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SURALAYA GBU as Part of PT.IPUP SuralayaSteam Coal PP3,400 MW (+40 MW)UP PriokGT, CCGT & Diesel PP1,446 MWUP SemarangCCGT & SPP1,469 MWUP Perak GratiSPP & CCGT864 MWJakartaBandungSemarangSurabayaPT IP Total InstalledCapacity = 8,978 MW(+40MW)BanjarnegaraJawa-Bali InstalledCapacity = 18,696 MWGratiUP SagulingHydro797 MWUP KamojangGeothermal360 MWUP MricaHydro306 MWUP BaliGT & Diesel335 MW3


CONSTRUCTION PERIODNO. ITEM <strong>Unit</strong> 1 <strong>Unit</strong> 2 <strong>Unit</strong> 3 <strong>Unit</strong> 4 <strong>Unit</strong> 5 <strong>Unit</strong> 6 <strong>Unit</strong> 71 Construction 1980 1984 19942 First Firing 26.05.84 11.03.85 28.05.88 04.02.89 22.06.96 26.01.97 14.07.973 Synchronize 24.08.84 11.06.85 25.08.88 22.04.89 16.12.96 26.03.97 19.09.974CommercialOperation04.04.85 26.03.86 06.02.89 06.11.89 25.06.97 11.09.97 19.12.975Retrofit (JBIC)danUprating(20MW #1-2)15 Jul 11s/d11 des 11(commercialOperation)29 okt 10s/d08 Jul 11(commercial OP)1 nov 09s/d21 Jan 10(commercial OP)9 Apr 10s/d17 Mei 10(commercial OP)- - -4


500 KV JAVA-BALI SYSTEMPLTU M. KARANGPLT(G)U PRIOKPLTU SURALAYABEKASIPLTGU M. TAWARCILEGONPLTA CIRATAPLT(G)U SEMARANGPLTG SUNYARAGIPLTGU GRESIKGANDULGRESIKCILBINONGPLTU PAITONPLTA SAGULINGUNGARANBDG. SEL.M. RANCANKRIANPLTG PEMARONPLTP KAMOJANGPower Plant System Sub Control System Main Control (Load Dispatcher)PLTG GILIMANUKPLTD PESANGGARAN5


Lokasi PLTU Suralaya <strong>Unit</strong> 1 s/d 7IntakeCanalHeat CanalCoal YardWWTPStation1 - 7Ash Valley6


MAIN EQUIPMENT SPECIFICATIONUNIT CAPACITY :- <strong>Unit</strong> 1-4 : 4 X 400 MW- <strong>Unit</strong> 5-7 : 3 X 600 MW• MAIN CONTROL SYSTEM <strong>Unit</strong> 1-4 : DCS YOKOGAWA <strong>Unit</strong> 5-7 : DCIS BAILEY• STEAM TURBINEManufacturer : Mitsubishi Heavy Industries• GENERATORManufacturer : Mitsubishi Electric Company• BOILERManufacturer : Babcock & Wilcox• COAL HANDLING SYSTEMManufacturer : - Samsung - Flender7


ORGANIZATIONPT. PLN(Persero)GENERATINGUNIT(<strong>Unit</strong> Indukpembangkitan)LOADTRANSMISSION ANDCONTROLUNIT(<strong>Unit</strong> IndukPenyalurandanpengaturanBeban)PT.PembangkitanJawa BaliPT. PJBPT.IndonesiaPowerAREA UNIT(<strong>Unit</strong> IndukWilayah)SERVICES UNIT(<strong>Unit</strong> Jasa-Jasa)DISTRIBUTIONUNIT(<strong>Unit</strong> IndukDistribusi)DEVELOPMENTUNIT(<strong>Unit</strong> IndukPengembangan)OTHERS(lain-lain)SURALAYA CFPPPRIOK (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 : SuralayaGENERAL MANAGERDEPUTYGENERAL MANAGEROPERATION &MAINTENANCEDEPUTYGENERAL MANAGERGENERAL AFFAIRDEPUTYGENERAL MANAGERPRIMARY ENERGYAUDIT SPECIALISTOPERATION MANAGERUNIT 1-4OPERATION MANAGERUNIT 5-7HR & PR MANAGERIT & FINANCE MANAGERPLANNING & INVENTORY OFPRIMARY ENERGY MANAGERCOAL HANDLING MANAGERLAW & CONTRACT SPECIALISTHSE, QUALITY &ENVIRONMENT MANAGERMAINTENANCE MANAGERUNIT 1-4LOGISTIC MANAGERASH HANDLING MANAGERMAINTENANCE MANAGERUNIT 5-7CIVIL MANAGERENGINEERING &ASSET MANAGEMENTMANAGERSPECIALIST


HUMAN RESOURCES PROFILEBased on education levelBased on ageQuantity : 725 person


Suralaya Contribution to JAMALI(Jawa-Madura-Bali Network)YEARPRODUCTION OF SURALAYAPRODUCTION OF INDONESIAPOWERGRID INTERCONECTIONNEEDS2012 22.351 GWh 39.449 GWh 145.545 GWhOTHER POWER PLANTPRODUCTIONMarket Share of Indonesia Power = 27 %Peak Load of Jamali Grid = 21,600 MW11


PRODUCTION – SALES – COAL CONSUMPTION12


PRODUCTION25,00020,00015,00010,0005,000-2007 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 22,35013


SALES25,00020,00015,00010,0005,000-2007 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 21,12014


COAL CONSUMPTION14,00012,00010,0008,0006,0004,0002,000-2007 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 11,07315


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 ReportSURALAYA20


Subject : <strong>Unit</strong> 4NO. ITEM TIMELINE1 Construction 19842 First Firing 04 February 19893 Synchronize 22 April 19894 Commercial Operation 06 November 19894 Partially Retubing 23 May – 4 August 20095Retrofit (JBIC) : Control System modificationfrom Panel to Computer Based9 April 2010 -17 May 2010 (commercial OP)21


Subject : <strong>Unit</strong> 4100.00E A F18.00EFOR%90.0080.0070.0060.0050.0040.0030.0020.0010.000.002009 2010 2011 2012E A F 67.09 84.00 94.49 80.46%16.0014.0012.0010.008.006.004.002.000.002009 2010 2011 2012EFOR 16.13 6.14 3.47 4.20Year Inspection Periodic Duration(Day)2009 Serious Inspection & Retubing Boiler 732010 Retrofit DCIS Program JBIC 382012 Mean Inspection 252009 EFOR high cause by Boiler leak and Boiler partial retubing.2010 EFOR decrease cause we had done retrofit DCIS to minimizeEFOR and boiler leak22


Subject : <strong>Unit</strong> 425.00SdOFTHERMAL EFFICIENCY35.0020.0030.0015.0025.00X10.00%20.005.0015.000.002009 2010 2011 2012SdOF 19.29 9.00 5.00 3.0010.002009 2010 2011 2012THERMAL EFF 33.03 33.02 32.95 31.52Thermal 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 DATANO DESCRIPTION Engine <strong>Unit</strong>PRE OUTAGE POST OUTAGE100 % MCR 100 % MCR30 Des 2011 11 Mei 2012DIFFERENTIALDIFFERENTIATIONPERCENTAGE1 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 oncoal specification from Bukit Asam (SumateraIsland), which categorized as sub-bituminous coalrank• 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 SourcesBukit AsamPKP2BKPSURALAYA


Suralaya Power Plant Coal Consumption


Coal Stock Policy• PT. Indonesia Power Coal Stock Policy :– The quantity of coal in the stock pile is between20 – 35 day coal consumption– Equal to 660.000 – 1.155.000 MT (average of coalconsumption is 33.000 MT/Day)Note :– Coal Stockyard Capacity is about 21 ha (volume about1.500.000 MT )


COAL SPECIFICATIONPARAMETERPT. BA PT. BERAU PT. KIDECO MID CONTRACTADCSpesifikasi Contract Rejection Level Contract Rejection Level Contract Rejection Level Contract Rejection Level Contract Rejection LevelCalorific Value5.100 kcal/kg > 7.000 kcal/kg - 4.700 kcal/kg 4,700 - 5,100 < 4.700 kcal/kg 4.800 kcal/kg >4.800 Kcal/kg 5.000 kcal/kg 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 < 1,150cHGI 55 - 64 < 48 % Min. 48 > 48% Min. 48 < 48 50% < 50 50-60 < 50 atau > 60Slagging Index - - - - > medium > medium ≤ medium > mediumFouling Index - - - - > medium > medium ≤ medium > mediumCoal 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


STOCK AREA IMPROVEMENTBEFORE(single pile)1Settling basin21AFTER(triple pile)331


TERIMA KASIHTHANK YOU32

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