Star Energy Geothermal Salak

Steam Turbine
Lifetime Assesment

Bali, 13 March 2019

Ilham Kurniawan
Diva E Nataprawira
Edi Garnadi
Introduction

❑ Star Energy Geothermal Salak (SEGS)

field is located along the Sunda Volcanic
Arc in West Java Province, Indonesia,
about 70 KM south of Jakarta.
❑ SEGS is one of the largest geothermal
fields in Indonesia and is categorized as
the sixth largest in the world.
❑ SEGS is capable to produce 377 MW of
steam to generate electricity.
❑ SEGS operates 3 x 65.6 MW steam
turbine to produce electricity and
provides the remaining steam to PLN to
produce 3 x 60 MW electricity.

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Background of Lifetime Assessment
(LTA)
❑ SEGS operates 3 unit Geothermal Steam
Turbines since 1997 which mean it has 20 to
21 years in operations.
❑ API 611 also specifies design lifetime as 20
years.

❑ Per OEM information, the existing unit has

entered the deterioration period and
performed precision rotor inspection.
❑ When turbine reaches their deterioration
period, more failure are expected.

❑ An opportunity to conduct steam turbine life

time assessment was done during Unit 4
major overhaul in 2017.

❑ Information about remaining steam turbine

lifetime is key information for power plant
operation and maintenance planning
process.

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LTA Overview

❑ Based on OEM experiences, there No Turbine Part Types of Damage

are some sections that will be 1 Seal Fin Fracture
monitored to determine the lifetime 2 LP Blade (blade with stellite Erosion
of Steam Turbine. coating)

❑ In Geothermal Steam Turbine, the 3 Blade Pitting Corrosion

failure mechanism of lifetime 4 Stationary Blade Ring (L-0,1) Erosion

assessment is mostly influenced by 5 Rotor Blade shroud Displacement
erosion. 6 Rotor and diaphragm blade area Erosion
❑ Steps on Steam Turbine Lifetime
7 Outer Casing Erosion and
Assessment: Corrosion
8 Gland Packing Ring Erosion/Corrosion

Data Collection Data Analysis Result & Recommendations

• Visual inspection • Pitting mapping and calculation • Forecast the erosion growth
• Pitting measurement • Measuring the silicon resin by until exceed its allowable
• Wastage measurement using 3D scanner and define the value and limit value
(erosion and corrosion) deviation on most eroded area

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Inspection Overview ~ 1

Rotor blade root 6

Inter stage seal
LP Blade 2 area
fin inspection 1
inspection

Blade inspection 3 Blade Shroud

inspection
5

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Inspection Overview ~ 2
Outer Casing inspection 7
Stationary Blade ring inspection 4

Diaphragm blade root area inspection 6

Gland Packing 8
Inspection

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Inspection Result Summary ~ 1

LP Blade (blade
Stationary Blade
Seal Fin with stellite Blade
coating) Ring (L-0,1)

Rotor and
Rotor Blade Gland Packing
diagphram blade Outer Casing
shroud area Ring

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Wastage Inspection Overview
Data collection
• Conduct visual inspection
• Take erosion depth sample
by resin on several potential
failure area.
Laboratory Analysis
• Model was scanned by 3D
model.
• Compare the erosion depth with
allowable design.
Remaining Life Calculation
• It was found that Stage 4 on
Turbine and Diaphragm has
significant erosion.
• Predicted remaining life is 5 years
(aggressive mode).
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Inspection Summary & Forward Plan
Inspection Summary
• Erosion on blade groove area of
stationary side (inner casing&
stationary holder) and rotor was the
source of lifetime limitation.
• The remaining lifetime of turbine rotor
and diaphragm/inner casing (SBH 1) is
around 5 years.
• Replacement of diaphragm/inner
casing (SBH 1) and rotor is
recommended at next overhaul.
• OEM does not recommend to repair
the erosion at the rotor as the weld
repair will introduce to SCC (Sulfide
Corrosion Cracking).
Forward Plan
• Plan to conduct monitoring on the next
major overhaul.
• Open communication with other
Geothermal Steam Turbine Users to
check for other similar case(s).
• Start engagement with engineering
consultants to assess turbine rotor
condition and provide recommendation
of existing type of damage.
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Question and Answer