POWER October 2012 - 44

TOP PLANTS
oping countries throughout the world. The
expanded plant generates approximately 8.5
billion kWh/year of electricity, " he said.
Expansion Project Profile
Located on a 150-hectare plot, Units 3 and 4
required a total investment of approximately
$2.08 billion from the Japan Bank for International
Cooperation and other commercial
banks (Figure 1).
Sumitomo Corp.'s erection division performed
mechanical and electrical construction
for all Unit 3 and 4 areas, except the
boiler island. Other major contractors for
the expansion project included Mitsubishi
Heavy Industries Ltd. (furnished and erected
the boiler island) and Mitsui Engineering and
Shipbuilding Co., Ltd. (civil construction).
The B&V-supplied equipment was erected
by Sumitomo and also subcontracted to an Indonesia
national contractor with Japanese supervision.
Johnson noted that " China-sourced
equipment supplied by B&V was not erected
by a Chinese contractor, " which proved to be a
challenge. Toshiba Corp. Power Systems Co.,
as a separate entity working for Sumitomo,
provided the turbine island's equipment, including
the turbine, condenser, transformers,
and distributed control system (DCS).
1. From the ground up. Units 3 and
4 at Tanjung Jati Electric Generating Station
in Indonesia are shown during the initial construction
phase. Now that the two younger
sibling units are operational, they share the
workload with Units 1 and 2. The 2,640-MW
coal-fired power plant provides approximately
12% of the electricity available on the JavaBali
grid. Courtesy: Black & Veatch
Despite the fact that multiple entities
were involved in procurement, supply, construction,
and commissioning, all construction
with commissioning occurred within
the time available and met all project milestone
dates, Johnson said.
Promoting Top Environmental
Performance
The design of Tanjung Jati Units 3 and 4
includes a flue gas desulfurization system
and electrostatic precipitators to reduce air
emissions. Johnson explained that, " together
with the equipment installed at Units 1
and 2, the project includes some of the first
examples of modernized air quality control
technology at a major power plant in Asia. "
Indonesian law requires that the boiler
island's environmental control equipment at
Units 3 and 4 (supplied by B&V) meet sulfur
dioxide (SO2) emission limits of 300 mg/Nm3
and total particulate matter emission limits of
50 mg/Nm3 at the stack outlet. In addition,
Indonesian environmental law required limestone
consumption guarantees.
" The Chinese-supplied environmental
control equipment, as demonstrated during
performance testing, was able to achieve
SO2 and particulate matter emission values
significantly lower than these limits, " Johnson
said. " Limestone consumption was also
significantly lower than required. "
Building at an Operating Facility
Original planners of the Tanjung Jati power
plant designed the site to accommodate the
addition of two more units, and Units 3 and
4 are essentially independent of the first
two. For example, the two new units have a
separate control room.
Johnson said that B&V's scope for the
project was engineering and procurement,
plus commissioning for the boiler island
auxiliary equipment package. B&V was not
directly responsible for construction. However,
coordinating the design and equipment
supply to interface with an operating facility
presented challenges. B&V's design had to
ensure that there would be minimal impact
to Units 1 and 2's operations during construction
and commissioning. This required
consideration of the existing plant operation
and maintenance requirements during the
construction phase.
Johnson explained that the coal-handling
system design presented a complex challenge
because Unit 3 and 4's coal storage area is on
the west side of the site, although Units 3 and
4 are located east of Units 1 and 2. Therefore,
coal conveyors were designed to route coal
across Units 1 and 2 to reach Units 3 and 4.
The project team used a pipe conveyor to
transport coal across the existing facility for
44
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minimal impact on the operation of existing
units during construction and commissioning
of the coal-conveying system. Johnson
said, " The pipe conveyor design is such that
the conveyor can make a directional change
without the addition of a transfer tower and
additional conveyors. Yard piping was also
routed in such a way that no impact occurred
to the existing facility. "
Successful Integration of Chinese
Equipment
A significant project hurdle involved using
Chinese equipment for the boiler island
auxiliary equipment supply. Johnson said
that this challenge was " amplified " by the
fact that the China-sourced equipment was
erected by an Indonesian erection contractor
who, in turn, was supervised by Japanese
contractors. In the past, Chinese contractors
who were most familiar with the Chinesesourced
equipment were in charge of erecting
this equipment during construction
projects.
Johnson explained that prior to the Tanjung
Jati expansion project the B&V project
team spent several years screening and
prequalifying Chinese equipment suppliers.
Specifically, they focused on selecting the
most qualified Chinese companies based on
their ability to meet the quality, schedule,
and cost requirements, and their demonstrated
track record of meeting performance
guarantees. During the expansion project,
the B&V project team closely monitored the
Chinese equipment suppliers' performance
through extensive document reviews and applying
a rigorous quality review program.
One example of the challenges the B&V
project team members faced was when they
had to integrate some Chinese equipment
control requirements with a Japanesesupplied
DCS. Johnson said that resolving
this problem required close communication
and coordination to ensure all the Chinese
equipment's control needs were met and
integrated into the overall plant DCS control
requirements.
" The utilization of Chinese-sourced
equipment and materials built to Chinese
codes and standards for the boiler island
auxiliary equipment and then integrating
it with non-Chinese equipment supplied
by others was quite challenging, " Johnson
said. To overcome such obstacles, the Chinese
equipment had to be delivered on time,
erected by others, and then commissioned
by B&V to support all project milestones.
Fortunately, the Chinese equipment met all
required performance guarantees by a significant
margin, according to Johnson. ■
-Angela Neville, JD is POWER's
senior editor
POWER | October 2012
http://www.powermag.com
POWER October 2012

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