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PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT

DESIGN BASIS

May 21, 2012

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DOCUMENT NUMBER KMJ5-SGFC-PR-DTN-001

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PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 4 of 31

TABLE OF CONTENTS 1 2 3 INTRODUCTION ........................................................................................................ 6 OBJECTIVE ............................................................................................................... 6 ENVIRONMENT DATA .............................................................................................. 6 3.1 3.2 3.3 3.4 3.5 4 LOCATION ..................................................................................................... 6 METEOROLOGY DATA ................................................................................. 7 EARTHQUAKE ZONE .................................................................................. 12 LAND CONDITIONS AND TOPOGRAPHY .................................................. 12 ENVIRONMENTAL EFFECT ........................................................................ 12

DATA OF WELL CLUSTER A AND C ..................................................................... 12 4.1 4.2 CAPACITY OF STEAM PRODUCTION ........................................................ 12 CHEMICAL COMPOSITION ......................................................................... 12

OBJECTIVE OUTPUT ............................................................................................. 13 5.1 TURBINE STEAM REQUIREMENT.............................................................. 13

6 7

APPLICABLE CODE & STANDARD ....................................................................... 13 OPERATING PHILOSOPHY .................................................................................... 14 7.1 7.2 OPERATING PHILOSOPHY......................................................................... 14 EXPECTED DESIGN CONDITION ............................................................... 15

DESIGN CRITERIA.................................................................................................. 16 8.1 8.2 GENERAL .................................................................................................... 16 CRITERIA OF PIPE DESIGN ....................................................................... 17 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6 8.2.7 8.2.8 Steam Pipe ....................................................................................... 17 Piping Layout .................................................................................... 17 Piping of well ..................................................................................... 17 Tie In ................................................................................................. 18 The Length of Steam Pipe and Condensate ...................................... 18 Pipe Size Selection ........................................................................... 18 Pipe Support ..................................................................................... 19 Valve ................................................................................................. 19

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 5 of 31

8.2.9

Flange ............................................................................................... 19

8.2.10 Thermal Insulation ............................................................................. 19 8.2.11 Drain Pot and Steam Trap ................................................................. 20 8.2.12 Particle and Condensate Disposal..................................................... 20 8.2.13 Overload Protection........................................................................... 20 8.2.14 Thermal Expansion ........................................................................... 20 8.2.15 Pipe Stress Analysis.......................................................................... 20 8.3 MECHANICAL DESIGN CRITERIA .............................................................. 23 8.3.1 8.3.2 8.4 Equipment Strength Design............................................................... 23 Static Equipment ............................................................................... 23

INSTRUMENTATION DESIGN CRITERIA ................................................... 24 8.4.1 8.4.2 Pipe Protection towards Overpressure .............................................. 25 Monitoring Condition of Operation Equipment ................................... 26

8.5

CRITERIA OF DESIGNING CIVIL WORK AND STRUCTURE ..................... 26 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5 8.5.6 8.5.7 8.5.8 8.5.9 General ............................................................................................. 26 Building of Civil Service ..................................................................... 26 Pembersihan Lahan ............................. Error! Bookmark not defined. Earthwork .......................................................................................... 27 Soil Retaining Wall ............................................................................ 27 Support and Foundation Structure..................................................... 27 Box Culvert ....................................................................................... 29 Road Access ..................................................................................... 29 Drainage System............................................................................... 29

8.5.10 Landscaping and Repairing of Kamojangs ....................................... 31 8.5.11 ROW Pipeline.................................................................................... 31

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 6 of 31

INTRODUCTION In order to utilize geothermal steam Kamojang Geothermal Area, PT. Pertamina Geothermal Energy (PGE) intends to build a geothermal power plant (GPP) with a capacity of 30 MW in Desa Laksana, Kecamatan Ibun, Kabupaten Bandung, West Java Province. The project is a Total Project, is a new development of geothermal installations from the upstream to downstream, in which PGE will prepare all aspects: from distribution of steam from the wells to the plant, construction of GPP, and transmission of electrical energy from GPP to PT. PLN (PLN) through the interconnection of Java-Madura-Bali (Jamali). This document describes the basics of the design of steam gathering systems of GPP Kamojang unit 5 in the project "Creating Front End Engineering Design (FEED) Total Project Kamojang unit-5 (1x30MW)".

OBJECTIVE The main purpose of this document is to establish the basics of design and the parameters to be used for Creating Front End Engineering Design (FEED) Total Project Kamojang unit-5 (1x30MW)".

3 3.1

ENVIRONMENT DATA Location Kamojang Geothermal Area is located 42 KM Southeast of Bandung or 23 Km Northwest of Garut. This area is located in the Gandapura-Guntur volcano. Average altitude is 1,500 m above sea level. GPP Kamojang Unit-5 (1x30MW) is located in an area of about 4 ha which at present stood GPP Kamojang Unit-4 with a height of about 1 m above the road surface and rises to the East with a slope of about 10-15%.

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 7 of 31

Figure 3.1 Peta Lokasi Area Geothermal Kamojang

3.2

Meteorology Data According to Kerangka Acuan Kerja Pengadaan Jasa konsultan FEED Total Project Kamojang Unit 5 (1 x 30 MW) - Jawa Barat and 2011 and 2012 (January and February) Meteorology Data from PGE, Kamojang Area has meteorology data as the following:

Rainfall
Kerangka Acuan Kerja Annual average (mm) Maximum daily (mm) 2916 mm 107 mm PGE Meteorology Data 1229 mm 91.75 mm

Average of 80% rainfall occur in October to April, but rain also occasionally fall during dry season.

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 8 of 31

Air temperature
Kerangka Acuan Kerja Average annual air temperature Minimum air temperature Maximum air temperature 9.3 C 24.7 C 14.52 C 22.73 C 17 C PGE Meteorology Data 18.33 C

Humidity
Kerangka Acuan Kerja Average annual humidity 91% at 20.56 C PGE Meteorology Data 84.5% at 18.33 C

Wind
Kerangka Acuan Kerja Average wind velocity 1.5 m above ground Average wind velocity, 8 m above ground Maximum wind velocity, 1.5 m above ground Maximum wind velocity, 8 m above ground Wind direction North-South 8.5 m/s 3.1 m/s 2.25 m/s 2 m/s 1.1 m/s PGE Meteorology Data 0.01 m/s

Barometric Pressure
Kerangka Acuan Kerja Average barometric pressure 850 mBar PGE Meteorology Data 957 mBar

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 9 of 31

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 10 of 31

Figure 3.2 Peta Zona Gempa Indonesia

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 11 of 31

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 12 of 31

3.3

Earthquake zone According to the Indonesian Earthquake Zone Map from the Ministry of Public works published in 2010, the geothermal field of Kamojang is located in zone with Peak Ground Acceleration in bedrock on approximately 0.4 -0.5 g. This map has 2% of probability of exceed during 50 years. Therefore for the design needscriteria, 0.5 x dead weight of static equivalent force is used for 2 perpendicular direction (x and y axis).

3.4

Land Conditions and Topography The geothermal field of Kamojang located in an eroded-volcanic caldera and most of them are mainland and hills. Most areas are forests which some of them already opened by local residents for agriculture such as potatoes, cabbages, etc.

3.5

Environmental Effect The geothermal area of Kamojang and unit 5 Kamojang GPP are located in important areas such as conservation and production forest (they have function as natural conservation and recreation). Regarding to those reasons, the environmental consideration has the significant function in making design of GPP included its pipe design, for the sake of minimizing the negative effect of construction towards environment.

4 4.1

DATA OF WELL CLUSTER A AND C Capacity of Steam Production Recently, the drillings to 5 wells have been conducted but the characteristics of each well have not been obtained yet. The result of temporary discharge shows the 30MW of wells potency from three wells (Well of KMJ-79, KMJ-80 and KMJ-84).

4.2

Chemical Composition

The assumption of wells chemical composition are as follows:


Sodium ??? Kalium Calsium Silica : 0.5 : 0.26 : 2.9 : < 1.0 ppm ppm ppm ppm

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 13 of 31

ppm Natrium ??? Magnesium Bicarbonate Sulphate Chloride pH : 3.1 : 0.1 :4 : 11 : < 1.0 :5 ppm ppm ppm ppm ppm

The average composition of gas content of east-blocked wells of Kamojangs geothermal Area is as follows:
CO2 H2S Residual (H2, CH4, N2, dll) : 6.2 : 0.3 <2% ppm ppm

5 5.1

EXPECTEDOBJECTIVE OUTPUT Turbine Steam Requirement

The steamed-turbine generator is designed by steam inlet condition on a 6.5 bar absolute pressure and 3-5 Celsius above its saturation temperature. The steam flow is used to supply

GPP with 30MW-nett capacity and is expected below 225 tons/ hr. On that condition, the

steam-insoluble gas (NCGs) is 1%. GPP is expected to be able in operating of electrical energy production then distributed to network by 30MW-nett. For design needscriteria, the electrical-power plant is assumed to run as base load power plant with 90% of annually load factor.

APPLICABLE CODE & STANDARD

Table 6.1 shows the code and standard used in design.


Tabel 6.1 Code & Standard

No 1 2 3 4

Code & Standard ASME B31.1 API 5 L API 1104 API 610 Power Piping Line Specification

Title

Welding of Pipelines and Related Facilities Centrifugal Pump for Petroleum Services

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 14 of 31

No 5 6
7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Code & Standard API 619 API RP 554


ANSI B16.5 ANSI B16.9 ANSI B36.10 ASME Section VIII ASME Section IX UBC WRC 107 AWS D1.1 ASTM AISC-ASD ACI 318-2000 ISA NEMA NEC SSPC Vol.2 NFPA 10 NFPA 12 SII SNI MPR BS 5500 WRC 297 AISC SNI-03-1726-2002

Title Centrifugal Compressor for General Refinery Process Instrumentation and Control
Pipe Flanges and Flanges Fittings Factory-Made Wrought Steel Buttwelding Fittings Nozzle Design and Specification Boiler & Pressure Vessel Code Welding Qualification Uniform Building Code Welding Procedure and Specification Structural Welding Code Material Specification Allowable Stress Design for Structural Steel Building Code Requirement for Structural Concrete Instrumentation Standard Electric Component Standard Electric Code Steel Structure Painting and Coating Specification Standard for Portable Fire Extinguishers Fire Extinguishing System Standar Industri Indonesia Standar Nasional Indonesia Miyn Politie Reglement Calculation Proceduure for Local Stress Local Stress in Cylindrical Shell Due To External Loading on Nozzle Calculation for Vessel Support Base Ring Seismic Load Calculation

7 7.1

OPERATING PHILOSOPHY Operating philosophy As a whole, the design of GPP Kamojang Unit-5 (1x30 MW) project is divided into 2 main systems, upstream and downstream, they are: The upstream system consists of a production well piping system to turbine inlet of GPP and re-injecting piping from GPP to existing injection facilities.

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 15 of 31

The downstream system consist of a Geothermal Power Plant which unlimitedly covers steam turbine system, generator, all facility systems which support steam-generator turbine such as condenser, gas extraction system, cooling tower, 150 KV distribution system and electrical interconnection, and also utility system in GPP.

Steam used to drive power from turbine comes from 5 wells which are ready to produce 250 tons of steam / hr at 15 ksc of Well Head Pressure (WHP). Fluid Collection & Reinjection System (FCRS) is designed to operate by zero venting, which is no steam is discharged during normal operation. However, during GPP emergency situation, steam discharge is allowed through rock muffler. The all steam used for power generation is expected to be converted into condensate (minimum mass loss of fluid) and then will be injected into re-injected wells. Condensate re-injection is expected to be conducted by gravity and integrated to the existing re-injection systems of GPP 140 MW and GPP 60 MW. If the re-injection by gravity is not possible, then injection pump is used as the next alternative. The electricity produced by GPP Kamojang Unit -5 (1x30 MW) is distributed through 150KV system to existing switch yard of GPP Kamojang Unit-4 and to be interconnected to the network of state electricity firm (PLN).

Regarding to the location of Kamojang Geothermal Area and GPP above, which are located in important areas such as conservation and production forest (they have function as natural conservation and recreation), therefore the whole designs of GPP from upstream and downstream aforementioned that begins by connecting-flange of steam transmitting pipe in wing valve flange of wells until transformer 150 KV at interface point to PLNs facilities, must be designed to function effectively, efficiently, cheap to construct, easy to maintain, layout properly and aesthetic, having minimum negative effect of construction towards environment surrounding. 7.2 Expected Design Condition For the purposes of GPP engineering design of Kamojang Unit-5 (1x30MW), these condition is expected to be achieved: Available turbine inlet pressure 6.5-11.0 bar-absolute

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 16 of 31

Zero venting during normal operation Minimum mass loss of fluid (it is expected that all of the steam used to electrical power plant can be converted into condensate)

Aesthetic of the most proper and environmental friendly GPP layout Re-injection by gravity (if it is possible) and is integrated to the existed re-injection system

If it permits, it is considered the existence of interconnection piping to the existed pipeline of GPP Kamojang Unit-4

Interconnecting output to PLNs network. This design model is based on: o o Production capacity of the well, see sub chapter 4.1 Minimum operational capability that is expected in Cluster A and C

The new system design should as much as possible to be similar with existing production facility and should ease field operator in monitoring and maintaining.

The streamline of process must be designed as good as possible so that the interconnection between existed piping system and the new one can be well and synergistically conducted without disturbing the stability of the existed process.

The process design must produce safe and friendly system. Intermittent regime flow and Hammering phenomena must be avoided in fluid flow inside the pipe.

The new system must be adjusted with the available space. The new system is designed in such a way that minimize the interference time/ shut down of Kamojangs-unit 4 production units, especially when construction and installation.

Design must produce a system that has optimal investment to performance ratio. Process in the piping system and Geothermal Power Plant must fulfill the applicable standards and have high flexibility and high reliability.

Design life time 30 years. And all of the things are not mentioned, but will support the operational performance of GPP Kamojang Unit-5 1x30MW.

8 8.1

DESIGN CRITERIA General

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 17 of 31

The design for all utilities and materials related to the geothermal fluids must accommodate factors, namely abrasion, corrosion, chemical content of fluid, temperature, pressure, and others refer to suitable code and standard. Thus, it is expected that facility of production and re-injection of geothermal can be optimally and safely operated. 8.2 Criteria of Pipe Design Pipe system for GPP Kamojang Unit 5 is designed based on international standard. The pressure of pipe system design is determined as 1.21 times of

operationaloperating pressure and design temperature is determined as 1.21 times of operationaloperating temperature. 8.2.1 Steam Pipe Designing steam pipe must refer to ASME B31.1 Power Piping Code. Condition of pipe designing must suitable with the condition elaborated on document of hydraulic analysis and heat & mass balance - SGSFCRS. All steam-pipe lines must be isolatedinsulated by heat-resistant materials so that heat loss can be as minimal as possible to maintain the determined-operationaloperating condition which is friendly to environment surrounds them. 8.2.2 Piping Layout Here are the factors need to considerFactors should be considered in obtaining an optimal piping layout design: a. Location of production well of Cluster A and C b. Flexibility of operationaloperating condition. Piping system of production facility is automatically operated by using control system on normal condition, but it can also be manually operated in a certainparticular condition. c. Condition of topographyTopography (from mapping)). d. LandSoil condition (from landsoil analysis)). e. Availability of land use. f. 8.2.3 Road access for maintenance.

Piping of Each Well well

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 18 of 31

Piping from each well is designed by following these requirements: a. Wellhead usingshould be equipped with master valve standard that is adjusted by adapted according to field condition. b. AvailabilityFeasibility of physically wellhead movement upward and downward wellhead movement (related to support design). c. A spaceSpace availabity for throttle valve. d. AccommodatingAccommodate well shut in pressure. e. Availability of safe fuse of rupture disc and pressure relief device for steam line. f. Space availability for isolating installationinsulation. Pressure and

g. Space availability for installation of venting, Instrument (PT,TT),

Temperatur gauge, Sampling point, and TFT (Tressure Flow Test) Point. 8.2.4 Tie In Tie in on pipe can be conducted by some methods, they are: Tie in on the prepared point. Tie in can be conducted on isolated-flow pipe. Tie in can be conducted when operation is shut down. Tie in can be conducted the operation is running (hot tap)

ThingsFactors to considerbe considered when selecting a methods and doingto do tie in process in piping line are: 8.2.5 Selected tie in location must have enough space tofor work and good access for supplementaryauxillary equipments. EnsureAssure that operationaloperating condition does not change significantly when tie in is running. DecideSpecify tie in configuration so it meets criteria of voltagestress and flexibility. Consider leak potential of main pipe during tie in process.

The Length of Steam Pipe and Condensate The length of pipe is calculated based on pipe linepipeline plan (Piping Layout).

8.2.6

Pipe Size Selection

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 19 of 31

Deciding pipe sized is adjusted by itsPipe size are specified by fluid capacity. It refers to the fluid velocity showed in sub chapter 7.2 used generally in geothermal piping area. Here are things needFactors to considerbe considered in selecting pipe size: a. Wells characteristics. b. Capacity of fluid amount/ flowing/production that will be flowedfluid. c. Economical (diameter and pressure drop have optimal correlation). d. OperationalOperating pressure does not exceed the pressure of pipe design onat all possible operationalfeasible operating condition. e. Enthalpy reduction. f. 8.2.7 PipeAvailabilty of pipe size that is generally inat market.

Pipe Support Types of pipe support are calculated to all conditions occur in operation and other loads based on ASME B31.1 standard. The distance between supports must be adjusted with the according to pipe span analysis result of span pipe.

8.2.8

Valve All chosen valves and standards of manufacturing and testing design must meet ASME B31.1 requirements of Power Piping. For production facility design, valve class is divided into several levels, namely 900 lb class for wellhead to throttle valve, 300 lb class for valve of steam pipe line downstream to interface. All valves for steam line must use hot insulation to protect operationaloperating activities occur around valve. For developingexpanding production facility, it should use same specification with Unit 4 which aims at minimizing stock that is prepared to interchange.

8.2.9

Flange All flanges must follow the standard of ANSI B16.5. If there is a jointJoint between the flange and different materials, configuration of isolationinsulation joint must be applied to avoid galvanic corrosion.

8.2.10 Thermal IsolationInsulation

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 20 of 31

Designing isolation thermalThermal insulation design should considers thingsfactor as follows: SurroundEnvironment temperature and also minimizingminimize heat loss on operationalat operating condition. ConservationProtection to living things and surround environment. The ease of application/ changemaitenance if necessary, for instance in piping of wellhead, valve and instrumentation. 8.2.11 Drain Pot and Steam Trap Calculation, capacity design, number ofquantity, type and drain pot placement and steam trap are conductedspecified based on condensation formed inside the pipe. The recommended type of steam trap is inverted bucket or thermodynamic steam trap. 8.2.12 Particle and Condensate Disposal Particle and condensate collection and disposal inside the equipments occur when: a. WhenDuring steam blowing b. During pipe line heating c. During pipe line maintenance d. During full operationaloperating condition e. Steam trap /drain on a certainspecified points. 8.2.13 Overload Protection towards Overload Rupture disc will be applied inon steam pipe linepipeline from wellhead to tie in point to avoid effect caused by overpressure. 8.2.14 Thermal Expansion Expansion loop is used to accommodate pipe expansion. Application of expansion loop will be adjusted based on local area condition and is sought as efficient as possible without causing significant pressure reduction. The shape of expansion loop is horizontal and vertical depends on the area and technical things onfactor at field. 8.2.15 Pipe Stress Analysis of Piping Voltage Piping is designed according to ASME B.31.1 Power Piping Code. A complete piping system is analyzed and designed on some points:

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1. Load and Force on Piping System a. Load Effect According to load effect combined with the load and force will cause changes on pipe design such as: i. Live Load Live Load consists of flowedflowing fluids. ii. Dead Load Dead Load consists of pipe component pipe, valve, isolation and other permanent loads. iii. Test Load Test Load consists of load of testing fluid tester. b. Pressure Effect For the need of voltagestress analysis, design pressure is assumed as internal pressure effect occursapplied on the pipe system. c. Thermal Expansion Piping system design also considers moment and force of thermal expansion and contraction occur. d. Occasional Load i. Wind

Piping design includes wind load is based on International Standard SNI-181976 or using UBC 1997. Basic wind speed used in designingdesign is the biggesthighest wind speed. ii. Earthquake Earthquake effect is also included pipe and support design. 2. Combination of Load and Force Combination from loads and force for pipe system design is seen in Table 8.1 as follows:
Tabel 8.1 Combination of Load and Force
Load & Force Efek Berat Efek Internal Efek Dinamis Efek Ekspansi Tegangan Ijin

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 22 of 31

Stress

Live

Dead

Test

pressure

Angin

Gempa

Panas Sh Sh Sh

Sustain Load Occasion Stress Exspansion Thermal

k Sh k Sh Sa = f(1,25Sc + 0,25 Sh) Sa+Sh

Keterangan: Sh Sc K : Basic material allowable stress pada temperatur panas maksimumat maximum temperature : Basic material allowable stress pada temperatur dingin minimumat miniimum temperature : 1.2, Beban angin dan gempa terjadi kurang dariwind load and earthquake less than 1 % selama periode

operasiat one operation period F : Factor pengurangan range stress = 1,0

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 23 of 31

8.3

Mechanical design Criteria All mechanical equipment for production facility in Kamojang Geothermal Area must be designed based on the international standard.

8.3.1

Equipment Strength Design Design pressure is minimal 1.5 x operating pressure and must already accommodate factor of abrasion, corrosion, vibration, chemical content of fluid, temperature, pressure and others that refer to the applied code and standard.

8.3.2

Static Equipment Static equipments in this project are silencer, production separator, demister, and manifold. Production Separator and Demister used to drain dampwet steam before it is expanded to the steam turbine. Silencer is used for flashing condensate to the atmosphere pressure. Calculations that generally conducted in designing separator are as follows: 1. Dimensional sizing (diameter, tangent to tangent length) separator 2. Nozzle sizing nozzle 3. calculationCcalculation of thickness of shellvessel wall, head, and schedule of nozzle pipe 4. head type determination 5. rating and type of flange nozzle 6. MAWP determination 7. Calculation of width of reinforcing pad, also 8. Calculation of the weight of separator. Design criteria that will be used for static equipment design in this project refers to the standard of ASME Boiler and Pressure Vessel Code (BPVC) Sect. VIII.

8.3.2.1 Production Separator Separator is needed in process of early separating of steam phase and liquid phase (condensate). Type of separator used to process is vertical separator. ThingsFactors to considerbe concidered in designing steam separator are:

Expected input and output fluid capacity. Type of working fluid processed by separator

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 24 of 31

OperationalOperating pressure and temperature Available space Entrance access for maintenance (Manway/ manhole)

8.3.2.2 Demister Demister is used after separator to separate the steam from condensate. Demister uses web wire mesh that has web so that it can absorbstrain smaller condensate with the smaller particle. ThingsFactor to considerbe concidered in designing demister are:

Expected input and output fluid capacity. OperationalOperating pressure and temperature Available space Web material, not easily abraded and enter into turbine. Entrance access for maintenance (Manway/ manhole)

8.3.2.3 Silencer/Atmospheric Separator Silencer/Atmospheric separator is a separator with atmosphere pressure used for flashing condensate from pipeline, production separator, and demister. Fluid from silencer then flowed to the pond. 8.3.2.4 Manifold Manifold is basically a pipe used for dividing fluid flow. Condition of manifold design more less same with the one discussed in chapter 8.2. Manifold must be designed in such way that it does not cause flow pattern slug flow that can destroy pipe network. Manifold designs must refer to ASME B31.1 Power Piping Code.

8.4

Instrumentation Design Criteria

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 25 of 31

The applied instrumentation system is designed in such way so that it meets the needscriteria for monitoring and controlling process variable and equipment and pipe protection. Instrumentation system has to meet these needs: Pipe protection towards overpressure Monitoring and/ or controlling process variable related to pipe and separator line. Working Regulation of Pump and Compressor

Designed control system is adjusted with existing controlled system that is Supervisory Control And Data Acquisition (SCADA). RTU functions at monitoring important process variable on field which is remote from Control Room- such as pressure, temperature, and flow direction on discharge pipe of production well. RTU also functions at controlling. On this FEED, RTU only controls openings of throttle valve. MTU is located in Control Room Existing. MTU functions at collecting data for needs of monitoring in Control Room and giving target to RTU which processing logic and calculating for the needs of controlling. Data from RTU is sent to MTU in a series by standard protocol of industry through fiber optic fiber. 8.4.1 Pipe Protection towards Overpressure Protection towards overpressure using Pressure Relief Valve (PRV) and Rupture Disc (RD). PRV is used as a main protecting system towards overpressure whereas RD is as secondary protection. Type selection of safety relief device and its application are adjusted to location and equipment needs to protect. On supplementing utility such as air instrument system, it is only PRV used as safety relief devices. Configuration and application of RD and / or PRV refer to ASME Boiler and Pressure Vessel Code, Section VIIl, Div.1. Configuration of set pressure PRV and burst pressure RD are as follows:

1. If one RD or PRV is used as protecting equipment then related-burst pressure or set pressure safety relief device are smaller than or equals MAWP (Maximum Allowable Working Pressure) system. For that case, it is chosen set pressure or burst pressure that is smaller than MAWP.

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 26 of 31

2. If one RD or PRV is used as protecting equipment then related-burst pressure or set pressure safety relief device are as follows: a. First burst pressure RD is set equally or smaller than MAWP whereas second burst pressure RD is set 110% MWAP. b. First set of pressure PRV is set equally or smaller than MAWP whereas second set pressure PRV is set 110% MAWP. 3. If PRV and RD are used together as protecting system equipment then PRV must be applied as the main protection and RD as the secondary. Set pressure PRV must be equal or smaller than MAWP system. Burst pressure RD is set on 100% MAWP system. 8.4.2 Monitoring Condition of Operation Equipment Condition of operation equipment is monitored in local and also remote area from Control Room. Monitoring condition of operation equipment is using measurement instruments as follows: On well and pipe linepipeline a. Wellhead: Pressure Gauge, Pressure Transmitter. b. Production Pipe: Temperature Transmitter c. Cluster: Pressure Relief Device, Rupture Disc, Pressure and Temperature Indicator. d. Main Pipe: Pressure Relief Device, Rupture Disc, Pressure and Temperature Indicator. 8.5 8.5.1 CRITERIA OF DESIGNING CIVIL WORK AND STRUCTURE General Civil work covers site preparation, support structure, foundation, crossing bridge among pipes, platform well, drainage system, landscaping, etc. 8.5.2 Building of Civil Service Types of building construction are as follows: House Panel: foundation of river stone, brick wall, wave-asbestos roof. Pump shelter, air compressor, and transformer: profile steel frame, brick and zinc-alum wall, zinc-alum roof.

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 27 of 31

All foundations of mechanic equipment such as basin tap, silencer, also included pipe support adjusted by the result of soil test/ geotechnical.

8.5.3

Land Clearing Every area which passed by pipelines and production facility must be exempted for construction needs. All obstacles such as trees, bushes and buildings are exempted or moved by obeying these rules: Minimizing land acquisition Minimizing destruction in working area and conservation forest Piping system protection Landscaping

8.5.4

Earthwork Land cutting and filling must be adjusted by construction of pipe bends and other structures. Land cutting is done if an area needs to cut for construction or repairing and filling working area. Land cutting and filling should avoid erosion in future.

8.5.5

Soil Retaining Wall Type of soil retaining wall used is gabion strengthened with geo-synthetic sheet and concrete at the base. This gabion will be put in CLUSTER C, CLUSTER A and some certain pipelines areas.

8.5.6

Support and Foundation Structure Support and foundation structure are designed to retain dead load such as pipe weight and live load caused by expansion of heat, wind and earthquake effect. The foundations chosen on certain cases are: a. Steel pillar drive b. Concrete pillar drive c. Short hole of steel pillar d. Short hole of concrete pillar

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 28 of 31

e. Short hole to strengthen concrete pillar f. Spread footing

g. All structures protected by painting The used code and standard refer to international standard. The used code is in the previous part. Basic materials used for foundation are: Structural Steel ASTM A36 or its kind Concrete Using concrete with compressive strength proven by cylinder test on 28 days before casting on field (Structural Steel ASTM A36), except particularly stated on SNI-032847-2002 "Tatacara Perencanaan Struktur Beton untuk Bangunan Gedung", are as follows: K-125 (fc' = 10 MPa), K-250 (fc' = 21 MPa), K-500 (fc' = 42 MPa), cement type I for concrete of lean floor cement type I for general concrete cement type I for pre tense and PC pile

Load and force have to be included in calculation for designing support and foundation structure: Dead load Dead load is the weight of structure and foundation and all permanent materials. Live load a. Vertical load Live load consists of weight of fluid that is transported and also wellhead movement. b. Lateral load This load consists of friction force and resistance load. The meant friction force is the one caused by movement and expansion of heat and contraction, the

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friction factor= 0.3 max. Resistance load is the load caused by internal pressure and load of heat expansion on loop reaction. c. Test or load of fluid cleaner Test or load of fluid cleaner consists of load and fluid cleaner. d. Wind load Wind load is based on the Indonesian Standard that is SNI-18-1976 or UBC. Basic wind speed used in this design is 27 knots. e. Earthquake effect Method of coefficient of seismic is used also for design preparations. The calculation is based on UBC. f. Combination of load and force The calculation of combination between load and force must be conducted when designing. 8.5.7 Box Culvert Box culvert in facility construction for Kamojang Geothermal Area will be designed that pipelines will pass the road and road access for surround residents. 8.5.8 Road Access The road access of the new pipe inspection for operation and maintenance is planned to construct by using combination of coarse aggregate and fine aggregate materials. Road planning must also cover planning of surface drainage for protecting road structure from destruction caused by rainwater. 8.5.9 Drainage System Rainwater drainage system is designed for preventing of erosion on pipe blends and road. drainage system is also designed open in Kamojangs wells area. Drainage work consists of arrangement of drainage channels, pipes under the road or culvert and other related structures as follows: a. Intensity of rainwater

PEMBUATAN FRONT END ENGINEERING DESIGN (FEED) TOTAL PROJECT KAMOJANG UNIT 5 (1 x 30 MW) - JAWA BARAT TITLE DESIGN BASIS DOCUMENT NUMBER KMJ5-FC-PR-DTN-001 PAGE 30 of 31

Drainage system is measured by dividing the maximum intensity of rainwater on 100m/h. b. Coefficient Run-off, C (based on Schwab et al, 1981) refers to this below table:
Table 8.2 Run-off Coefficient C
Type of Drainage Area Business: Downtown area Neighborhood areas Residential: Single family areas Multi-unit detached Multi-units attached Suburban Apartement dwelling areas Industrials: Light areas Heavy areas Parks, cemetries Playgrounds Railroad-yards areas Unimproved areas Streets: Asphaltie Concrete Brick Drives dan walkes Roofs Lawns: Sdany soil flat, 2% Sdany soil evg 2-7% Sdany soil, step 7% 0.05-0.10 0.10-0.15 0.15-0.20 0.70-0.95 0.80-0.95 0.70-0.85 0.75-0.85 0.75-0.95 0.50-0.80 0.60-0.90 0.10-0.25 0.20-0.35 0.20-0.40 0.10-0.30 0.30-0.50 0.40-0.60 0.60-0.75 0.25-0.40 0.50-0.70 0.70-0.95 0.50-0.70 Run-off Coeff. C

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Type of Drainage Area Heavy soil, flat 2% Heavy soil evg 2-7% Heavy soil, step 7%

Run-off Coeff. C 0.13-0.17 0.18-0.22 0.25-0.33

8.5.10 Landscaping and Repairing of Kamojangs The work of area repairing and development are directly conducted based on these rules: a. Kamojangs well are designed by good aesthetic b. Construction from surround soil barrier c. Using combination of coarse aggregate and fine aggregate materials for supporting serviceability aspect and convenience in Kamojang Well area. d. The barriers of Kamojang wells area are using concrete.

8.5.11 ROW Pipeline The needed ROW pipeline will be optimized from land availability and also for minimizing the effect of destruction towards conservative forest area.