Papers # 2016 Berlin

The Star Energy Wayang Windu geothermal plant in Java, Indonesia, generates up to 227MW of electricity using the natural steam from deep beneath the earth. Once the steam has cooled and condensed it is returned to the underground reservoir through condensate pipelines and injection wells. By 2012 the existing steel pipeline was badly corroded due to the aggressive nature of the condensate and Star Energy identified PE100 as the best replacement material. This paper provides a background to the project and describes the materials selection, design and installation processes which Star Energy, their contractors and suppliers went through before concluding with some of the lessons that they learnt whilst undertaking the project.

The Star Energy Wayang Windu geothermal plant in Java, Indonesia, was completed in 1999 and today generates up to 227MW of electricity using steam from natural hot fluids deep beneath the earth. Once the steam has generated electricity using steam turbines it is cooled and condensed before being returned to the underground reservoir through a condensate pipeline and injection wells. Unfortunately, the condensate is very corrosive and its temperature can reach 50oC. In addition, the pipeline is laid in a hilly region and sections flow under gravity, which makes them prone to erosion. 

After nearly 15 years of operation the condensate pipeline at Wayang Windu had been extensively repaired and was ready to be replaced. Rather than replacing it with another steel pipeline, the Star Energy decided to examine other materials that did not suffer from corrosion. When the power plant was originally constructed, engineers had no option but to use steel, but over the last decade the availability of alternative pipe systems has greatly increased across South East Asia.

Having reviewed the options the Star Energy team decided to install a single 400mm OD SDR 11 PE100 above ground pipeline in order to evaluate the performance of this material in a new application, together with identifying the practical challenges in constructing a pipeline in what, to them, was a new material.

The paper describes the above in detail, together with the design and installation process which Star Energy, their contractors and suppliers went through. It also discusses some of the lessons that they learnt through undertaking the project.

Related keywords : PE100, geothermal, condensate, power plant.
Please note that the whole article content is available on PPCA website onlySource : 2016 Berlin

Related papers


Author(s) : Jacob John, Andrew J. Ortquist, Mats Thunwall, Patrik A. Roseen 2018 Las-Vegas

This study investigates production of crosslinked polyethylene (PEX) pipes using a resin obtained from a renewable resource via twin-screw extruder technology. PEX pipes were extruded using petroleum-based and renewable high-density polyethylene (HDPE) for comparison. Testing using relevant ASTM standards on the new...


Author(s) : Andrew Wedgner, Muhammad Qasim, Arsenio Sembrano 2018 Las-Vegas

Developments in material and pipe extrusion technology now enable converters to produce PE100 solid wall pipes of up to 2,800mm OD, but the use of such large diameters has been limited to industrial applications. This is now starting to change with water transmission pipelines of up to 1400mm OD being laid in the UAE...

High Quality PE Pipe Systems and Local Partnerships – Key Elements in Undertaking Sustainable Development Project

Author(s) : Andrew Wedgner, Keith Etherington, Saad Idrees 2014 Chicago

Often plastics get a bad press due to poor quality products and the mishandling of plastic waste. But when high quality pipe systems are employed, they can significantly improve the lives of people living in poor communities around the world. The success and sustainability of such projects is also often down to...

The Introduction of High Stress Crack Resistant PE100 and its use in several demanding projects in Asia and the Middle East

Author(s) : Wedgner Andrew 2012 Barcelona

PE100RC, HSCR, Stress, Asia, Middle East The rapid development of Asia and the Middle East, has called for an equally rapid expansion of their infrastructure networks. At the same time, increasing urbanization has led to an increased use of trenchless technology for the installation, replacement and renovation of...

Members of the Association

BOREALISBOROUGEINEOS O&PIRPCKorea Petrochemical IND. Co., LTDLyondellBasellPetroChina Dushanzi Petrochemical CompanyPRIME POLYMERSABICSCG Chemicals & Thai PolyethyleneSinopecTASNEE