The Retrofit SUDEG project was carried out at the Tambak Lorok Gas & Steam Power Plant for the end-user PT PLN Indonesia Power - UBP Semarang. This project focused on upgrading and modernizing the Startup Diesel Engine Generator (SUDEG) control system to improve operational reliability, monitoring capability, and overall system performance.

The scope of work included retrofitting the existing engine control system from Wartsila to GE Nexus Control, replacing existing field wiring connected to the DAQ system with a new integration to the DCS panel located in the Central Control Room (CCR), and upgrading several critical systems from analog to digital technology. These upgrades covered the governor speed control, Automatic Voltage Regulator (AVR), and generator protection system. In addition, comprehensive testing and commissioning activities were performed to ensure the entire system operated safely and efficiently according to operational standards.

One of the major challenges during this project was the critical role of the power plant in supporting electricity supply for Karimunjawa Island, especially considering its importance as a tourism destination. Because of this, the project had to be completed within a strict timeline to minimize operational disruption. Another challenge was the outdated condition of the engine and the limited availability of technical documentation, requiring the engineering team to perform re-engineering and redesign activities based on available data and user descriptions.

Through this retrofit and upgrade project, the power plant gained a more reliable and modern digital control system capable of providing improved engine performance monitoring and operational transparency. The migration from analog to digital systems also simplified hardware configuration while delivering more accurate control and protection for both the engine and generator. Furthermore, the implementation of a state-of-the-art Human Machine Interface (HMI) enabled historical data logging, helping engineers perform troubleshooting and identify the root cause of issues more quickly and effectively.

The project was successfully completed, resulting in a fully upgraded and retrofitted control system that supports higher operational efficiency, improved reliability, and better long-term maintainability for the SUDEG unit.

Share