PROFILE of PT.INDONESIA POWER UPB SURALAYA

PROFILE of PT.INDONESIA POWER UPB SURALAYA

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REGULATION • • • •

UUD ‘45 Undang-Undang  UU No. 30/2007 tentang Energi, dll. Peraturan Pemerintah  PP No. 70/2009 tentang Konservasi Energi InPres, KePres, PerPres  InPres No. 13/2011; PerPres No. 05/2006, PerPres 71/2011, PerPres 01/2014, dll. • PerMen, KepMen  PerMen ESDM No. 13/2012, PerMen ESDM No. 14/2012, PerMen ESDM No. 15/2012, dll.

Our Activity on Energy Management Implementation at Suralaya Unit 5 -Start on April 14th, 2015-

Identification of Legal Requirements

Arrange the Measurement Plan Consider the Alternative / Renewable Energy

Determine the Operating Critical Parameter of SEU

Energi Sources / Utilized Data Analysis

Significant Energy Used (SEU) Identification

Determine the driving factors

Set the energy indicator, Base Load & Baselines

Improvement Opportunity Identification

SEU Update Operational control assesment Identification of Personal Influence to SEU

Arrange the training plan

Set Objectives and Energy target

Arrrange the action plan to improve Plant performance

Energy Consumption Case : Unit 5 , CAPACITY : 600 MW (Real Capacity : 575.2 MW) Energy Consumption HSD 0,067% PS (Electricity ) 1,89%

Premium 0,007% LPG 0,00000003%

Coal 49,87% Steam 48,25%

    

Coal Electricity Diesel Oil Premium LPG

Based on Plant Data CFPP Suralaya Unit 5 , during 2013 – 2015 as follow : Heat rate = 2,571.651 kcal/kWh (= 10,209.45 BTU/kWH) Average energy efficiency = 33.50 %

Significant Energy User of Coal -Unit 5-

0%0% 0%

SEU of Coal

Boiler 100%

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Indonesia Power UP Suralaya

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Significant Energy User of Steam -Unit 5LP Heater 3 (Bled LP Heater 4 (Bled Steam Steam Flow)[kg/H] LP Heater 2 (Bled 0,79% Flow)[kg/H] Steam Flow)[kg/H] 1,57% HP Heater 6 (Bled Steam 0,7% Flow)[kg/H] Deaerator (Bled 2,26% LP Heater 1 (Bled Steam Steam Flow)[kg/H] Flow)[kg/H] 2,98% 0,54% HP Heater 7 (Bled Steam Flow)[kg/H] 2,37% HP Heater 8 (Bled Steam Flow)[kg/H] 1,33% Main Steam Flow [kg/H] 33,85% Cold Reheat Steam Flow[kg/H] 24,82%

SEU of Steam

Hot Reheat Steam Flow[kg/H] 28,81%

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Indonesia Power UP Suralaya

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Significant Energy User of Electricity -Unit 5-

0.34 0.91

0.39

1.16 0.27 0.64

-

0.02 7.86

5.77 7.46

10.36

-

1.25

6.71 5.87

SEU of Electricity

2.68

2.68

5.87 6.50 10.74 8.83 1.27 0.99 0.97

0.60

1.09

19-May-15

0.84

0.36

3.14

2.45 1.98

Indonesia Power UP Suralaya

PCP LVS A Turbine LVS A Ash Handling LVS A Boiler LVS A 3,3 kV SWGR A CWP LVS A CEP A C3WP A Booster BFP-T A IDFan A FDFan A PAFan A CWP A Coal Handling SWGR A Aux. Island Station LVS A Ash Handling SWGR A PCP LVS B Turbine LVS B Ash Handling LVS B Boiler LVS B 3,3 kV SWGR B CEP B C3WP B C3WP C Booster BFP-T B IDFan B FDFan B PAFan B CWP B Coal Handling SWGR B Ash Handling SWGR B CW LVS B Station LVS B

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Benchmarking The Energy Efficiency and Heat Rate used in CFPP (Coal Fired Power Plant)

Based on : 1. US - NETL (National Energy Technology Laboratory), 2010 , the average of Energy Eficiency for the top 10% in USA – CFPP (Coal Fired Power Plant ) was = 33.80% ( Using subbituminus coal , high pressure sub-critical type CFPP i.e :1800 – 2600 psig) and the average net heat rate around = 10.500 BTU/kWh 2. IEA – International Energy Agency Study , 2013 , for subcritical type CFPP over 500 MW , in United Kingdom , the average energy efficieny was : 38 – 44 % (Increasing the Efficiency of Existing Coal-Fired Power Plants, 2014) Performance of CFPP Suralaya Unit 5 , as follow : Heat rate = 10,209.45 BTU/kWH Average energy efficiency = 33.50 %

Walkthrough Energy Audit (Finding of Energy Efficient Improvement Opportunity) • Visiting Boiler Area ( The highest Uses Energy )Unit 5 71,5

56,6

Total Heat Loss due to Radiation & Convection = 51,564 kW

63,0

13,577 kW

61,2

71,4

13,644 kW

62,4

60,0

70,3

68,1

63,5

58,1

53,0

10,606 kW 62,7

64,5

Ambien Air Temp (33 C)

60,2

13,736 kW

Unit 4 (based on ambient air temp = 33 C)

HRH Steam (140)

57,3

Eco Hopper (264)

• • • •

Heat Loss per Mar 2015 = 51,564 kW × 744 hour = 388,363.52 kWhth/month = 388,391,667.99 kcal/month Coal Loss per March 2015 = 388,391,667.99 ÷ 4,716 = 6,994.63 kgs/month Financial Loss per March 2015 = 6,994.63 × 760 IDR = 5,315,921 IDR per March 2015 7 Units / Year = 5,315,921 × 12 × 7 = 446,537,376 IDR /year

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Goal… The 3E & Z Issues • Energy efficiency Improvement (savings) in a structured and logical : – Profitability Improvement  Economical – Energy resilience Improvement  Energi ( Resilience ) Goal – Minimizing Environment Impact  Emission Reduction Goal – Zero Accident Goal ( including : the safety of the equipment , the safety of the environment and the safety of the human life )

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The main opportunities to achieve the Goal : 1. Increasing coal combustion operation :  optimizing air combustion ratio (specify the O2 excess in flue gas , using O2 excess detector)  optimizing the size of pulverized coal from coal mill unit  optimizing the heat transfer coefficient in Boiler by optimizing soot blower performance 2. Steam and Condensate Recovery 3. Coal Quality Assurance 4. Heat Recovery System include :  Economizer Optimizing ,  Heat Insulation Retrofit .

Action Plan

Action Plan

EFFICIENCY ENERGY IMPROVEMENT SURALAYA 2014 - 2018 NO

1

PROGRAM KERJA

AKTIVITAS

1. Ganti sector plate --> Double 1. Modifikasi system perapat pada Air Sealing , Resetting cleareance Heater minimal & penggantian dg sistem 'Scratch' Optimasi pola operasi Sector Improvement performa Air 2. Penggantian Elemen Air Heater plate Heater 2. Penggantian Elemen Air Heater 3. Pola Operasi Soot Blower Air Heater material Enamel 3. Optimalisasi pola pengoperasian SB AH

1. Penggantian Motor - motor Besar untur mengembalikan efisiensi

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SASARAN

Penurunan Pemakaian Sendiri unit 1-7

KONDISI AKTUAL

Design Temp 140 ° C Actual Temp 145 °C ( *Full load, example Case Unit 1-4) Losses 6 Kcal / kwh atau setara dg Rp 348.307,00/jam

1. penggantian motor-motor penggerak alat bantu dengan yang lebih Efisien,Pemasangan VSD pada Coal Feeder 1-4 Target PS SLA 1-7 : 5,50%, realisasi 5,53%

2. Penggantian Lampu LED 3. Optimasi ESP

2. Penggantian Lampu LED Target PS SLA 1-4 : 6,38%, realisasi 6,42% 3. Improvement Rectifier, Rapper Motor, Transporter System Target PS SLA 5-7 : 4,80%, realisasi 4,72% *Case Target vs Realisasi thn 2013

Roll in/out HP Heater unit 1-4. 4

Pengembalian Performa Feed Water Heater

MEASURABLE

Setiap kenaikan temperatur gas buang 10 °C effisiensi turun 1,65%

TIME LINE

Resetting clearance minimal : 1. Unit 1 - November 2015

GOAL Dry Gas losses

Auxiliary Power

2. Unit 2 - April 2015 3. Unit 6 & 7 - OH thn 2015

Pengadaan Mill thn Selisih Aux Power dengan Output Generator 2015 Penggantian PAF thn 2016 Pengadaan IDF thn 2016 ESP Unit 2 dan unit 5 tahun 2014

Penggantian HP Heater akibat banyaknya Tube Shell yang di plug Setiap penurunan temperature 10 °C, Effisiensi Unit 2 HPH 7 TAHUN akibat bocor. Design Temp 250.9°C turun 3,75% 2015 Actual Temp 246°C (*Full Load, example Case Unit 1-4 ) Losses 246.6 Kcal/kwh atau setara dg Rp. 160.863,00/jam

Auxiliary Power

Turbine Efficiency

EFFICIENCY ENERGY IMPROVEMENT SURALAYA 2014 - 2018 NO

PROGRAM KERJA

AKTIVITAS 1. Optimasi Ball Cleaning System 1-7

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Improve Condensor Performance

2. Optimasi Chlorine Injection

SASARAN

4. Cleaning Tube Condensor 4. Water Jet Tube Condensor 1. Penggantian Part Soot Blower (Lance Tube, cable, Poppet Valve, Motor, Gear Mengaktifkan semua soot blower sesuai pola operasi Box) penggantian material soot blower 2. Improve Grade lance tube area platen yang sudah tidak layak operasi ( Mengoptimalkan kerja Soot super heater bengkok, rusak ) blower 1-7 3. Setting Pressure Steam Secara Rutin,

1. Optimasi fungs Boiler Drain Valve, Turbin Drain Valve 7

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Optimasi valve valve bertekanan tinggi

2. Optimasi fungsi Drain Trap

MEASURABLE

Setiap penurunan vacuum condensor sebesar 5 Press Condensor Design 55,3 mmHg unit 1-4 point terjadi kenaikan Heat Rate sebesar 10,67 1. Penggantian pompa ball cleaning dan Unit 5-7 tekanan absulute : 63 mmHg. % 2. Pengadaan modul dan rehab Press Condensor Actual 55,00 mmHg (absolute sistem control & instrumen press vacuum)

3. Optimasi Vacuum Pump dan Main Air 3. penggantian impeller vaccum Ejector pump

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KONDISI AKTUAL

--> Losses 0,17 Kcal/kwh atau setara Rp. 9.493 / jam (*Example Case Unit 1-4, Full Load)

TIME LINE

GOAL

5-7 secara bertahap dari tahun 2013-2016 1-2 secara bertahap dari tahun 2014-2015 Chlorine Plant Rehabilitasi bertahap dari tahun 2012 - 2017

Turbine Efficiency

Main Steam Design Temp 539°C, Actual Temp 538oC --> Losses 0,07 Kcal/kwh atau Rp. Setiap penurunan temperature 2 °C terjadi 3.988/jam penurunan effisiensi sebesar 0,075% ReHeat Steam Design Temp 539°C, Actual Temp 538,7oC --> Losses 0,06 Kcal/kwh atau Rp. 3.514/jam Air penambah dengan pengoperasian SB adl 0.67% dr Steam Flow ( tanpa pengoperasian SB 0.51%, hasil test performance) *Example case Unit 1-4 , Full Load

Main Steam Design Temp 539°C, Actual Temp 1. Memperbaiki kebocoran seluruh 538°C --> Losses 0,07 Kcal/kwh atau Rp. Valve bertekanan tinggi 3.988/jam ReHeat Steam Design Temp 539°C, Actual 2. Menmperbaiki dan memperbaiki Temp 538,7°C --> Losses 0,06 Kcal/kwh atau Steam Trap yang rusak Rp. 3.514/jam

3. Optimasi fungsi Attemperator System 3. Mengganti valve yang mengalami Valve (TCV, PCV) bocor 1. Pengendalian 10 parameter utama Optimalisasi pola operasi balancing operasi dan temperature gas buang damper gas buang Design Temp 140°C 2. Improvement pola operasi Mill ( Start Actual Temp 145°C (*Full load, Example Case Optimalisasi pola operasi dan / stop / Inerting ) Memperbaiki kualitas Uap Unit 1-4) pengendalian temperatur gas 3. Improvement Pola operasi Soot buang Blower Mengurangi pemakaian HSD 4. Optimasi sistem By Pass saat Start Up Menjaga kehandalan boiler ( tube Losses 6 Kcal / kwh atau setara dg Rp reheat ) 348.307,00/jam Unit 1-4

Setiap penurunan temp main steam 10 0C, enthalpy turun 6 Kcal/kg, atau 7.200.000 Kcal/jam, atau penurunan efisiensi 0,96%

Boiler Efficiency

Plant Heat Rate (thermal efficiency) Setiap OH unit 1-7

Minimize air penambah max 1.5% dari steam flow (ton/jam) Setiap penurunan temp hot reheat steam 10oC, enthalpy turun 5 Kcal/kg, atau 4.800.000 KCal/jam, atau penurunan efisiensi 0,64% Setiap kenaikan temperatur 10°C effisiensi turun 1,65% Setiap Start Unit Plant Heat Rate (thermal efficiency)

EFFICIENCY ENERGY IMPROVEMENT SURALAYA 2014 - 2018 NO

PROGRAM KERJA

AKTIVITAS

SASARAN

KONDISI AKTUAL

Penambahan titik pengukuran gas buang Penambahan titik pengukuran gas , O2/CO analyser buang , O2/CO analyser Design value 3%

9

10

Optimasi Exces Air

TIME LINE

GOAL

Setiap kenaikan O2 1% dlm flue gas, Effisiensi Unit 1-7 tahun 2013 turun 0,5% 2018

Actual condition 2,96 %, data pengukuran Penambahan titik pengukuran pada sisi air heater outlet dirata-rata dan temperature gas buang di sisi Masuk ESP Ketepatan data nilai temperature dikalikan dengan perbandingan asumsi aliran A dan B gas buang yang terbaca oleh alat flue gas, dengan memasang lebih banyak ukur sebagai inputan dan pantauan disisi masuk ESP data lebih valid sehingga bisa efficiency thermal mewakili nilai kerugian dari gas buang. Losses 0.18 Kcal/Kwh atau setara Rp.9800,00/jam

Mengurangi rugi rugi panas Repair isolasi pipa dan dinding boiler aribat radiasi yang terbuka

Plant Heat Rate (thermal efficiency)

Plant Heat Rate (thermal efficiency) Mengganti isolasi yang rusak

Menaikan fineness yang masuk dalam ruang bakar dengan kwalitas lolos Repair , penggantian dan resetting saringan 200 mesh dan Mengurangi clearance Throat ring pada batasan Pyrite optimumnya. 11 Improvement performa Mill

MEASURABLE

Repair & penggantian Tire & GRS Adjusment spring tension Assesment Mill Performance, mengukur clean and dirty air test pada tiap-tiap coal pipe dan setting kecepatan minimumya.

Setiap OH unit 1-7 Unburn combustibles, radiation, and unaccounted Setiap OH unit 1-7 Boiler Efficiency

Assesment thn 2016

Terima Kasih Jl. Jend. Gatot Subroto Kav. 18 Jakarta Selatan 12950 www.indonesiapower.co.id [email protected]