SURALAYA GBU as Part of PT.IP
UP Perak Grati
SPP & CCGT 864 MW
Jakarta
Bandung Surabaya
Semarang
Grati
Banjarnegara
UP Suralaya Steam Coal PP
3,400 MW (+40 MW)
UP Priok GT, CCGT & Diesel PP
1,446 MW
UP Semarang CCGT & SPP 1,469 MW
Jawa-Bali Installed Capacity = 18,696 MW
PT IP Total Installed Capacity = 8,978 MW
(+40MW)
UP Saguling Hydro
797 MW
UP Kamojang Geothermal
360 MW
UP Mrica Hydro
306 MW
UP Bali GT & Diesel
335 MW
3
CONSTRUCTION PERIOD
4
NO. ITEM Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7
1 Construction 1980 1984 1994
2 First Firing 26.05.84 11.03.85 28.05.88 04.02.89 22.06.96 26.01.97 14.07.97
3 Synchronize 24.08.84 11.06.85 25.08.88 22.04.89 16.12.96 26.03.97 19.09.97
4 Commercial Operation
04.04.85 26.03.86 06.02.89 06.11.89 25.06.97 11.09.97 19.12.97
5
Retrofit (JBIC) dan Uprating (20MW #1-2)
15 Jul 11 s/d
11 des 11 (commerci
al Operation
)
29 okt 10 s/d
08 Jul 11 (commerc
ial OP)
1 nov 09 s/d
21 Jan 10 (commerc
ial OP)
9 Apr 10 s/d
17 Mei 10 (commerc
ial OP)
- - -
5
PLTU SURALAYA
PLTU M. KARANG PLT(G)U PRIOK
PLTGU M. TAWAR
PLTA CIRATA PLT(G)U SEMARANG
PLTGU GRESIK
PLTU PAITON
PLTG SUNYARAGI
PLTA SAGULING
PLTP KAMOJANG
CILEGON
GANDUL
CILBINONG
BDG. SEL. M. RANCAN
UNGARAN
GRESIK
KRIAN
PLTD PESANGGARAN
PLTG GILIMANUK
PLTG PEMARON
BEKASI
Power Plant System Sub Control System Main Control (Load Dispatcher)
500 KV JAVA-BALI SYSTEM
MAIN EQUIPMENT SPECIFICATION
7
UNIT CAPACITY : - Unit 1-4 : 4 X 400 MW - Unit 5-7 : 3 X 600 MW • MAIN CONTROL SYSTEM
Unit 1-4 : DCS YOKOGAWA Unit 5-7 : DCIS BAILEY
• STEAM TURBINE Manufacturer : Mitsubishi Heavy Industries • GENERATOR Manufacturer : Mitsubishi Electric Company • BOILER Manufacturer : Babcock & Wilcox • COAL HANDLING SYSTEM Manufacturer : - Samsung - Flender
8
ORGANIZATION
PT. PLN (Persero)
GENERATING UNIT
(Unit Induk pembangkitan)
LOAD TRANSMISS
ION AND CONTROL
UNIT (Unit Induk Penyaluran
dan pengaturan
Beban)
PT. Pembangkitan
Jawa Bali PT. PJB
PT. Indonesia
Power
SURALAYA CFPP PRIOK (COMBINE CYCLE PP)
SAGULING (HYDRO PP)
KAMOJANG (GEOTHERMAL PP)
MRICA (HYDRO PP)
SEMARANG (COMBINE CYCLE PP)
PERAK GRATI (COMBINE CYCLE PP) BALI (GT AND DIESEL PP)
AREA UNIT (Unit Induk Wilayah)
SERVICES UNIT (Unit Jasa-Jasa)
DISTRIBUTION UNIT
(Unit Induk Distribusi)
DEVELOPMENT UNIT
(Unit Induk Pengembangan)
OTHERS (lain-lain)
ORGANIZATION : Suralaya
GENERAL MANAGER
AUDIT SPECIALIST
DEPUTY GENERAL MANAGER
OPERATION & MAINTENANCE
DEPUTY GENERAL MANAGER
PRIMARY ENERGY
DEPUTY GENERAL MANAGER
GENERAL AFFAIR
HSE, QUALITY & ENVIRONMENT MANAGER
OPERATION MANAGER UNIT 1-4
MAINTENANCE MANAGER UNIT 5-7
ENGINEERING & ASSET MANAGEMENT MANAGER
LOGISTIC MANAGER
HR & PR MANAGER
IT & FINANCE MANAGER
PLANNING & INVENTORY OF PRIMARY ENERGY MANAGER
ASH HANDLING MANAGER
COAL HANDLING MANAGER
MAINTENANCE MANAGER UNIT 1-4
OPERATION MANAGER UNIT 5-7
SPECIALIST
LAW & CONTRACT SPECIALIST
CIVIL MANAGER
Suralaya Contribution to JAMALI (Jawa-Madura-Bali Network)
YEAR PRODUCTION OF SURALAYA PRODUCTION OF INDONESIA POWER
GRID INTERCONECTION NEEDS
2012 22.351 GWh 39.449 GWh 145.545 GWh
11
Market Share of Indonesia Power = 27 % Peak Load of Jamali Grid = 21,600 MW
OTHER POWER PLANT PRODUCTION
13
PRODUCTION
2007 2008 2009 2010 2011 2012PRODUCTION [GWH] U1-4 11,836 11,410 10,081 10,017 9,688 9,295PRODUCTION [GWH] U5-7 11,335 10,230 12,570 13,039 13,715 13,055PRODUCTION [GWH] U1-7 23,171 21,640 22,651 23,057 23,403 22,350
-
5,000
10,000
15,000
20,000
25,000
14
SALES
2007 2008 2009 2010 2011 2012SALES [GWH] U1-4 11,039 10,705 9,597 9,421 9,060 8,671SALES [GWH] U5-7 10,901 9,693 11,756 12,333 13,079 12,449SALES [GWH] U1-7 21,941 20,398 21,353 21,754 22,139 21,120
-
5,000
10,000
15,000
20,000
25,000
15
COAL CONSUMPTION
2007 2008 2009 2010 2011 2012COAL CONSUMPTION [mil Ton] U1-4 6,389 6,317 5,257 5,127 4,902 4,849COAL CONSUMPTION [mil Ton] U5-7 6,059 5,307 6,375 6,616 6,752 6,224COAL CONSUMPTION [mil Ton] U1-7 12,448 11,624 11,632 11,744 11,653 11,073
-
2,000
4,000
6,000
8,000
10,000
12,000
14,000
Subject : Unit 4
21
NO. ITEM TIMELINE
1 Construction 1984
2 First Firing 04 February 1989
3 Synchronize 22 April 1989
4 Commercial Operation 06 November 1989
4 Partially Retubing 23 May – 4 August 2009
5 Retrofit (JBIC) : Control System modification from Panel to Computer Based
9 April 2010 - 17 May 2010 (commercial OP)
2009 2010 2011 2012E A F 67.09 84.00 94.49 80.46
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
%
E A F
2009 2010 2011 2012EFOR 16.13 6.14 3.47 4.20
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
16.00
18.00
%
EFOR
22
Year Inspection Periodic Duration (Day)
2009 Serious Inspection & Retubing Boiler 73 2010 Retrofit DCIS Program JBIC 38 2012 Mean Inspection 25
2009 EFOR high cause by Boiler leak and Boiler partial retubing. 2010 EFOR decrease cause we had done retrofit DCIS to minimize EFOR and boiler leak
Subject : Unit 4
2009 2010 2011 2012THERMAL EFF 33.03 33.02 32.95 31.52
10.00
15.00
20.00
25.00
30.00
35.00
%
THERMAL EFFICIENCY
2009 2010 2011 2012SdOF 19.29 9.00 5.00 3.00
0.00
5.00
10.00
15.00
20.00
25.00
X
SdOF
23
Thermal Efficiency Timeline activities : • Improve Coal Calorific Value • 2009 : Partial Boiler Retubing and Air Heater Outage • 2010 : Retrofit System Control DCIS • 2011 : Replace motor coal feeder using VFD motor • 2012 : Air Heater Outage • 2012 : Low Load Operation (Efficiency decreased)
Subject : Unit 4
LATEST OUTAGE PERFORMANCE TEST DATA
24
NO DESCRIPTION Engine Unit
PRE OUTAGE POST OUTAGE
DIFFERENTIAL DIFFERENTIATI
ON PERCENTAGE
100 % MCR 100 % MCR
30 Des 2011 11 Mei 2012
1 GROSS GENERATOR OUTPUT MW 395,36 398,82 3,46 0,88%
2 NETT GENERATOR OUTPUT MW 372,45 375,06 2,61 0,70%
3 TURBINE HEAT RATE kCal/kWh 2.003,65 1.950,16 -53,49 -2,67%
4 TURBINE EFFICIENCY % 42,92 44,10 1,18 2,74%
5 BOILER EFFICIENCY (Heat Loss) % 83,64 82,43 -1,21 -1,45%
6 AUXILIARY POWER % 5,79 5,96 0,17 2,94%
7 GROSS PLANT HEAT RATE (Heat Loss) kCal/kWh 2.395,58 2.365,77 -29,81 -1,24%
8 NETT PLANT HEAT RATE (Heat Loss) kCal/kWh 2.542,92 2.515,69 -27,23 -1,07%
9 PLANT EFFICIENCY (Heat Loss) % 35,90 36,35 0,45 1,25%
10 NET PLANT EFFICIENCY (Heat Loss) % 33,82 34,19 0,37 1,09%
11 COAL CALORIFIC VALUE kCal/kg 5.276,00 4.422,00 -854,00 -16,19%
12 SPECIFIC FUEL CONSUMPTION (Heat Loss) 0,45 0,53 0,08 17,78%
13 Condenser Cleanliness Factor % 93,26 89,61 -3,65 -3,91%
Coal Supply
• Suralaya coal-fired power plant was built based on coal specification from Bukit Asam (Sumatera Island), which categorized as sub-bituminous coal rank
• Another Supply from : – PT. Berau Coal (East Kalimantan) – PT. Kideco Jaya Agung (East Kalimantan) – PT. Adaro Indonesia (South Kalimantan) – KP from Kalimantan (South Kalimantan) – KP from Sumatera (Lahat, Bengkulu, Jambi)
• PT. Indonesia Power Coal Stock Policy : – The quantity of coal in the stock pile is between
20 – 35 day coal consumption – Equal to 660.000 – 1.155.000 MT (average of coal
consumption is 33.000 MT/Day) Note : – Coal Stockyard Capacity is about 21 ha (volume about
1.500.000 MT )
Coal Stock Policy
COAL SPECIFICATION
29
PARAMETER
Spesifikasi Contract Rejection Level Contract Rejection Level Contract Rejection Level Contract Rejection Level Contract Rejection Level
Calorific Value 5.100 kcal/kg> 7.000 kcal/kg - <4.700 kcal/kg4,700 - 5,200 > 4.700 kcal/kg 4,700 - 5,100 < 4.700 kcal/kg 4.800 kcal/kg >4.800 Kcal/kg 5.000 kcal/kg <4.800 Kcal/kg
Total Moisture max 28,00 > 31 % maks 30 > 32,5% maks 32 > 30 % 30% > 30 % ≤ 28 % > 30 %
Ash Content max 8,00 > 13 % maks 8 > 10% maks 8 > 8 % 8% > 8% ≤ 6 % > 8%
Sulfur Content max 0,80 > 1,2 % maks 1,05 > 1,1% maks 1,00 > 1,00 % 1% > 1% ≤ 0.80 % > 1%
Nitrogen Content 0.70 - 1.10 > 1,1% - > 1,2% - > 1,1% 1,10% >1,1% ≤ 1 % >1%
Ash Fusion Temperature 1010 - 1500 < 1.200 c Min. 1010 > 1.010 Min. 1010 < 1.010 c 1150c < 1,150c 1150c < 1,150c
HGI 55 - 64 < 48 % Min. 48 > 48% Min. 48 < 48 50% < 50 50-60 < 50 atau > 60
Slagging Index - - - - > medium > medium ≤ medium > medium
Fouling Index - - - - > medium > medium ≤ medium > medium
Coal Size 2.38 mm max 45,00 > 45 % maks 32,5 > 32,5% maks 35 > 35% 25% > 25% ≤ 20 > 25%
Coal Size 50/70 mm 32 min 97 % > 3 % maks 7,5 > 7,5% maks 10 > 10% 3% > 3% ≤ 2 > 5%
ADCPT. BA PT. BERAU PT. KIDECO MID CONTRACT
Hopper “K” & BF.20/21,
BF 26/27,MS.13/14 Hopper “L” Hopper “M”
RH. “D” &
BF.09/10
Plant Distribute Hopper & BF 501A/B, BF 601A/B, BF 701A/B
COAL BUNKER COAL BUNKER Unit 7 Unit 5 Unit 6 Unit 4 Unit 2 Unit 3 Unit 1
Coal stock area
SC. 22
SC. 25
SC. 24
SC. 23
BC. 26
BC. 27 BC. 21
BC. 20
SC.30
SC. 31 SC. 29
SC. 28
ST / RE 2
Telescopic Chute
Belt Weigher
BC. 502B
BC. 502A
BC. 702B
BC. 702A
BC. 602B
BC. 602A
BC. 02
BC. 17
BC. 16
BC. 15 BC. 11
BC. 12
BC
. 14
BC
. 13
BC. 703A
BC. 703B
Coal Ship
Coal Ship
COAL HANDLING SYSTEM SURALAYA POWER PLANT
UNITS 1 ~ 7 JH. “H”
JH. “G” &
HG36/37, HG40/02
JH.”B” &
C S. & MS.03/04
JH. “J” &
HG. A/B
JH.”F”
JH. ”C” &
MCC, BF.11/12, MS.09/10
JH. “E” &
Coal Sampling
CHCR
Telescopic Chute
M/H. & BF.32/33
RH.”A” & BF.03/04
BS.34/35
BS.02
BS.36/37 Alat Berat
TL 02