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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
CONSTRUCTION PERIOD 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) - - - 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
Lokasi PLTU Suralaya Unit 1 s/d 7 Intake Canal Heat Canal Coal Yard WWTP Station 1-7 Ash Valley 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
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
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
HUMAN RESOURCES PROFILE Based on education level Based on age Quantity : 725 person
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 OTHER POWER PLANT PRODUCTION Market Share of Indonesia Power = 27 % Peak Load of Jamali Grid = 21,600 MW 11
PRODUCTION SALES COAL CONSUMPTION 12
PRODUCTION 25,000 20,000 15,000 10,000 5,000-2007 2008 2009 2010 2011 2012 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
SALES 25,000 20,000 15,000 10,000 5,000-2007 2008 2009 2010 2011 2012 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
COAL CONSUMPTION 14,000 12,000 10,000 8,000 6,000 4,000 2,000-2007 2008 2009 2010 2011 2012 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
EAF CF EFF THERMAL NETTO
EFOR SdOF AUX POWER
HEAT RATE CALORIFIC VALUE OF COAL CONSUMPTION
NETT THERMAL EFFICIENCY (1997 2012) 19
Comparison of Suralaya CFPP on GSEP Efficiency Report SURALAYA 20
Subject : Unit 4 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) 21
Subject : Unit 4 100.00 E A F 18.00 EFOR % 90.00 80.00 70.00 60.00 50.00 40.00 30.00 20.00 10.00 0.00 2009 2010 2011 2012 E A F 67.09 84.00 94.49 80.46 % 16.00 14.00 12.00 10.00 8.00 6.00 4.00 2.00 0.00 2009 2010 2011 2012 EFOR 16.13 6.14 3.47 4.20 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 22
Subject : Unit 4 25.00 SdOF THERMAL EFFICIENCY 35.00 20.00 30.00 15.00 25.00 X 10.00 % 20.00 5.00 15.00 0.00 2009 2010 2011 2012 SdOF 19.29 9.00 5.00 3.00 10.00 2009 2010 2011 2012 THERMAL EFF 33.03 33.02 32.95 31.52 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
LATEST OUTAGE PERFORMANCE TEST DATA NO DESCRIPTION Engine Unit PRE OUTAGE POST OUTAGE 100 % MCR 100 % MCR 30 Des 2011 11 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 2.003,65 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% 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)
Coal Supply Sources Bukit Asam PKP2B KP SURALAYA
Suralaya Power Plant Coal Consumption
Coal Stock Policy 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 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 5.100 kcal/kg > 7.000 kcal/kg - <4.700 kcal/kg 4,700-5,200 > 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% 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
STOCK AREA IMPROVEMENT BEFORE (single pile) 1 Settling basin 2 1 AFTER (triple pile) 3 31
TERIMA KASIH THANK YOU 32