Proceedings World Geothermal Congress 2010

Bali, Indonesia, 25-29 April 2010

Design of Wayang Windu Unit 2 Geothermal Power Station

Naoko Yamaguchi
1-1 Tanabeshinden, Kawasaki-ku, Kawasaki-city 210-9530, Japan
[email protected]

Keywords: Wayang Windu, Indonesia, West Java, single Wayang Windu geothermal power station has been owned
flash, plant performance, Integrated Control System, intake and operated by Star Energy Geothermal (Wayang Windu)
screen cleaning Limited, SEG (former Magma Nusantara Limited). The
power station is named after two mountains Gunung
ABSTRACT Wayang and Gunung Windu. ("Gunung" means a mountain
in Indonesian.)
Wayang Windu geothermal power station, owned and
operated by Star Energy Geothermal (Wayang Windu) Construction of Wayang Windu geothermal power station
Limited, has been operating its first unit (Unit 1) from started in 1997. Originally, scope of the construction was
1999. Although construction of the second unit (Unit 2) was two identical generating units ("Unit 1" and "Unit 2") with
also scheduled at the same time as Unit 1, it was suspended gross output of 110MW for each, scheduled to start
due to the economy crisis. At that moment, the civil and operation around the same time. However, due to the
architectural works including all equipment foundations Indonesian economic crisis which coincidentally grew with
were completed. the progress of the Wayang Windu construction project,
continuation of Unit 2 construction fell into difficulties. In
After a decade, the Unit 2 construction was resumed. It was
the result, only the civil and architectural works were
not just a recommencement of the suspended works; it also
continued toward completion as they had already
involved some design improvements on the performance
commenced for both units, and all other works associated
and operability under the restrictions of the existing
with Unit 2 were suspended.
constructs and materials. This paper introduces
representative items of those improvements. Just after a decade, in 2007, the construction of Unit 2 was
resumed. In this new project, it was aimed to make
The construction of Unit 2 was completed ahead of the
improvements to the existing design; SEG had accumulated
original schedule and the commercial operation started
knowledge of the actual operating conditions through their
from February 2009 with producing more than the target
experience of plant operation and maintenance, and
gross output of 117MW.
established a concept of design improvements. The
implementations of the concept which made by Fuji
1. INTRODUCTION Electric Systems (FES) are introduced in Clause 3 of this
Indonesia is a leading country in terms of geothermal power paper.
generation, and is expected to have the world largest
potential of the geothermal resources. In recent years, the 2. OVERVIEW OF POWER STATION
Indonesian government has been strongly promoting
Wayang Windu geothermal power station is located in
extensions of the geothermal power generation aimed at a
Pangalengan, approximately 40km south of Bandung, West
substitution of a certain part of the consumption of oil and
Java, Indonesia. A tea plantation surrounds the power
other fossil fuels.
station and its altitude is about 1700m above sea level. The
West Java, where the Wayang Windu geothermal power ambient conditions are typical for highland climate in the
station is located, is one of the major regions abundant in tropical regions; the atmospheric pressure is around
geothermal resources in Indonesia. Development of 830mbar, most of the time the ambient temperature is
geothermal power stations in this area has been most below 20deg.C, and the relative humidity is close to 100%.
progressed due to its geographic advantages such that the
central cities, Jakarta and Bandung, are located nearby.

Figure 1: Location of Wayang Windu Figure 2: Photo of the power station viewing from the
tea plantation

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Figure 3: Layout of power station

This power station adopts a single-flash, condensing system Consequently, restrictions for each equipment were as listed
for power generation. Unit 1 and 2 are arranged in parallel below, which let our study turn to focusing on lowering the
as shown in Figure 3. The geothermal steam delivered from condenser pressure rather than increasing the steam
SAGS (Steamfield Above Ground System) is received by pressure or flow.
the steam header at the power station boundary. Inside the
power station, Unit 1 and 2 have separate systems for the ¾ Steam turbine: To be identical to Unit 1
main processes such as steam supplies and cooling water
circulations. Also the electricity generated by the Unit 1 and ¾ Condenser: To be identical to Unit 1 (Only nozzle
2 turbine-generators is dispatched to the substation size and numbers could be changed)
individually. Each unit has a single-cylinder double-flow
steam turbine with 697mm (27") long last row blades, ¾ Hotwell Pump: Dimensions to be almost same as Unit
associated with a 137.5MVA / 13.8kV TEWAC generator. 1 due to the pit size

¾ Cooling Tower: Length and width to be almost same

3. DESIGN IMPROVEMENT IN UNIT 2 as Unit 1 due to the cold water basin size
This clause outlines the improvements implemented in the
Unit 2 design from the original design employed for Unit 1. To lower the condenser pressure, increase of the cooling
water flow and decrease of the cooling water temperature
3.1 Plant Performance are required.
The first priority of the SEG improvement concept was Increase of the cooling water flow affects the capacity of
increase of the power output. However, as described above, hotwell pumps and cooling tower. For the hotwell pumps,
the construction works and material procurement for Unit 2 the only way to increase capacity was modification of
was partially completed. Especially, the all foundations had impellers since shifting to a larger model was not possible
been made according to the original equipment designs, due to the dimension restriction. Also the increase of
change of the equipment dimensions and weights was cooling tower capacity was limited as the basin size was
limited. In addition, it was decided to make the turbine, unchangeable. As a result of detail studies, the rated cooling
generator and condenser to be identical to Unit 1 in order to water flow was increased about 7%.
utilize the existing resources as much as possible.
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Decrease of the cooling water temperature requires better situation, reconstruction of the control concept was done
cooling tower performance, i.e. the approach was to be during the Unit 2 engineering. The main subjects were,
made smaller by increasing the heat exchange surface area.
For this purpose, higher cooling tower was adopted; the a) Automate the operators' APC manipulation
new height was set to be 18m whereas the original height
was 12.5m from the basin curb to the top of fan stack. The b) Optimize the role of each control function
rated approach of cooling tower decreased from 8deg.C to
5.5deg.C. c) Add necessary interlocks for the combined operation of
Unit 1 and 2
According to these design changes, the condenser pressure
was lowered from 0.12bar to 0.11bar. Comparison of (a) Automation of APC Manipulation
parameters between Unit 1 and 2 is shown in Table 4. In order to automate the operators' APC manipulation, a
function to maintain the turbine internal flow rate was
Table 4: Comparison of process values between required. As the internal flow rate is represented by the
Unit 1 and 2 turbine wheel chamber pressure, a control function to adjust
the set value of APC by monitoring the wheel chamber
Unit 1 Unit 2 pressure was added. This function was named "WCPC"
Condenser Pressure 0.12 bar(a) 0.11 bar(a) (Wheel Chamber Pressure Control).
Cooling water flow 4.64 m3/s 4.97 m3/s
Approach of cooling tower 8 deg.C 5.5 deg.C (b) Optimization of Control Function Roles
Cooling water temperature (*) 23.5 deg.C 22.5 deg.C The fact that the turbine-generator output had been adjusted
* Note:
Since the design wet bulb temperature was changed from
by using APC rather than SLC is considered to have
15.5deg.C to 17deg.C based on the present site condition, the suggested that positional relation between a control device
apparent difference of rated cooling water temperature between and its corresponding controlled object should be as close
Unit 1 and 2 is smaller than the actual operation. as possible. As a result of many discussions in the design
The overall plant cycle of Unit 2 is shown in Figure 5. review and operation checks during the commissioning,
roles of the control functions in the normal operation was
3.2 Integrated Control System configured as follows.
SAGS and the power station, whose process flow is - Turbine-generator output: controlled by WCPC
indicated in Figure 6, have an integrated control system.
Integration is implemented by the following control - Separator and header pressure: controlled by PPC-V
functions.
- Production of wellhead: controlled by SPC
Primary Pressure Control (PPC)
In this configuration, some steam venting to the atmosphere
Pressure control of the separators in SAGS and steam is expected due to the difference of the response time
header at the boundary of power station, by manipulating between PPC-V and SPC, but it is still within the
the turbine governor and SAGS vent valves acceptable level. In case the venting must be more strictly
"PPC-G" is a sub-module of PPC, it controls the pressure limited, WCPC will be switched to PPC-G.
by modulating the opening of turbine governor valves
through Automatic Power Control (APC), one of the (c) Addition of Interlocks for Unit 1 & 2 Combined
functions equipped in the turbine governor. Operation
"PPC-V" is another sub-module of PPC. It controls the
Normally, Unit 1 and 2 SAGS operates with all crossover
pressure by modulating the vent valves in SAGS.
valves opened as shown in Figure 6, which is called
"Combined Operation". In this operation mode, some
Secondary Pressure Control (SPC) behaviors of the controllers have to be different from the
Pressure control of the steam header by manipulating the independent operation of each unit to avoid interferences
wellhead control valves between Unit 1 and 2. The required behaviors are listed
below. Interlock logic circuits were added to establish (or
Secondary Load Control (SLC) check if established) these conditions when Unit 1 and 2 is
Turbine-generator output control by manipulating the going to shift to Combined Operation mode.
wellhead control valves
- PPC-V operates the all vent valves of Unit 1 and 2
The main feature of the original control concept was the sequentially
optimized steam pressure control by coordinated action of
- PPC-G has to be disabled in both Unit 1 and 2
PPC-G and PPC-V, which was intended to maintain the
steam pressure stable and minimize steam venting to the - SPC can be enabled in either Unit 1 or 2
atmosphere. However, in the actual operation of Unit 1,
higher priority was given to a fine tuning of the turbine- - The vent valves rapidly open when a turbine-generator of
generator load in order to generate maximum output either Unit 1 or 2 trips.
obtainable by the operating condition at every moment. For
this purpose, PPC-G was usually disabled and the operators 3.3 Cleaning Facility of Cooling Tower Intake Screen
were directly manipulating the APC of turbine governor; as
there is a limitation on the turbine internal steam flow rate, Cleaning of the intake screens installed in a corner of the
the maximum obtainable output varies depending on the cooling tower basin is one of the touch works in the power
ambient condition, especially the wet bulb temperature. station operation. Typically, screen cleaning is done with
Therefore, the operators increased the target of APC during
the night time, and vice versa in the day time. Based on this

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the following procedure: Insert a spare screen → Withdraw hoist every time. In Unit 2, a new cleaning system was
designed which enables cleaning without withdrawal of the
the screen to be cleaned→ Clean the screen by water jet→ screens. As shown in Figure 7, a vertical guide which
moves horizontally by hand is provided for each screen.
Store the cleaned screen as a spare As the screens are large
and heavy (dimension is 6.2m height x 2.7m width), the
operators have to insert and withdraw screens by using a

from SAGS

10.7 bar(a) Generator

Condensate 117 MW
Re-injection
Turbine

Gas Removal
Condenser
0.11 bar(a) System
Cooling Tower
NCG

Hotwell Pump
Coolers

Aux. Cooling Water Pump

Figure 5: Unit 2 plant cycle

Unit 1 Turbine
Rock
Muffler

Crossover Valves
(Normally Open)

From Rock
Production Well Muffler

Unit 2 Turbine

Steam
M Header

To Reinjection Well
Scrubbers

Separators

Figure 6: Process flow of SAGS and power station

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Figure 7: Intake screen cleaning system

Figure 8: Samples of inlet ports for intake screen cleaning system

By lifting up and down an inlet port through this guide, Thanks to the SEG's solid experiences and knowledge on the
trashes on any part of the screen can be drawn by the screen actual plant operation, FES was able to make the new
cleaning pump. The inlet port is changeable and the trashes designs for Unit 2 with well-balanced flexibilities and
accumulated on the bottom of the pit can be also removed as simplicities. As a result, Unit 2 has been operating with
shown in Figure 8. superior performance on both the power output and steam
consumption rate. Wayang Windu Unit 2 could be a good
This new cleaning system enabled every regular cleaning reference of large single-flash geothermal power plant in the
with only 2 or 3 operators, and the time for preparation was world.
significantly reduced.
REFERENCES
4 CONCLUSION Murakami, H., Kato, Y., and Akutsu, N.: Construction of the
Construction of the Wayang Windu Unit 2 geothermal Largest Geothermal Power Plant for Wayang Windu
power project has been successfully completed at the end of Project, Indonesia, Proceedings, World Geothermal
February 2009, about 2 weeks ahead of the contract Congress 2000, (2000), 3239 - 3244.
schedule, and immediately the commercial operation
followed. Skoric, P., Boutot, R., Scott, J., Iwata, A.,: Wayang Windu
Integrated Control System – The Control Concept for

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Modern Geothermal Plant, Proceedings, World

Geothermal Congress 2000, (2000), 3303 - 3308.