TABLE OF CONTENTS

REVISION HISTORICAL SHEET ................................................................................................................2

TABLE OF CONTENTS ................................................................................................................................3

1. INTRODUCTION ..................................................................................................................................4

2. PROBLEM DESCRIPTION ...................................................................................................................5

3. REFERENCE ..........................................................................................................................................6

4. OWNER EXPECTATION .....................................................................................................................6

5. SCOPE OF WORK FOR ENGINEERING CONSULTANT ................................................................6

6. TIME FRAME ........................................................................................................................................7

7. INFORMATION REQUIRED FROM ENGINEERING CONSULTANT............................................7

Page 3 of 7
Consortium of Sumitomo Corporation and PT REKAYASA INDUSTRI
TERM OF REFERENCE
Document No : Rev No. Contract No :

UBL3&4-G-0-G0-TOR-AA0-001R 0 798/PGE000/2014-S0

1. INTRODUCTION
PT. Rekayasa Industri (Rekind) has finished the EPCC Work for Ulubelu Unit 3&4 Geothermal Power
Project (2 X 55 MW) which is owned by PT Pertamina Geothermal Energy. The project is located at
Tanggamus, Lampung, Indonesia. The project is divided into two main areas consist of Power Plant
Area and SAGS Area.

The SAGS for Ulubelu Unit 3&4 comprises of pipeline and distribution header from production well
Cluster I, G, K, C, H, Central Separator, Scrubbing Line, Steam Vent Station, Brine Reinjection Wells,
Steamfield Drainage System, Condensate Reinjection Wells, and Inter Connection Piping between
Unit 1&2 and Unit 3&4 in Cluster B and Cluster C.

The geothermal fluid (two phase steam) is transported from each production well cluster in pipe
headers and then collected to a 52 inch main pipe header and transferred to Central Separator.

The central separator station consists of three separator vessels [UBL0LBJ01AT004/5/6 (Sep#4;Sep#5
;Sep#6)], each designed for a steam flow of 350 TPH. All three separators operate at common
pressure set point, which is 9.05 BarA. The pressure on the system is maintained to be constant by
discharge of steam to the turbines and through vent valves. The two phase geothermal fluid is
separated in the central separator station with separator efficiency 99,95%. The produced steam are
transferred to the Scrubbing Line Header, while the brine are transferred to the brine reinjection
header.

All separators are provided with isolation valves on two phase, steam and brine pipelines upstream
and downstream of each vessel to allow isolating individual separators. Permanent annubar flow
meters that connected to DCS are installed on each of the steam pipelines. On other side, an orifice
type flow meters that connected to DCS is also installed on the common brine reinjection header
pipeline.

Each separator is provided a Pressure Safety Valvewhich is installed in the steam line upstream of the
isolation valve, to protect the equipment from overpressure condition. The discharge pressure of the
PSV is set higher than the control valve at the Vent Station but lower than the PSD Station at the
main steam header pipeline so that the PSV will open prior to the PSD. The PSV is set to discharge
open at 9,5 Barg.

The level of brine in the separator are maintained by a modulating level control valve (LCV),
operating on position signals from the brine level position transmitters. Brine is discharged to the
gravity flow brine reinjection header through the LCV, controlled by the Level Indicator Controller
which maintaned in normal brine level of Separator [2539 mm from bottom of tangent line]. The
setting alarm High High brine level Separator in 4266 mm from bottom of Tangent Line and for Low
level in 812 mm from bottom of tangent line of brine information from the Level Indicator at the
separator. All transmitters are with remote seals (flanged type), to keep the transmitters isolated
from process fluid.

A pneumatically operated emergency brine dumping valve (EDV) is provided for each separator to
discharge brine to EDV AFT in case the brine level in the separator is too high to prevent separator
flooding. The EDV is provided with a motorized isolation valve for stroking. The MOV is set normally
open. In case of malfunction close of the valve, the brine emergency line is provided with a bypass
Page 4 of 7
Consortium of Sumitomo Corporation and PT REKAYASA INDUSTRI
TERM OF REFERENCE
Document No : Rev No. Contract No :

UBL3&4-G-0-G0-TOR-AA0-001R 0 798/PGE000/2014-S0

valve that can be operated from DCS. The EDV is configured to FAIL OPEN on loss of air or control
signal. The EDV will open based on High High level [4419 mm from bottom of Tangent Line] and will
close when the level switch no longer gives the High High signal. The brine will be discharged to
separator pond through EDV AFT.

2. PROBLEM DESCRIPTION
From March 2017 up to January 2018, Ulubelu Unit 3&4 was operated with total load ±90 MW
(gross) or (±82 MW nett) only due to shortage of two phase steam supply. With this condition, the
Central Separator was experiencing unbalance condition where there was “high-high level” problem
of Sep#5 (Separator which is located in the middle).

To reduce the level of Sep#5 and to balance the liquid level of all separators, some action were taken
as follow:
- Throttling of inlet valve of Sep#5 and Sep#6 (10-25% open). It should be normally open 100%
- Open the bypass of LCV Sep#5 and LCV Sep#6 . It should be normally closed

Note: when the inlet valve of Sep#5 was throttled, the level of Sep#6 had a tendency to get higher and
at certain condition it will reach High-High level as well. Therefore to decrease the level of Sep#6, the
inlet valve of Sep#6 was also throttled. The bypass of LCV Sep#6 is also opened. Please refer to
Attachment-A (1) and A(2) to get more detail of action or trial which had been conducted to central
sepatator in order to balance the liquid level.

By doing those action as above, liquid level of Sep#5 could be decreased, liquid level of all separator
was almost balance and EDV dumping to AFT could be prevented. This condition was maintained up
to January 2018 and the load generation is stable ((±82 MW net).

Since mid of January 2018, Ulubelu Unit#1 has been shutdown for periodic maintenance. During that
period, the two phase steam from Unit#1 (by interconnecting line between Unit 1&2 and Unit 3&4)
could be utilized to increase load generation of Ulubelu Unit 3&4. The current condition of Ulubelu
Unit 3&4 is operated with total load ±106 MW (gross) or (±98 MW nett). At this load, liquid level of
Sep#5 is getting High-High again and EDV dumping to AFT occur repeatedly in the adjacent time

In order to balance the liquid level of central separator and prevent EDV dumping, some action were
taken as follow:
For Sep#5:
- Throttling of inlet valve of Sep#5 (25% open). It should be normally open 100%
- Open the bypass of LCV Sep#5. It should be normally closed
- “Crack open” (about 3%) the bypass of EDV (it should be normally close). Therefore there is
continuous brine flow to AFT

For Sep#6:
- Open the bypass of LCV Sep#6. It should be normally closed
- Fully open the inlet valve of Sep#6 (previously it was throttled).

By doing those action level of Sep#5 & Sep#6 could be decreased (but it is still quite high) and EDV
dumping repeatedly could be reduced.

Page 5 of 7
Consortium of Sumitomo Corporation and PT REKAYASA INDUSTRI
TERM OF REFERENCE
Document No : Rev No. Contract No :

UBL3&4-G-0-G0-TOR-AA0-001R 0 798/PGE000/2014-S0

Actually there is still two phase steam from Unit#1 which could be utilized to Ulubelu Unit 3&4, but if
more two phase steam is added to central separator of Unit 3&4, the separator level is not
controllable for Sep#5 and Sep#6 eventhough some action as above had been taken. As of now the
Ulubelu Unit 3&4 is operated at ±98 MW net, this condition is maintained up to Unit 1 is operated
again (it is scheduled on Mid of Mar 2018).
Attached is the DCS trending data (duration: 26 Jan 2018 – 2 Feb 2018) for Separator at 98 MW net
with condition of Sep#5 and Sep#6 are as above.

Simultaneously, PGE is now drilling new production well (Cluster J, 3 wells) to increase two phase
steam for load generation of Unit 3&4. We still do know when the drilling and new pipeline
installation will be finished.
PGE are so worry if they finish the drilling and the installation of new pipeline from Cluster J, the two
phase steam cannot be utilized optimally to get 110 MW nett load of Unit 3&4.

3. REFERENCE
a. Attachment-A. Testing/Trial Data to Balance the Liquid Level of Central Separator
b. Attachment-B. Investigation Report to PGE
c. Attachment-C. Planing to Balance Central Separator and The Result
d. Attachment-D. PFD
e. Attachment-E. P&ID
f. Attachment-F. Layout

4. OWNER EXPECTATION
OWNER (PGE) expected that central separator could be able to supply steam for 2 x 55 MW (110 MW
net) load generation with condition as follow:

1. Liquid level of central separator is almost balance


2. No throttling of inlet separator
3. No bypass of LCV is opened
4. LCV is modulating (less than 85%) not 100% open

5. SCOPE OF WORK FOR ENGINEERING CONSULTANT


Based on problem description and owner expectation above, Rekind requests Engineering Consultant
to conduct assessment study of unbalance liquid level of central separator with scope of work as
follow:

1. Conduct site visit, collect data and do testing/sampling data if required (measuring
instrument/tools to be provided by engineering consultant)
2. Have meeting and give presentation for preliminary study
3. Simulate with CFD software or other software/application/program to explain the phenomenon
of two phase steam behaviour at the inlet piping of central separator and the impact to the liquid
level of separator

Page 6 of 7
Consortium of Sumitomo Corporation and PT REKAYASA INDUSTRI
TERM OF REFERENCE
Document No : Rev No. Contract No :

UBL3&4-G-0-G0-TOR-AA0-001R 0 798/PGE000/2014-S0

4. Modelling steam line from central separator to power plant and brine line from central separator
to reinjection well to know the impact to the liquid level of separator
5. Find the root cause of unbalance liquid level of central separator
6. Give some solution or recommendation to solve the issue of unbalance liquid level of central
separator with minimum shutdown duration and to achieve Owner expectation as explained in
section 4.
7. Provide final report (2 copies hard file and 1 soft file)

6. TIME FRAME
Deffect Liability Periode (DLP) for Ulubelu Unit 3&4 will be end in October 2018. Rekind expected
that before DLP is end, central separator issue could be resolved and able to be operated as per
Owner expectation.

The schedule to complete the scope of work of Enginering consultant as explained in item 5 is two (2)
months after contract signing.

7. INFORMATION REQUIRED FROM ENGINEERING CONSULTANT


The Engineering Consultant shall submit the quotation including but not limited to :
1. Execution Planning to conduct the assessment study (complete with breakdown schedule)
2. Cost summary (unit rate based)
3. Consulltant project key personnel resumes
4. Manpower planning for executing the assessment study
5. Others (if any)

Page 7 of 7
Consortium of Sumitomo Corporation and PT REKAYASA INDUSTRI

S-ar putea să vă placă și