SURALAYA GBU as Part of PT.IP

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2 SURALAYA GBU as Part of PT.IP 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 UP Perak Grati SPP & CCGT 864 MW Jakarta Bandung Semarang Surabaya PT IP Total Installed Capacity = 8,978 MW (+40MW) Banjarnegara Jawa-Bali Installed Capacity = 18,696 MW Grati UP Saguling Hydro 797 MW UP Kamojang Geothermal 360 MW UP Mrica Hydro 306 MW UP Bali GT & Diesel 335 MW 3

3 CONSTRUCTION PERIOD NO. ITEM Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 1 Construction First Firing Synchronize Commercial Operation 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)

4 500 KV JAVA-BALI SYSTEM PLTU M. KARANG PLT(G)U PRIOK PLTU SURALAYA BEKASI PLTGU M. TAWAR CILEGON PLTA CIRATA PLT(G)U SEMARANG PLTG SUNYARAGI PLTGU GRESIK GANDUL GRESIK CILBINONG PLTU PAITON PLTA SAGULING UNGARAN BDG. SEL. M. RANCAN KRIAN PLTG PEMARON PLTP KAMOJANG Power Plant System Sub Control System Main Control (Load Dispatcher) PLTG GILIMANUK PLTD PESANGGARAN 5

5 Lokasi PLTU Suralaya Unit 1 s/d 7 Intake Canal Heat Canal Coal Yard WWTP Station 1-7 Ash Valley 6

6 MAIN EQUIPMENT SPECIFICATION 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 7

7 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 AREA UNIT (Unit Induk Wilayah) SERVICES UNIT (Unit Jasa-Jasa) DISTRIBUTION UNIT (Unit Induk Distribusi) DEVELOPMENT UNIT (Unit Induk Pengembangan) OTHERS (lain-lain) SURALAYA CFPP PRIOK (COMBINE CYCLE PP) MRICA (HYDRO PP) SAGULING (HYDRO PP) SEMARANG (COMBINE CYCLE PP) KAMOJANG (GEOTHERMAL PP) BALI (GT AND DIESEL PP) PERAK GRATI (COMBINE CYCLE PP) 8

8 ORGANIZATION : Suralaya GENERAL MANAGER DEPUTY GENERAL MANAGER OPERATION & MAINTENANCE DEPUTY GENERAL MANAGER GENERAL AFFAIR DEPUTY GENERAL MANAGER PRIMARY ENERGY AUDIT SPECIALIST OPERATION MANAGER UNIT 1-4 OPERATION MANAGER UNIT 5-7 HR & PR MANAGER IT & FINANCE MANAGER PLANNING & INVENTORY OF PRIMARY ENERGY MANAGER COAL HANDLING MANAGER LAW & CONTRACT SPECIALIST HSE, QUALITY & ENVIRONMENT MANAGER MAINTENANCE MANAGER UNIT 1-4 LOGISTIC MANAGER ASH HANDLING MANAGER MAINTENANCE MANAGER UNIT 5-7 CIVIL MANAGER ENGINEERING & ASSET MANAGEMENT MANAGER SPECIALIST

9 HUMAN RESOURCES PROFILE Based on education level Based on age Quantity : 725 person

10 Suralaya Contribution to JAMALI (Jawa-Madura-Bali Network) YEAR PRODUCTION OF SURALAYA PRODUCTION OF INDONESIA POWER GRID INTERCONECTION NEEDS GWh GWh GWh OTHER POWER PLANT PRODUCTION Market Share of Indonesia Power = 27 % Peak Load of Jamali Grid = 21,600 MW 11

11 PRODUCTION SALES COAL CONSUMPTION 12

12 PRODUCTION 25,000 20,000 15,000 10,000 5, PRODUCTION [GWH] U1-4 11,836 11,410 10,081 10,017 9,688 9,295 PRODUCTION [GWH] U5-7 11,335 10,230 12,570 13,039 13,715 13,055 PRODUCTION [GWH] U1-7 23,171 21,640 22,651 23,057 23,403 22,350 13

13 SALES 25,000 20,000 15,000 10,000 5, SALES [GWH] U1-4 11,039 10,705 9,597 9,421 9,060 8,671 SALES [GWH] U5-7 10,901 9,693 11,756 12,333 13,079 12,449 SALES [GWH] U1-7 21,941 20,398 21,353 21,754 22,139 21,120 14

14 COAL CONSUMPTION 14,000 12,000 10,000 8,000 6,000 4,000 2, COAL CONSUMPTION [mil Ton] U1-4 6,389 6,317 5,257 5,127 4,902 4,849 COAL CONSUMPTION [mil Ton] U5-7 6,059 5,307 6,375 6,616 6,752 6,224 COAL CONSUMPTION [mil Ton] U1-7 12,448 11,624 11,632 11,744 11,653 11,073 15

15 EAF CF EFF THERMAL NETTO

16 EFOR SdOF AUX POWER

17 HEAT RATE CALORIFIC VALUE OF COAL CONSUMPTION

18 NETT THERMAL EFFICIENCY ( ) 19

19 Comparison of Suralaya CFPP on GSEP Efficiency Report SURALAYA 20

20 Subject : Unit 4 NO. ITEM TIMELINE 1 Construction First Firing 04 February Synchronize 22 April Commercial Operation 06 November Partially Retubing 23 May 4 August Retrofit (JBIC) : Control System modification from Panel to Computer Based 9 April May 2010 (commercial OP) 21

21 Subject : Unit E A F EFOR % E A F % EFOR Year Inspection Periodic Duration (Day) 2009 Serious Inspection & Retubing Boiler Retrofit DCIS Program JBIC Mean Inspection EFOR high cause by Boiler leak and Boiler partial retubing EFOR decrease cause we had done retrofit DCIS to minimize EFOR and boiler leak 22

22 Subject : Unit SdOF THERMAL EFFICIENCY X % SdOF THERMAL EFF 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) 23

23 LATEST OUTAGE PERFORMANCE TEST DATA NO DESCRIPTION Engine Unit PRE OUTAGE POST OUTAGE 100 % MCR 100 % MCR 30 Des Mei 2012 DIFFERENTIAL DIFFERENTIATI ON PERCENTAGE 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, ,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, ,77-29,81-1,24% 8 NETT PLANT HEAT RATE (Heat Loss) kcal/kwh 2.542, ,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, ,00-854,00-16,19% 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% 24

24 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)

25 Coal Supply Sources Bukit Asam PKP2B KP SURALAYA

26 Suralaya Power Plant Coal Consumption

27 Coal Stock Policy PT. Indonesia Power Coal Stock Policy : The quantity of coal in the stock pile is between day coal consumption Equal to MT (average of coal consumption is MT/Day) Note : Coal Stockyard Capacity is about 21 ha (volume about MT )

28 COAL SPECIFICATION PARAMETER PT. BA PT. BERAU PT. KIDECO MID CONTRACT ADC Spesifikasi Contract Rejection Level Contract Rejection Level Contract Rejection Level Contract Rejection Level Contract Rejection Level Calorific Value kcal/kg > kcal/kg - <4.700 kcal/kg 4,700-5,200 > kcal/kg 4,700-5,100 < kcal/kg kcal/kg >4.800 Kcal/kg 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 > 1,1% - > 1,2% - > 1,1% 1,10% >1,1% 1 % >1% Ash Fusion Temperature < c Min > Min < c 1150c < 1,150c 1150c < 1,150c HGI < 48 % Min. 48 > 48% Min. 48 < 48 50% < < 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% 29

29 Coal Ship M/H. & BF.32/33 COAL HANDLING SYSTEM SURALAYA POWER PLANT UNITS 1 ~ 7 JH. H BS.34/35 Coal Ship RH. A & BF.03/04 JH. B & C S. & MS.03/04 JH. G & HG36/37, HG40/02 JH. J & HG. A/B BS.36/37 BS.02 BC. 02 Telescopic Chute JH. F ST / RE 2 Coal stock area CHCR BC. 16 BC. 17 RH. D & BF.09/10 JH. C & BC. 15 MCC, BC. 11 BF.11/12, MS.09/10 BC. 12 JH. E & Coal Sampling Alat Berat Telescopic Chute BC. 703A BC. 702A BC. 702B Plant Distribute Hopper & BF 501A/B, BF 601A/B, BF 701A/B BC. 602A BC. 502A SC.30 Hopper M BC. 13 Belt Weigher BC. 14 BC. 26 Hopper K & BC. 20 BF.20/21, BC. 27 BF 26/27,MS.13/14 BC. 21 SC. 28 SC. 24 Hopper L SC. 22 BC. 703B BC. 602B BC. 502B SC. 31 SC. 29 SC. 25 SC. 23 TL 02 Unit 7 Unit 6 Unit 5 Unit 4 Unit 3 Unit 2 Unit 1 COAL BUNKER COAL BUNKER

30 STOCK AREA IMPROVEMENT BEFORE (single pile) 1 Settling basin 2 1 AFTER (triple pile) 3 31

31 TERIMA KASIH THANK YOU 32