The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia 3.2. Confirmation of Current Status and Issues Relating to Operation and Maintenance 3.2.1. Thermal Power Stations 3.2.1.1. Recent Status of Power Generation in Java-Bali Regions In Java-Bali regions as a whole, the power generating patterns from Monday through Friday are as shown in Figure 3.2-1 and the light-up time zone is 17:00 to 18:00 hours and the peak time zone is 17:00 to 22:00 hours. However, the peak time zone in Jakarta-Banten area is 09:00 to 22:00 hours. Most of the thermal power stations of Indonesia Power and PJB perform operation without using governor-free function although the Grid Code (PLN’s technical standard) provides that governor-free operation be performed. It is recommended that frequency fine-tuning operation utilizing the governor-free function be performed so that frequency can be stabilized. However, in case the above function is utilized, it is necessary to put the overload preventing security device into usable condition. * The Japanese electric power companies perform function confirmation tests of the security device to safely stop units as frequently as once a month. Source ； INDONESIA POWER data Figure 3.2-1 Daily Load Curve in Java-Bali Regions (22 August, 2006) 3 - 57 Final Report
Transcript
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
3.2. Confirmation of Current Status and Issues Relating to Operation and Maintenance 3.2.1. Thermal Power Stations 3.2.1.1. Recent Status of Power Generation in Java-Bali Regions
In Java-Bali regions as a whole, the power generating patterns from Monday through Friday are as shown in Figure 3.2-1 and the light-up time zone is 17:00 to 18:00 hours and the peak time zone is 17:00 to 22:00 hours. However, the peak time zone in Jakarta-Banten area is 09:00 to 22:00 hours. Most of the thermal power stations of Indonesia Power and PJB perform operation without using governor-free function although the Grid Code (PLN’s technical standard) provides that governor-free operation be performed.
It is recommended that frequency fine-tuning operation utilizing the governor-free function be performed so that frequency can be stabilized. However, in case the above function is utilized, it is necessary to put the overload preventing security device into usable condition. * The Japanese electric power companies perform function confirmation tests of the security device to safely stop
units as frequently as once a month.
Source ； INDONESIA POWER data
Figure 3.2-1 Daily Load Curve in Java-Bali Regions (22 August, 2006)
3 - 57 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
3.2.1.2. Operation Records Figure 3.2-2 shows the annual operation records of Year 2004 seen from the viewpoint of operation hours of the thermal power stations under the study. Figure 3.2-2 also covers 3 hydraulic power stations for reference. The following can be observed from this Figure 3.2-2.
1) Gilimanuk Power Station recorded the highest operating rate of 95.5% among the twelve thermal power stations.
2) In Java Island, PLTU Unit is basically in charge of the base load and PLTGU and PLTG Units are in charge of the peak load. In Bali Island, Gilimanuk P/S is in charge of the base load and Pesanggaran P/S and Pemaron P/S are in charge of the peak load.
3) Currently, the five highest ranking power stations in operating hours (ratios) are as stated below. Except Gilimanuk Power Station, PLTU power stations which are in charge of the base load are in the higher ranks followed by PLTGU power stations which are in charge of the peak load. This order is line with ELD (Economical Load Dispatcher)
No. P/S Type Location Average SH
1 Gilimanuk PLTG Bali 92.4%
2 Suralaya PLTU (Coal) Jakarta-Banten 89.4%
3 Perak PLTU (MFO) Java-East 82.6%
4 Paiton PLTU (Coal) Java-East 82.5%
5 Gresik Java-East 72.9% PLTGU＋PLTG
4) As for forced outage, the five highest ranking power stations with short outage times
(ratios) are currently as shown below. The smallest forced outage ratio of 0.2% corresponds to 18 outage hours (=8,760 hrs × 0.2%), while the highest outage was 3.7% recorded at Perak P/S. This corresponds to the annual outage hours of 324 hours. Thus, at this moment the forced outage hours vary from 18 hours to 324 hours. The forced outage hours tend to increase also in 2005.
No. P/S Type Location Average FOH (D)
1 Pemaron PLTG Bali 0.2%
2 Gilimanuk PLTG Bali 0.3%
3 Tanjung Priok PLTGU + PLTG (+PLTU) Jakarta-Banten 0.7%
4 Gresik PLTGU + PLTG + PLTU Java-East 0.9%
5 Tambak Lorok PLTGU + PLTU Java-Central 0.9%
5) Both IP and PJB, which are power generating companies, have no obligation to make accident reports to PLN but have to submit a direct report to Board of PLN and press conference. They have to make finance status reports to PLN.
Final Report 3 - 58
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Gili
man
uk P
/S (P
LT
G)
Tan
jung
Pri
ok P
/S (P
LT
GU
+PL
TG
+PL
TU
)20
0320
0420
0520
0320
0420
05SH
-95
.589
.3SH
69.9
70.8
-PO
H-
3.9
8.3
POH
23.3
23.0
-M
OH
-0
0M
OH
0.6
0.2
-FO
H (D
)-
0.4
0.1
FOH
(D)
0.8
0.6
-FO
H(L
)-
00
FOH
(L)
0.1
0.0
-R
SH-
0.2
2.2
RSH
5.4
5.4
-To
tal
-10
010
0To
tal
100
100
-
Sura
laya
P/S
(PL
TU
)M
uara
Taw
ar P
/S (P
LT
GU
+ P
LT
G)
2003
2004
2005
2003
2004
2005
SH88
.490
.3-
SH31
.456
.667
.7PO
H7.
85.
5-
POH
47.2
20.6
15.0
MO
H1.
21.
0-
MO
H9.
613
.64.
3FO
H (D
)1.
12.
1-
FOH
(D)
1.2
1.6
2.0
FOH
(L)
0.0
0.0
-FO
H(L
)-
--
RSH
1.6
1.2
-R
SH10
.57.
511
.0To
tal
100
100
-To
tal
100
100
100
Pera
k P/
S (P
LT
U)
Sagu
ling
P/S
(PL
TA
)20
0320
0420
0520
0320
0420
05SH
-84
.480
.7SH
40.6
46.5
58.1
POH
-0
10.1
POH
24.5
12.4
3.4
MO
H-
6.5
4.8
MO
H1
0.8
1.6
FOH
(D)
-4.
43.
0FO
H (D
)0.
20.
20.
2FO
H(L
)-
00.
7FO
H(L
)-
--
RSH
-4.
70.
7R
SH33
.740
36.7
Tota
l-
100
100
Tota
l10
010
010
0
Paito
n P/
S (P
LT
U)
Gra
ti P/
S (P
LT
GU
+PL
TG
)%
2003
2004
2005
2003
2004
2005
SH83
.788
75.7
SH-
31.1
50.9
POH
10.2
7.3
16.8
POH
-2.
21.
2M
OH
3.3
1.0
4.9
MO
H-
6.7
1.9
FOH
(D)
0.7
2.3
2.6
FOH
(D)
-1.
71.
7FO
H(L
)-
--
FOH
(L)
--
-R
SH2.
11.
50
RSH
-58
.344
.3To
tal
100
100
100
Tota
l-
100
100
Gre
sik
P/S
(PL
TG
U +
PL
TG
+ P
LT
U)
Sudi
rman
P/S
(PL
TA
)20
0320
0420
0520
0320
0420
05SH
71.7
73.1
73.9
SH34
.136
.839
POH
5.5
5.4
7.9
POH
2.4
1.8
2.3
MO
H1.
31.
10.
8M
OH
--
-FO
H (D
)1.
10.
90.
7FO
H (D
)0
0.1
0FO
H(L
)-
--
FOH
(L)
--
-R
SH20
.419
.516
.6R
SH63
.561
.358
.7To
tal
100
100
100
Tota
l10
010
010
0
Tam
bak
Lor
ok P
/S (P
LT
GU
+ P
LT
U)
Pesa
ngga
ran
P/S
(PL
TG
+ P
LT
D)
2003
2004
2005
2003
2004
2005
SH69
.372
.773
.9SH
-30
.438
.4PO
H12
.85.
98.
8PO
H-
3.7
5.5
MO
H0.
30.
50.
4M
OH
-0.
13.
4FO
H (D
)1.
00.
51.
3FO
H (D
)-
0.1
0.4
FOH
(L)
0.0
0.0
0.0
FOH
(L)
-0.
10
RSH
16.6
20.4
15.6
RSH
-65
.852
.3To
tal
100
100
100
Tota
l-
100
100
Pem
aron
P/S
(PL
TG
)C
irat
a P/
S (P
LT
A)
Mua
ra K
aran
g P/
S (P
LT
GU
+ P
LT
U)
Suta
mi P
/S (P
LT
A)
2003
2004
2005
2003
2004
2005
2003
2004
2005
2003
2004
2005
SH-
-28
.7SH
1821
.828
.2SH
85.1
8071
.7SH
POH
--
22.9
POH
4.6
3.3
3.7
POH
8.1
7.3
15.9
POH
MO
H-
-5.
5M
OH
12.5
2.2
7M
OH
4.2
7.8
9.3
MO
HFO
H (D
)-
-0.
2FO
H (D
)0.
10.
10.
2FO
H (D
)2.
54.
52.
9FO
H (D
)FO
H(L
)-
-0
FOH
(L)
--
-FO
H(L
)-
--
FOH
(L)
RSH
--
42.6
RSH
64.8
72.7
60.9
RSH
0.1
0.4
0.1
RSH
Tota
l-
-10
0To
tal
100
100
100
Tota
l10
010
010
0To
tal
00
0
Not
e:PL
TU :
Con
vent
iona
l the
rmal
pow
er st
atio
n (O
il-fir
ed P
ower
Sta
tion
and
Coa
l-fire
d Po
wer
Sta
tion
or b
lock
)SH
:Ser
vice
Hou
rsPL
TG:G
as tu
rbin
e th
erm
al p
ower
stat
ion
(or b
lock
)PO
H:P
lann
ed O
utag
e H
ours
PLTG
U:C
ombi
ned
Cyc
le p
ower
stat
ion
(or b
lock
) M
OH
:Mai
nten
ance
Out
age
Hou
rsPL
TD:D
iese
l Pow
er S
tatio
n (o
r blo
ck)
FOH
(D):
Forc
ed O
utag
e H
ours
cau
sed
by p
ower
stat
ion
PLTA
:Hyd
ro p
ower
stat
ion
FOH
(L):
Forc
ed O
utag
e H
ours
cau
sed
by p
ower
grid
syst
emR
SH:R
eser
ve S
hutd
own
Hou
rs (=
Stan
d by
)So
urce
:D
evel
oped
by
the
JIC
A S
tudy
Tea
m b
ased
on
the
prov
ided
dat
a by
eac
h po
wer
stat
ion
Paito
n P/
S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Gre
sik
P/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Gra
ti P/
S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Pera
k P/
S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Mua
ra T
awar
P/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Tam
bak
Lor
ok P
/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Tan
jung
Pri
ok P
/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Sura
laya
P/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Mua
ra K
aran
g P/
S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Pesa
ngga
ran
P/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Gili
man
uk P
/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Pen
0%20
%40
%60
%80
%10
0%
2003
2004
2005
mar
o P
/S
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Sudi
rman
P/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Sagu
ling
P/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Cir
ata
P/S
020
4060
8010
0
2003
2004
2005
SHPO
HM
OH
FOH
(D)
FOH
(L)
RSH
Suta
mi P
/S
0%20
%40
%60
%80
%10
0%
2003
2004
2005
RSH
FOH
(L)
FOH
(D)
MO
HPO
HSH
Fig
ure
3.2-
2
Ann
ual O
pera
tion
Perf
orm
ance
Rel
atin
g H
ours
(%) f
or O
bjec
tive
Pow
er S
tatio
ns
3 - 59 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
• It is recommended that PLN and MEMR develop “Regulation on power generation facility
related accident reports” aiming to more actively participate in the operation and maintenance of power stations.
• In order to reduce forced outage hours and increase power generation energy, it is essential to
tackle the following and prevent repetition of similar accidents. For example, < Tasks for scheduled inspection work >
① As for equipment which have repeatedly experienced similar accidents, it is important that the maintenance such as thorough inspection and adjustments are performed as intensive monitoring equipment during the scheduled inspection work period.
② It is also important to make efforts to reduce the work period and ensure high operation ratio of the unit through rationalization of the scheduled inspection work.
< Tasks for the prevention of routine accidents >
It is crucial to promptly study measures against unexpected accidents such as Irregular Frequency and System Faults.
For example, < Operational aspect >
a. Education and training of troubleshooting of the unit utilizing simulators are considered to be the most effective.
b. It is necessary to regularly conduct “function checking tests of security devices” to safely stop the plants in case of the unit trips.
< Maintenance aspect >
a. Since insufficient repairs frequently occur due to delay in procuring materials, it is necessary to establish a material management system to promptly cope with accidents by utilization of IT.
b. It is very important to make efforts to prevent deterioration of facilities by means of predictive and preventive maintenance performed by IP and PJB power stations.
c. It is essential to promote improvement of the skills of the thermal power staff and promote information sharing.
Final Report 3 - 60
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
3.2.1.3. Numbers of Outage Times and Hours (from 2003 to 2005) The number and hours of forced outages are analyzed including the causes as mentioned later for 75 units (PLTU: 23, PLTG: 12, PLTGU: 40) among the objective thermal power stations. As for details, please refer to Table 3.2-11 and Table 3.2-12.
(1) Number of outages and hours by unit type
The numbers of outages and hours during the three years from 2003 to 2005 are as shown below4.
Table 3.2-2 Forced Outage (Hours) for Thermal Power Stations
Sources : INDONESIA POWER & PJB data
Type 2003
Table 3.2-1 Forced Outage (Times) for Thermal Power Stations
105
150134
49 49
90
280
339
423434
538
647
0
100
200
300
400
500
600
700
1 2 3
PLTU PLTG PLTGU Total
Type 2003 2004 2005 Total PLTU 105 150 134 389 PLTG 49 49 90 188
PLTGU 280 339 423 1,042Total 434 538 647 1,619
Sources : INDONESIA POWER & PJB data
Numbers of Forced Outages are too many and have been increasing in the past 3 years.
Causes of Forced Outage Code % TimesA: Instrumentation and Control A 40.4% 157B: Turbine/Generator B 20.3% 79C: Boiler and Auxiliaries C 27.5% 107D: Cable/Relay D 3.3% 13E: Inerter E 0.5% 2F: Transformer F 0.5% 2G: System Fault or Irregular Frequency G 4.1% 16H: Others H 3.3% 13
100.0% 389Total
40.4%
20.3%
27.5%
3.3%0.5% 0.5%
4.1% 3.3%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
A B C D E F G H
Dominant causes are: － I & C : 50.3% (e.g.) ・Ignition Trouble ・Temperature Control Trouble ・Flame Out Trip － Turbine & Generator: 36.2% (e.g.) ・Balancing Turbine/Generator ・Exciter System Trouble
Causes of Forced Outage Code % TimesA: Instrumentation and Control A 50.0% 94
68B: Turbine/Generator B 36.2%C: Cable/Relay C 3.7% 7D: Electrical Fault or Irregular Frequency D 2.7% 5E: System Fault or Irregular Frequency E 3.7% 7F: Derating F 3.2% 6G: Others G 0.5% 1
100.0%Total 188
50.0%
36.2%
3.7% 2.7% 3.7% 3.2%0.5%
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
A B C D E F G
Final Report 3 - 62
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-5 Number of Forced Outages (Times) for PLTGU
Sources : INDONESIA POWER & PJB data
Dominant causes are: － I & C : 36.8% (e.g.) ・Exhaust Temperature High ・Flame Out Trip ・Ignition Trouble － Turbine & Generator: 17.9% ・Condenser Plugging ・Starting Motor Trouble
Causes of Forced Outage Code % TimesA: Instrumentation and Control A 36.8% 383B: Turbine/Generator B 17.9% 186C: HRSG and Auxiliaries C 10.4% 108D: Relay D 1.2% 12E: 6kV Bus E 0.8% 8F: UPS System F 0.3% 3G: Electrical G 1.1% 11H: System Fault or Irregular Frequency H 7.4% 77I: Derating I 14.6% 152J: Others J 9.7% 101
The numbers of forced outages of PLTU, PLTG and PLTGU Units tend to increase year after year due mainly to accidents and troubles of Instrument & Control and Turbine & Generators.
－The numbers of forced outages (times) due to failure of Instrument & Control is large because of repetitive occurrence of similar accidents due to unsatisfactory combustion adjustments and ABC adjustments (to specified temperature, pressure, etc.). In order to prevent recurrence of such accidents, it is essential to study alteration of the control circuits and be sure to perform combustion adjustments and ABC adjustments, etc. at scheduled inspection work. Since similar accidents also repetitively occurred on turbines/generators, it is necessary to thoroughly make the balance adjustments during scheduled inspection work.
－In order to prevent repetitive occurrence of similar accidents and oversight of inspection during scheduled inspection, it is necessary to review and reinforce the current scheduled inspection system.
－In order to promptly cope with accidents of the facilities, it is essential to review the education and training for trouble-shooting of the units utilizing simplified simulators (new installation) and current material procurement management system.
－The following should be tackled in earnest as measures to prevent deterioration of the facilities. ・ Facility maintenance and management aiming to expand not only the exclusive diagnosing
technique but also the definition of CBM (Condition Based Monitoring) including routine inspection
・ Implementation of inspection of thickness of pipelines for power generation ・ Reinforcement of efforts to perform facility based maintenance
－It is also very important to improve skills of thermal power operators
－Efforts should be made to energetically promote sharing of useful information so that safe and stable operation of the power stations can be continued.
3 - 63 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
3.2.1.4. Routine Management Condition
(1) Confirmation of the current status
1) The power stations of Indonesia Power and PJB have acquired international certifications of ISO 14001(Environment Management System) of Integrated management system, ISO 9001 (Quality Management Systems) and OHSAS 18001 (Occupational Health and Safety Management Systems) and the general manager and staff of each power station have been enthusiastically making enormous efforts for the routine operation, maintenance and management.
2) Both Indonesia Power and PJB have been operating power stations since 1995 based on various indices defined by NERC (North America Electric Reliability Council). PJB Headquarters have introduced MOP (Maintenance Optimization Program) and are now implementing the program at Gresik, Paiton and M. Karang.
3) Trips/Shutdowns/Derating, etc. frequently occur at the power stations and the number of forced outages (times/hours) is overwhelmingly large when compared with that experienced by the power stations in Japan. Under such situation, operators of each power station are busy with troubleshooting of the facilities, while maintenance workers are busy with routinely occurring emergency works, scheduled inspection works and large-scale repair works.
(2) Implementation status of routine inspection (inspection items, conditions, frequency, etc.) <Operation>
Both Indonesia Power and PJB implement routine inspection under organizational systems similar to each other.
Contents Shift system 3 shifts by 4 teams (All time monitoring system):
inspection ・ Based on Logsheet specifying operation managing values, patrol inspection of Ground
Floor, Boiler area, Turbine area, etc. is conducted 2 times/shift and 6 times/day (08:00, 13:00, 16:00, 20:00, 23:00, 05:00). (Note: Almost of IP and PJB power stations takes every hour.)
・ See “Logsheet of Suralaya power station of Indonesia Power” on APPENDIX TH-1 for inspection items.
Operation monitoring of Control Room
・ Output of generators, temperature and pressure of each equipment are recorded and monitored based on Logsheet every 30 minutes (or hour).
・ As for Inspection items, see “Logsheet Control Room of Suralaya power station of Indonesia Power” on APPENDIX TH-2 for inspection items.
Others ・ At IP and PJB power stations, frequency of inspection is decided based on Log Sheet for all facilities, such as weekly, monthly, quarterly, and biannually.
・ At the time of weekly inspection or monthly inspection, switchover of auxiliary machines such as compressors is conducted.
* At some power stations, a unit trip was caused by “governor-free test” of turbines.
Final Report 3 - 64
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
< Maintenance >
・ Based on Logsheet, weekly inspection or monthly inspection is conducted and scheduled inspection work is also performed by establishing the work schedule.
・ At IP/PJB power stations, Condition-Based Monitoring (of power source, voltage, temperature and pressure) is performed for machinery of less importance (pumps, motors, fans, compressors, etc.).
Especially, at PJB, machinery analysis and monitoring by John S. Michell is adopted. Environmental monitoring data (NOX, SOX, P, etc.) are also collected.
< Keeping and Management >
Logsheet of patrol (results), design library, manuals maker’s instructions and test records are kept and managed at each power station’s Library.
－ Inspection through CBM (Condition Based Monitoring) is conducted basically with the exclusively diagnosing tool, but in order to prevent unforeseen facility troubles, it is very important to maintain and manage facilities aiming to expand the definition of CBM.
－ If there are any facilities, valves, etc. which do not have any description of such equipment, it is important to establish a procedural guideline and display names of equipment from the viewpoint of preventing erroneous operation at the time of operation and maneuvering and performing work.
－ It is also important to describe standard values and normal ranges for all instruments.
－ Trips, Shutdowns, Derating, etc. have occurred routinely at each power station. Under such situation, it is necessary to prevent oversight in patrol inspection and review ways to conduct reasonable patrol inspection instead of simply conducting patrol inspection based on Logsheet.
(3) Preparation status of manuals and guidelines
Based on the questionnaire survey, the Study Team has confirmed that the following manuals and guidelines have been prepared.
1) Guideline for thermal power handling jobs:
① Standard guidelines which are common to operation and maintenance - Guideline for handling of accidents/troubles. - Guideline for handling of work sheet. - Guideline for disposal of industrial waste.
② Guidelines for operation (including environment and chemicals): - Guideline for Names of thermal power station facilities. - Guideline for management of lubricant oil, etc.
3 - 65 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
- Guideline for procedure for operational power stoppage. - Guideline for water quality control.
2) Guidelines for quality control of scheduled inspections: - Guideline for prior assessment of work safety. - Guideline for preparation of specification. - Guideline for operation management of environment and chemical.
3) Manuals for management of power station operating jobs: - Manual for operator training. - Manual for operation jobs. - Manual for operation ad maneuvering. - Manual for patrol inspection management. - Manual for scheduled tests. - Manual for measurements to be taken in case an alarm is issued. - Manual for managements of valve locking. - Manual for safety and health activities. - Manual for environmental security management. - Manual for patrol inspection standards for maintenance workers. - Manual for security standards for power station facilities. - Manual for handling panel operation. - Manual for scheduled inspection work of measurement and control equipment. - Manual for budget plans and execution management.
－ The procedural guidelines have not been established for the scheduled inspection at both IP and PJB. (The inspections are conducted in accordance with scheduled inspection manuals proposed by the manufacturers.)
－ In order to improve quality of the scheduled inspection works and establish reliability of the equipment, it is necessary to prepare “Procedural guideline for the implementation of scheduled inspections”, “Inspection guideline”, “Inspection procedure” and “Procedural guideline for welding inspections” which are unique to IP and PJB. It is also crucial to attempt preparation and expansion of the manuals for quality and safety assurance.
(4) Operation, maintenance, management of material procurement, etc.
In order to conduct further operation and maintenance and management of material procurement, PJB employs ELLIPSE a consultant of Australian Mincom, while Indonesia Power employs MAXIMO, American MRO Software. They link the following modules by intra-office LAN to share information.
* ELLIPSE is the latest Version of MIMS (Mincom Information management system)
Final Report 3 - 66
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
ELLIPSE (PJB) and MAXIMO (IP) are almost the same modules with each other.
① Operation and Maintenance Module Equipment Register Work Order (Predictive/Preventive/Corrective Maintenance) Production Statistic Fuel ＆ Oil ※IP uses own its program for fuel & oil called PRONIA ② Material Management Module Cataloger Inventory Control Management Warehouse Inventory Tracking Purchase Order ③ Finance Module Journal Ledger COA : charge of Account Journal Holding Fixed Asset Financial Management ④ Labor Costing Module ⑤ Account Payable Module ※IP uses ORACLE for account payable ⑥ Human Resources Module Planning Establishment Training Payroll
In view of the current status that accidents and troubles of facilities occur repetitively because of insufficient repairs due to delay in procuring materials, it is necessary to improve the company-wide material procurement management.
※ At the moment IP uses own program for Human Resources System
IP is still developing Human Recourses system and use ORACLE
3 - 67 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
(5) Education and training
A. Indonesian Power and PJB provide the following education and training to the whole personnel.
< Indonesian Power >
① DIKLAT PENGADAAN － Recruitment Training Basic Course for Freshmen
②DIKLAT PEMBINAAN － Skill / Knowledge up Training Middle Course for some level and / or task staff
③DIKLAT PENGEMBANGAN － Developing Training Advanced Course for promotion or rotation staff
④DIKLAT PELEPASAN － Retirement Training Mental spirit training Enterprise training for
pre-retired person
⑤Certification / New Module － Examination for operators and maintenance staff (New standard program) ・Module 0－General ・Module 1－for Auxiliary Equipment ・Module 2－for Boiler System Equipment ・Module 3－for Turbine/Generation Equipment ・Module 4－for Efficiency Operation
< PJB >
① Full Package Education and Training for PLTU , PLTGU, and PLTG －From Basic Course to Full standard for operators and maintenance staff.
②Refreshment Training －Middle Course of rotation staff
③ Certification / New Module (New standard program) －Examination for operators and maintenance staff ・Module 0－General ・Module 1－for Auxiliary Equipment ・Module 2－for Boiler System Equipment ・Module 3－for Turbine/Generation Equipment ・Module 4－for Efficiency Operation
B. At PLN Suralaya Unit, the following education and training are provided to the operators and maintenance personnel of Indonesia Power and PJB.
① On-Site Simulator Training for PLTU (Coal-Fired, 400 MW・600 MW) －CRT based PLTU Simulator －Panel based PLTU Simulator
Final Report 3 - 68
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
－Panel based Ancillary PLTU Simulator －Generator operation Simulator etc.
② Generator unit Operation Training －Boiler ＆ Turbine Operation for PLTU －HRSG ＆ Turbine Operation for PLTU －Logic ＆ Sequence for Operator －Basic Training (Level 1, 2, 3) for PLTU ・Boiler Operation ・Turbine Operation －Basic Training (Level 1, 2, 3) for PLTG and PLTGU －Generator Operation Analysis etc.
③Generator unit Maintenance Training －General Maintenance for PLTU －Machine Maintenance for PLTU (Level 2, 3, 4) －Electric Maintenance for PLTU (Level 2, 3, 4) －Instrument and Control Maintenance for PLTU (Level 2, 3, 4) －Balancing ＆ Alignment －Vibration Analysis －3 Phase Electric Motor －Water Treatment etc.
C. Other education and training consist of lectures, discussions, etc. which are combined with simulated training and OJT on site.
・ PLN Suralaya Unit has 5 Senior Instructors, out of whom 3 persons are scheduled to retire in 2006. They are faced with a great difficulty in selecting the successors. PLN needs to promptly select the successors and it is very important to bring up Instructors.
・ The training simulator is the most effective to improve the skills of operators in the “normal starts and stops of the unit” and “troubleshooting of the unit”; however, since there is no such simulator for PLTU (400 MW and 600 MW coal-fired thermal power), it is necessary to install a simulator for PLTGU.
・ It is necessary to improve the current education of newcomers so that the reliability of the thermal power stations of Indonesia Power and PJB can be enhanced and maintained.
・ It is also very important to prevent lessons gained from accidents, troubles, etc. from fading with time, prevent recurrence of similar accidents and pass on the skills to next generations and tackle these tasks as part of the routine education at Indonesia Power and PJB Division.
3 - 69 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
3.2.1.5. Status of Maintenance Management
(1) Implementation status of scheduled inspections
・ The overall adjustment of specific schedules of the scheduled inspections at power stations in Java-Bali regions is made by P3B.
・ The process and interval of the scheduled inspections are established by each power station based on the recommendations of the equipment manufacturers.
・ The standard inspection periods and intervals and the actual results for the past 3 years from 2003 to 2005 are as shown in Table 3.2-6.
・ There are some scheduled inspection works whose periods were extended or in which repair works could not be done during designated work periods due to delay in the procurement of replacements, spare parts, parts, etc.
・ Quality control during scheduled inspection work is conducted jointly by the power station and the maintenance teams (UBHAR/UHAR). However, since replacements of poor quality are used, machinery damage and troubles have frequently occurred once commercial operation is restored.
・ Deterioration of facilities has occurred. There are some equipment which do not always exhibit sufficient function or whose capacities are deficient. As for such defective machineries, orders have already been placed for replacements; however, repairs have not been made due to delay in procuring such replacements.
(2) Plans and actual results of the scheduled inspections by unit in 2006
Table 3.2-7 shows Scheduled Maintenance and Inspection plans and results of Indonesia Power and PJB.
－ The insufficient repairs and deterioration of plants due to delay in procuring materials are common to both IP and PJB and urgent improvements are required for the whole company.
－ It is also important to take measures to reduce scheduled inspection period so that safer inspections and high operation rates can be ensured.
－ Since damage of equipment due to aging deterioration of power generation facilities is expected to increase, it is very important to review the inspection system at the time of scheduled inspections to prevent oversight of inspections. It is also necessary that improvements be made in the routine maintenance work.
Final Report 3 - 70
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-6 (1) Records of Scheduled Maintenance/Inspection for 2003, 2004 and 2005 by Unit Type
Standard Plan Actual Standard Plan Actual Standard Plan ActualType (days) (days) Type (days) (days) Type (days) (days)
~10,000 (H) ~10,000 (H) ~10,000 (H) ~10,000 (H) ST-2.0 SE 55 56 SI 28 24TU-1 SI 28 28 ME 34 35
0 TU-2 ME 44 36 SI 29 29TU-3 SI 30 30 ME 33 39
(GT) TU-3 SI 31 30 None ME+ 35 61 8,000*CDF (H) TU-4 SE 92 60 None SI+ 30 39
-0 -(GT) GT-1.1 TI 29 26 None CI 11 9 8,000*CDF (H) GT-1.2 TI 29 28 None CI 11 9
GT-1.3 CI 14 14 TI 27 24 CI 11 90 ST-1.0
TI: Turbine Inspection: HGPI GT-2.1 FYI 14 10 None TI 26 32FYI: First year Inspection GT-2.2 FYI 14 11 None None
(ST ) GT-2.3 FYI 14 8 None None--
0 --(30 d) (18 d) (45 d)
8,000 (H) 8,000 (H) 8,000 (H) 8,000 (H)
Simple Mean Simple Serious
(18 d)
6,000 (H)
None
None
Type A Type B Type A Type C
6,000 (H) 6,000 (H) 6,000 (H)
(18 d) (30 d) (18 d) (45 d)
Simple Mean Simple Serious
8,000 (H) 8,000 (H) 8,000 (H) 8,000 (H)
(10 d) (30 d) (10 d) (45 d)
(7 d) (14 d) (7 d) (45 d)
Type A Type B Type A Type C
Simple Serious
6,000 (H) 6,000 (H) 6,000 (H) 6,000 (H)
(28 d) (30 d) (28 d) (45 d)
Simple Mean Simple Serious
(7 d) (28 d) (7 d) (50 d)
CI HGPI CI MI
6,000 6,000 6,000 6,000
(21 d) (30 d) (21 d) (45 d)
CI(7 d) HGPI(28 d) CI(7 d) MI(45 d)
SE(45 d)
8,000 (H) 8,000 (H) 8,000 (H)
8,000 (H) 8,000 (H) 8,000 (H)
SI(21 d) ME30 d) SI(21 d)
Simple Mean Simple Serious
Simple Mean
2003 2004 2005Unit No.
Muara Tawar(PJB)
Tambak Lorok(IP)
Perak(IP)
Tanjung Priok(IP)
P/S
Muara Karang(PJB)
Grati(IP)
Suralaya(IP)
Scheduled Maintenance / Inspection Standard Type / Interval / Period
(28 days) (30 days) (28 days) (60 days)
8,000 (H) 8,000 (H) 8,000 (H) 8,000 (H)
(45 d)
Serious
8,000 (H) 8,000 (H) 8,000 (H)
CI HGPI
8,000 (H)
Simple Mean Simple
8,000 (H) 8,000 (H) 8,000 (H)
8,000 (H)
CI MI
None
(28 d) (30 d) (28 d) (45 d)
(7 d) (14 d) (7 d)
1
3 - 71 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-6 (2) Records of Scheduled Maintenance/Inspection for 2003, 2004 and 2005 by Unit Type
Standard Plan Actual Standard Plan Actual Standard Plan ActualType (days) (days) Type (days) (days) Type (days) (days)
(GT) GT-1.1 MI 45 CI 10 10 TI 25 35GT-1.2 TI 25 CI 10 9 MI 45 45GT-1.3 TI 25 CI 10 11 MI 45 44
0 ST-1.0 SE 45 SI 18 12 SE 45 -GT-2.1 TI 25 TI 25 28 MI 45 45
TI: Turbine Inspection: HRSG GT-2.1 CI 10 10 -GT-2.2 MI 45 CI 10 9 TI 25 32
(ST) GT-2.2 - CI 10GT-2.3 CI 10 CI 10 10 MI 45 50GT-2.3 TI 25 MI 45 45 MI 45 45
0 ST-2.0 SE 45 SI 18 - SE 45 -GT-3.1 CI 10 TI 25 25 CI 10 10GT-3.2 CI+Co. 30 MI 45 34 CI 10 8GT-3.3 CI+Co. 30 MI 45 37 CI 10 10ST-3.0 ME 30 ME 30 35 SI 18 16TU-1 SI 16 SE 45 - SE 45 50TU-2 ME 30 ME 30 31 SI 16 15TU-3 SI 18 ME 30 35 SE+Granti 100 100TU-4 ME 30 SI+ 35 29 SE+Granti 100 98GT-1 CI 10 - - - HGPI 25 24GT-2 - - HGPI 25 22
(ST) TU-1 ME 42 ME 42 53 SI 26 26TU-1 SE 60 122TU-2 SE 57 SI 26 26 ME 42 -
0 -(GT: Alstom; GT-1, GE; GT-2) GT-1 MI 45 83 HGPI 30 26 CI 9 5
2005Standard Type / Interval / PeriodScheduled Maintenance / Inspection
Unit No.2003 2004
Final Report 3 - 72
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-7 Plans/Actual of Scheduled Maintenance/Inspection for 2006 by Unit Type (As of July 2006)
< Indonesia Power >
2006 2006 Standard Plan Actual Standard Plan Actual Power
Station unit No.
Type (days) (days) Power Station unit
No. Type (days) (days)
Tu-1 None GT-1.1 MI 101 94 Tu-2 None GT-1.2 HGPI 31 28 Tu-3 ME 30 27 GT-1.3 None Tu-4 ME 30 30 ST-1.0 SI 21 Tu-5 SE 60 56 GT-2.1 CI 8 5 Tu-6 ME 30 GT-2.2 MI 33 49
Suralaya
Tu-7 SI+ 30 GT-2.3 MI 51 In progress GT-1.1 B 14 12
Tambak Lorok
ST-2.0 SE 51 GT-1.2 B 14 13 Tu-1 SI 28 GT-1.2
Tanjung
C 45 Tu-2 SE 51 Priok
GT-1.3 B 14 13 Tu-3 SI+ 76 ST-1.0 None GT-1 A 9 9 GT-2.1 B 14 9
Gilimanuk GT-1 B 14
GT-2.2 C 45 GT-1 CI 14 11 GT-2.3 B 14 GT-2 MI 45 35
Pemaron
ST-2.0 MI 42 GT-2 CI 14 Tu-3 SI+Re 60 GT-1 None Perak Tu-4 ME+Reh 60 GT-2 CI 14 6
GT-1.1 None GT-3 MI 50 63 GT-1.2 MI 41 93
Pesanggaran
GT-4 MI 55 55 GT-1.3 MI 41 ST-1.0 MI 28 27 GT-2.1 None GT-2.2 TI 26 25
Grati
GT-2.3 TI 26 23
< PJB >
2006 2006 Standard Plan Actual Standard Plan Actual Power Station unit
No. Type (days) (days)
Power Station unit No.
Type (days) (days) Tu-1 SE 60 Tu-1 SI 16 16 Tu-2 ME 45 In progress Tu-2 SE 45 In progress Tu-3 SE 60 66 Tu-3 SE+Grant 100 99 Tu-4 SE 60 Tu-3 SI 18 Tu-5 ME 75 85 Tu-4 SI 18 Tu-5 SE 60 GT-1 None GT-1.1 HGPI 30 GT-2 CI 10 10 GT-1.2 CI 14 GT-1.1 CI 10 9 GT-1.3 CI 14 GT-1.1 MI+RI 45
Muara Karang
ST-1.0 SI 18 GT-1.2 CI 10 10 GT-1.1 B 21 14 GT-1.2 TI 25 GT-1.1 A 8 GT-1.3 CI 10 GT-1.2 B 21 10 ST-1.0 SE 45 GT-1.2 A 8 GT-2.1 CI 10 10 GT-1.3 C 45 60 GT-2.2 MI+RI 45 GT-1.3 A 8 8 GT-2.3 MI+RI 60 60 GT-1.3 B 21 ST-2.0 SE 45 47 ST-1.4 SE 45 40 GT-3.1 MI GT-2.1 A 8 9 GT-3.2 TI 25 25 GT-2.1 C 45 GT-3.3 TI 25 22 GT-2.2 A 8 9
Gresik
GT-3.0 SE 45
Muara Tawar
GT-2.2 C 45 Tu-1 None Paiton Tu-2 SE+ 75 73
Sources : INDONESIA POWER & PJB data
3 - 73 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
(3) Management of work plans
Indonesia Power and PJB confirm the status of the Preventive/Predictive/Corrective Maintenance and the new work plans, taking into account the 5-year midterm work plans and load balance by the internal meetings as listed below.
Internal Meetings at Power Station
Items Main Agenda
1 － Yearly Meeting (Develop 5 year Plan by Unit)
－ Planned Outage Scheduling
Rehabilitation, Major Modification , Re-powering, and Scheduled Inspection Plan etc.
－ Detail Planning & Scheduling of individual Outages － First Line Maintenance work orders Load Balancing － Monthly Schedule & Load Balancing － For coal
4 － Weekly Meeting (Develop Plan of the Week)
－ Work outside Outages － not urgent(required after 7 days) ・Preventive Maintenance ・Corrective Maintenance
5 － Daily Meeting (Develop Plan of the Day)
－ Work outside Outages － urgent (required in less than 7 days) ・Preventive Maintenance ・Corrective Maintenance
It is essential to collect and put together actual data of accidents and have discussions at such Internal Meetings in an effort to solve pending items in terms of the facilities and operations of the power stations so that appropriate troubleshooting can also be carried out.
(4) Information sharing among power stations
As shown in Table below, efforts have been made by the power stations of Indonesia Power and PJB to share information on the operation and maintenance of such power stations.
Final Report 3 - 74
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Information Exchange Meetings among the power stations Items PJB Indonesia power
Working Group Meeting New Information Sharing Meeting ・Attendance ・Frequency ・Main Agenda
－Start from 2006 －Specialist －Every 6 months －Good Practice Information Sharing
None Internal Meeting =Weekly meeting
It is very important to have Information Exchange Meetings regularly on such information as is useful for safe and stable operation of the power stations, namely, information on tasks for all management and personnel such as 1) measures to prevent critical disasters and 2) measures to prevent accidents affecting power supply so that overall spiraling improvement of performance can be achieved.
3.2.1.6. Operation and Maintenance Management System
(1) Organizations of Indonesia Power and PJB Power Stations
A typical organizational chart of a power station of Indonesia Power and PJB is as shown below.
3 - 75 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Organization Chart of an Indonesia Power Station
GENERAL MANAGER
SPESIALIS
OPERASIDAN
NIAGAPEMELIHARAAN LOGISTIK
SISTEMDANSDM
KEUANGAN HUMAENJINIRING
MANAJER
AUDITOR
Source : INDONESIA POWER data (T.PRIOK)
Organization Chart of a PJB PowerStation
MANAGER
AUDITOR ENJINIRING
OPERASI PEMELIHARAANKIMIADANLK 3
KEUANGANSUMBERDAYA
MANUSIAUMUM
Source : PJB data (M. KARANG)
The organizations of Indonesia Power and PJB which are engaged in operation and maintenance management of the power stations are of the same structure with each other.
(2) Routine Maintenance Management System of Power Stations
As shown in Table 3.2-8, Indonesian Power has established Maintenance System based on Location of Facilities while PJB has established Maintenance System based on Category of Maintenance Method. Therefore, Indonesia Power and PJB conduct maintenance management under the systems which are different from each other.
< Measures to cope with troubles due to deterioration of aging facilities > Since unpredictable troubles due to aged deterioration of power generation facilities are expected to increase in the future, it is essential for both Indonesia Power and PJB to consider reviewing the methods to tackle routine facility maintenance from the viewpoint of maintaining reliability of the facilities. For instance, measures to reinforce facility based maintenance are as follows: ① Inspection activities focusing on investigation of deterioration status of the whole
facilities ② Visual inspection by maintenance personnel who are familiar with their own
facilities ③ Study on the employment of new exclusive diagnosing tools as preventive measures
against deterioration of facilities
Final Report 3 - 76
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-8 System for Maintenance Division at Power Station Duty Main Task
Indonesia Power (IP)
(Deputy General Manager) ↓ ・Manager ↓ ・Supervisor Senior
IP adopts Maintenance System Based on Location of Facilities, while PJB adopts Maintenance System Based on Category of Maintenance Method. IP is recommended to strengthen their maintenance system and PJB is recommended to switch their maintenance system to the Maintenance System Based on Location of Facilities because it is envisaged the aged deterioration of power facilities is accelerating in the future.
(3) Sharing of roles between Power Station and Maintenance Business Unit (UBHAR/UHAR) for Scheduled Maintenance
As shown in Table 3.2-9 and Table 3.2-10, there are differences between Indonesia Power and PJB in the details of assistance provided by the Maintenance Business Unit (UBHAR/UHAR) in Scheduled Inspection Work and Scheduled Special Order Maintenance Work.
Indonesia Power’s UBHAR/UHAR : Main facilities such as boilers, turbines, generators, etc. PJB’s UBHAR/UHAR : All facilities such as main turbines, auxiliary
machinery and commonly used facilities.
Maintenance System Based on Category of Maintenance Method
Maintenance System Based on Location of Facilities
3 - 77 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
< Review of Quality Control System for Scheduled Inspection Work >
While the Quality Control of the Scheduled Inspection Work is performed jointly by Maintenance Division (UBHAR/UHAR), in view of the current status in which troubles due to inappropriate maintenance have frequently occurred and the increase of unexpected troubles due to aged deterioration of the power station facilities, it is recommended that Quality Control System be established with the user’s power station taking a leadership role.
Table 3.2-9 Sharing of Role between Maintenance Department of the Power Station and
Maintenance Business Unit (UBHAR/UHAR)
○ ：Responsible Task Indonesia Power PJB Category of Maintenance Power Station UBHAR Power Station UBHAR
1. Corrective Maintenance & Emergency work for PLTU, PLTGU and PLTG
e.g. ① Unscheduled maintenance work
(Fire accident or Trouble) ② Maintenance work against malfunctions
of facilities in operating division
○ ○
Major Accident
or Trouble
○ ○
Major Accidentor
Trouble
2. Predictive Maintenance for PLTU, PLTGU and PLTG
e.g. ① Condition-based maintenance should be
carried out on the low priority facilities ・Pump/Motor/Fan/Compressor, etc.
○ ━ ○ ━
3. Preventive Maintenance for PLTU, PLTGU and PLTG
e.g. ① Daily maintenance work ② Planning maintenance ③ Scheduled inspection work ④ Scheduled special order maintenance
・Main Facility・Auxiliary ・Ancillary ・Quality control
Remarks; UBHAR ; Maintenance Business Unit
In Scheduled Inspection Work, UBHAR/UHAR of IP are in charge of the main facilities and UBHAR/UHAR of PJB are in charge of all the facilities including main turbines, auxiliary machinery and commonly used facilities.
Final Report 3 - 78
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-10 Support System in UBHAR for Scheduled Maintenance/Inspection Work < Indonesia Power >
－ UBHAR Head-office in Jakarta city carries out two services as follows Internal Service for Indonesian Power’s Power station External Service for another IPP/companies －UBHAR Teams are dispatched to 5 units to support maintenance areas of each thermal power
station in JAVA-BALI Region ・Suralaya Area，T. Priok Area，Perak-Grati Area and Bali Area, Semarang Area －Each UBHAR Area Team carries out coordinating Scheduled Inspection works and Special
Order Maintenance works －UBHAR Head-office dispatches 1 or 2 persons (Expert persons) in order to support Quality
Control for UBHAR Area Team during Scheduled Inspection work which are Serious (Major)，Mean and Simple Inspection
<PJB>
－ UBHAR Head-office at Gresik carries out the internal service only for PJB’s power station － Every thermal power station in PJB has unit support maintenance as subordinate of UBHAR
They works for Scheduled Inspection Work and Special Order Maintenance Work － UBHAR Head-office dispatches 2 persons (Specialist, Supervisor) in order to support Quality
Control of UBHAR at power station during Scheduled Inspection works which are Serious (Major), Mean and Simple Inspection
UBHAR
(4) Status of regular personnel interchanges between operators and maintenance personnel
It appears that once the assignments of newcomers are fixed, their jobs are rarely changed. There have been few cases of regular personnel interchanges.
It is very important to regularly effect personnel changes between operators and maintenance staff so that improvement of the overall skills can be achieved. From the viewpoint of improving skills of the maintenance personnel of the power stations, personnel changes with the Maintenance Business personnel should be effected at regular intervals.
3 - 79 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-11 (1) Summary of Forced Outage for 2003, 2004 and 2005 at Each Unit Type PL
TU U
nit
Sur
alay
a P
/SP
aito
n P
/SM
uara
Kar
ang
P/S
Gre
sik
P/S
Tam
bak
Loro
k P
/SP
erak
P/S
Bas
e Lo
ad U
nit
Bas
e Lo
ad U
nit
Bas
e Lo
ad U
nit
Bas
e Lo
ad U
nit
Bas
e Lo
ad U
nit
Bas
e Lo
ad U
nit
Coa
l Fire
dC
oal F
ired
MFO
/HS
D/N
G F
ired
MFO
/NG
Fire
dM
FO F
ired
MFO
Fire
d
4x40
0MW
+ 3
x600
MW
2 x
400
MW
3x10
0MW
+ 2
x200
MW
2x10
0MW
+ 2
x200
MW
2x50
MW
+ 1
x200
MW
2 x
50M
W
Tro
uble
Item
sTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hour
s
1In
stru
men
tatio
n an
dC
ontro
l42
(9.2
)24
0.04
12(3
8.7)
71.7
574
(45.
6)1,
442.
807
(41.
7)75
.96
17(3
7.0)
145.
475
(14.
7)35
0.82
157
(40.
4)2,
326.
84
2Tu
rbin
e / G
ener
ator
14(1
1.5)
300.
728
(25.
8)15
1.14
33(2
0.4)
1,28
6.71
3(2
5.0)
40.9
58
(17.
4)37
3.41
13(3
8.2)
877.
4079
(20.
3)3,
030.
33
3B
oile
r and
Aux
iliar
ies
34(7
5.3)
1,97
6.69
11(3
5.5)
696.
3632
(19.
8)1,
849.
5814
(30.
4)56
3.08
16(4
7.1)
6,02
3.41
107
(27.
5)11
,109
.12
4C
able
/Rel
ay T
roub
le3
(1.9
)22
.20
4(3
3.3)
5.92
6(1
3.0)
37.9
413
(3.3
)66
.06
5In
verte
r Tro
uble
2(1
.2)
21.3
32
(0.5
)21
.33
6Tr
ansf
orm
er T
roub
le2
(1.2
)14
1.40
2(0
.5)
141.
40
7S
yste
m F
ault
or Ir
regu
lar
Freq
uenc
y10
(3.1
)82
.23
5(3
.1)
20.6
91
(2.2
)26
.57
16(4
.1)
129.
49
8O
ther
s2
(0.9
)23
.70
11(6
.8)
227.
7213
(3.3
)25
1.42
Tota
l10
2(1
00)
2,62
3.38
31(1
00)
919.
2516
2(1
00)
5,01
2.43
14(1
00)
122.
8346
(100
)1,
146.
4734
(100
)7,
251.
6338
9(1
00)
17,0
75.9
9
(Ref
eren
ce A
ttach
men
t She
ets)
- Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Nov
.) at
Pai
ton
and
Sura
laya
P/S
- Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Dec
.) at
Mua
ra K
aran
g P/
S
- Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Oct
.) at
Gre
sik
P/S
- Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Oct
.) at
Tam
bak
Loro
k P/
S
- Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
May
) at P
erak
P/S
Sou
rce
: Ind
ones
ia P
ower
, PJB
dat
a
Rem
arks
Tota
l
Final Report 3 - 80
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-11 (2) Summary of Forced Outage for 2003, 2004 and 2005 at Each Unit Type
PLTG
Uni
tM
uara
Taw
ar P
/SG
rati
P/S
Pes
angg
aran
P/S
Gili
man
uk P
/SP
emar
an P
/SP
eak
Load
Uni
tP
eak
Load
Uni
tP
eak
Load
Uni
tB
ase
Load
Uni
tP
eak
Load
Uni
tH
SD
Fire
dH
SD
Fire
dH
SD
Fire
dH
SD
Fire
dH
SD
Fire
d2
x 14
0 G
T3
x 10
0.8G
T1x
21.4
+ 1
x20
+ 2x
421
x 13
3.8G
T2
x 48
.8G
T T
roub
le It
ems
Tim
es (%
)H
ours
Tim
es (%
)H
ours
Tim
es (%
)H
ours
Tim
es (%
)H
ours
Tim
es (%
)H
ours
Tim
es (%
)Ho
urs
1In
stru
men
tatio
n an
dC
ontro
l21
(48.
8)71
6.11
56(7
0.9)
657.
604
(11.
4)12
.09
2(2
0.0)
26.1
311
(52.
4)31
.81
94(5
0.0)
1,44
3.74
2Tu
rbin
e / G
ener
ator
15(3
4.9)
388.
0618
(22.
8)40
7.99
24(6
8.6)
394.
504
(40.
0)15
.72
7(3
3.3)
87.3
568
(36.
2)1,
293.
62
3C
able
/ R
elay
Tro
uble
2(5
.7)
18.9
42
(20.
0)15
.80
3(1
4.3)
8.12
7(3
.7)
42.8
6
4El
ectri
cal F
ault
5(6
.3)
44.4
95
(2.7
)44
.49
5Sy
stem
Fau
lt or
Irre
gula
rFr
eque
ncy
1(2
.3)
0.48
4(1
1.4)
13.1
52
(20.
0)3.
477
(3.7
)17
.10
6D
erat
ing
6(1
4.0)
77.7
06
(3.2
)77
.70
7O
ther
s1
(2.9
)8.
021
(0.5
)8.
02
Tota
l43
(100
)1,
182.
3579
(100
)1,
110.
0835
(100
)44
6.70
10(1
00)
61.1
221
(100
)12
7.28
188
(100
)2,
927.
53
(Ref
eren
ce A
ttach
men
t She
ets)
- Sum
mar
y of
For
ced
Out
age
for 2
004
and
2005
(~ O
ct.)
at M
uara
Taw
ar P
/S- S
umm
ary
of F
orce
d O
utag
e fo
r 200
3, 2
004
and
2005
(~ D
ec.)
at G
rati
P/S
- Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Oct
.) at
Pes
angg
aran
P/S
, Gili
man
uk P
/S a
nd P
emar
an P
/S
Sou
rce
: Ind
ones
ia P
ower
, PJB
dat
a
Tota
l
Rem
arks
3 - 81 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-11 (3) Summary of Forced Outage for 2003, 2004 and 2005 at Each Unit Type PL
TGU
Uni
tTa
njun
g Pr
iok
P/S
Gre
sik
P/S
Mua
ra K
aran
g P
/SPe
ak L
oad
Uni
tP
eak
Load
Uni
tPe
ak L
oad
Uni
tH
SD/N
G F
ired
HS
D/N
G F
ired
NG
Fire
d3x
130G
T +
1x20
0ST
3x13
0GT
+ 1x
200S
T3x
112.
5GT
+ 1x
188.
9ST
3x11
2.5G
T +
1x18
8.9S
T3x
112.
5GT
+ 1x
188.
9ST
3x10
7.8G
T +
1x18
5ST
Tro
uble
Item
sTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rsTi
mes
(%)
Hou
rs
1In
stru
men
tatio
n an
dC
ontro
l25
(45.
5)24
1.52
11(2
1.6)
47.5
815
(30.
6)34
.74
12(1
9.0)
358.
0221
(37.
5)71
.61
57(5
0.9)
996.
54
2Tu
rbin
e / G
ener
ator
15(2
7.3)
214.
7627
(52.
9)16
1.42
5(1
0.2)
56.8
48
(12.
7)97
.40
3(5
.3)
103.
4425
(22.
3)1,
108.
36
3H
RS
G a
nd A
uxili
arie
s19
(38.
8)40
3.39
30(4
7.6)
177.
3417
(30.
4)14
5.42
3(2
.7)
84.2
8
4R
elay
Tro
uble
12(1
0.7)
255.
45
56k
V B
us T
roub
le5
(10.
2)13
.37
1(1
.6)
4.97
2(3
.6)
25.1
6
6U
PS S
yste
m T
roub
le1
(2.0
)6.
072
(3.2
)3.
58
7El
ectri
cal T
roub
le
8Sy
stem
Fau
lt or
Irre
gula
rFr
eque
ncy
13(2
3.6)
99.2
513
(25.
5)39
.68
4(8
.2)
4.59
9(1
4.3)
32.9
210
(17.
9)31
.40
10(8
.9)
102.
58
9D
erat
ing
10O
ther
s2
(3.6
)1.
271
(1.6
)22
.52
3(5
.3)
9.38
5(4
.5)
285.
33
Tota
l55
(100
)55
6.80
51(1
00)
248.
6849
(100
)51
9.00
63(1
00)
696.
7556
(100
)38
6.41
112
(100
)2,
832.
54
(Ref
eren
ce A
ttach
men
t She
ets)
- Sum
mar
y of F
orce
d O
utag
e fo
r 200
4 an
d 20
05 (~
Sep
.) at
Tan
jung
Prio
k P/
S- S
umm
ary o
f For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Dec
.) at
Gre
sik
P/S
- Sum
mar
y of F
orce
d O
utag
e fo
r 200
3, 2
004
and
2005
(~ D
ec.)
at M
uara
Kar
ang
P/S
Sour
ce :
Indo
nesi
a P
ower
, PJB
dat
a
Rem
arks
Final Report 3 - 82
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-11 (4) Summary of Forced Outage for 2003, 2004 and 2005 at Each Unit Type
PLTG
U U
nit
Mua
ra T
awar
P/S
Gra
ti P
/STa
mba
k Lo
rok
P/S
Pea
k Lo
ad U
nit
Pea
k Lo
ad U
nit
Pea
k Lo
ad U
nit
HS
D F
ired
HS
D F
ired
HS
D F
ired
3x14
0GT
+ 1x
220S
T3x
100.
8GT
+ 15
9.6S
T3x
109.
7GT
+ 1x
188S
T3x
109.
7GT
+ 1x
188S
T T
roub
le It
ems
Tim
es (%
)H
ours
Tim
es (%
)H
ours
Tim
es (%
)H
ours
Tim
es (%
)H
ours
Tim
es (%
)Ho
urs
1In
stru
men
tatio
n an
dC
ontro
l55
(20.
8)50
4.06
92(4
5.5)
727.
7355
(49.
1)55
5.69
40(5
2.6)
291.
6138
3(3
6.8)
3,82
9.10
2Tu
rbin
e / G
ener
ator
34(1
2.8)
556.
9433
(16.
3)38
6.48
18(1
6.1)
134.
2518
(23.
7)14
5.04
186
(17.
9)2,
964.
93
3H
RS
G a
nd A
uxili
arie
s3
(1.1
)4.
616
(3.0
)5.
0020
(17.
9)85
.44
10(1
3.2)
31.8
910
8(1
0.4)
937.
37
4R
elay
Tro
uble
12(1
.2)
255.
45
56k
V B
us T
roub
le8
(0.8
)43
.50
6U
PS
Sys
tem
Tro
uble
3(0
.3)
9.65
7E
lect
rical
Tro
uble
2(0
.8)
21.8
06
(5.3
)39
.68
3(3
.9)
1.80
11(1
.1)
63.2
8
8S
yste
m F
ault
or Ir
regu
lar
Freq
uenc
y13
(4.9
)17
4.06
1(0
.5)
4.28
4(3
.6)
10.0
877
(7.4
)49
8.84
9D
erat
ing
152
(57.
3)15
,871
.83
152
(14.
6)15
,871
.83
10O
ther
s6
(2.3
)20
2.87
70(3
4.7)
1,64
8.16
9(8
.0)
62.2
15
(6.6
)3.
2210
1(9
.7)
2,23
4.96
Tota
l26
5(1
00)
17,3
36.1
720
2(1
00)
2,77
1.65
112
(100
)88
7.35
76(1
00)
473.
561,
041
(100
)26
,708
.91
(Ref
eren
ce A
ttach
men
t She
ets)
- Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Oct
.) at
Mua
ra T
awar
P/S
- Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Dec
.) at
Gra
ti P
/S- S
umm
ary
of F
orce
d O
utag
e fo
r 200
3, 2
004
and
2005
(~ N
ov.)
at T
amba
k Lo
rok
P/S
Sou
rce
: Ind
ones
ia P
ower
, PJB
dat
a
Tota
l
Rem
arks
3 - 83 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (1) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station Su
mm
ary
of F
orce
d O
utag
e fo
r 200
3, 2
004
and
2005
(~ O
ct.)
at M
uara
Taw
ar P
/SN
o. o
f Uni
t Tro
uble
s (T
imes
)To
tal S
hutd
own
(Out
age)
Hou
rs (H
ours
)P
LTG
U-B
lock
1P
LTG
-Blo
ck 2
PLT
GU
-Blo
ck 1
PLT
G-B
lock
2Tr
oubl
e Ite
ms
GT1
.1G
T1.2
GT1
.3S
T1.4
Tota
lG
T2.1
GT2
.2To
tal
GT1
.1G
T1.2
GT1
.3S
T1.4
Tota
lG
T2.1
GT2
.2To
tal
1.55
2176
504.
0671
6.11
1,22
0.17
1)Pu
lse
Ala
rm T
roub
le7
18
33
614
121.
020.
5012
1.52
8.48
22.3
530
.83
152.
35
2)Ig
nitio
n Tr
oubl
e4
41
93
710
1941
.13
28.7
618
.65
88.5
463
.09
258.
3332
1.42
409.
96
3)Tu
rbin
e/B
earin
g Te
mpe
ratu
re H
igh
21
32
25
18.7
01.
3720
.07
130.
2313
0.23
150.
30
4)Lu
bric
ant O
il Tr
oubl
e5
55
100.
1110
0.11
100.
11
5)D
rum
Lev
el H
igh/
Low
44
420
.55
20.5
520
.55
6)O
ther
s12
55
426
21
329
103.
6214
.46
18.3
316
.86
153.
2717
9.05
54.5
823
3.63
386.
90
2.Tu
rbin
e / G
ener
ator
3415
4955
6.94
388.
0694
5.00
1)Tu
rbin
e3
42
110
25
717
25.0
992
.26
28.4
06.
4015
2.15
101.
1358
.66
159.
7931
1.94
2)G
enra
tor
11
35
22
739
.73
41.1
213
8.87
219.
7216
6.67
166.
6738
6.39
3)Au
xilia
ries
113
32
192
46
2511
8.22
25.3
031
.04
10.5
118
5.07
33.5
128
.09
61.6
024
6.67
3.H
RSG
and
Aux
iliar
ies
33
4.61
4.61
1)H
RS
G
33
3
4.61
4.61
4.61
2)Au
xilia
ries
4.2
22
21.8
021
.80
21.8
0
5.13
114
174.
060.
4817
4.54
1)Sy
stem
Tro
uble
43
13
1111
37.7
613
.13
7.67
114.
7217
3.28
173.
28
2)Fr
eque
ncy
Hig
h/Lo
w1
12
11
30.
330.
450.
780.
480.
481.
26
6.15
26
158
15,8
71.8
377
.70
15,9
49.5
3
1)By
Tro
uble
& R
epai
r6
112
313
06
613
614
3.95
4.80
8,19
8.51
8,34
7.26
77.7
077
.70
2)By
Insp
ectio
n22
2222
7,52
4.57
7,52
4.57
7.O
ther
s1
56
614
8.50
54.3
720
2.87
202.
87
4728
1517
526
514
2943
308
590.
7940
8.27
147.
0316
,190
.08
17,3
36.1
755
1.93
630.
421,
182.
3518
,518
.52
Sou
rce
: Ind
ones
ia P
ower
, PJB
Dat
a
Tota
l
Syst
em F
ault
or Ir
regu
lar F
requ
ency
Tota
l
Inst
rum
enta
tion
and
Con
trol
Tota
l
Der
atin
g
Con
vert
er T
roub
le
Final Report 3 - 84
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (2) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station
Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Oct
.) at
Gre
sik
P/S
Tota
l Shu
tdow
n (O
utag
e) H
ours
(Hou
rs)
PLTG
U-B
lock
1PL
TGU
-Blo
ck 2
PLT
GU
-Blo
ck 3
PLTU
Trou
ble
Item
sG
T1.1
GT1
.2G
T1.3
ST1
Tota
lG
T2.1
GT2
.2G
T2.3
ST2
Tota
lG
T3.1
GT3
.2G
T3.3
ST3
Tota
lU
-1U
-2U
-3U
-4To
tal
1.34
.74
358.
0271
.61
75.9
6
1)Fu
el G
as S
uppl
yPr
ess.
Trip
2.06
5.13
14.8
33.
8025
.82
26.4
719
8.52
4.20
229.
196.
8037
.39
1.47
4.28
49.9
4
2)M
FT T
rip6.
756.
755.
281.
757.
031.
7531
.85
33.6
0
3)Fi
re A
larm
Trip
3.15
78.2
781
.42
5.69
5.69
4)Lo
ss o
f Fue
l Trip
14.7
214
.72
5)Lo
ss o
f Fla
me
Trip
0.26
0.26
6)O
ther
s1.
171.
002.
174.
950.
9227
.44
14.1
047
.41
2.73
1.58
1.07
3.57
8.95
27.3
827
.38
2.Tu
rbin
e / G
ener
ator
56.8
497
.40
103.
4440
.95
1)Tu
rbin
e4.
9316
.30
21.2
31.
373.
650.
935.
9556
.87
56.8
71.
601.
60
2)Au
xilia
ries
13.5
513
.31
8.75
35.6
178
.93
78.9
346
.57
46.5
72.
5036
.85
39.3
5
3)G
ener
ator
3.00
2.95
6.57
12.5
2
3.H
RSG
and
Aux
iliar
ies
403.
3917
7.34
145.
42
1)H
RSG
45.1
535
2.21
397.
3660
.23
63.2
253
.89
177.
3467
.03
2.38
48.6
311
8.04
2)Au
xilia
ries
6.03
6.03
27.3
827
.38
4.R
elay
Tro
uble
1.28
1.72
2.92
5.92
5.6k
V B
us T
roub
le13
.37
13.3
74.
974.
9712
.58
12.5
825
.16
6.U
PS S
yste
m T
roub
le6.
076.
073.
583.
58
7.4.
5932
.92
31.4
0
1)Sy
stem
Tro
uble
3.41
3.41
23.4
12.
4525
.86
3.19
5.93
3.27
8.80
21.1
9
2)Fr
eque
ncy
Hig
h/Lo
w1.
181.
186.
560.
507.
0610
.21
10.2
1
8.O
ther
s22
.52
22.5
23.
450.
685.
259.
38
61.9
337
.15
398.
1621
.76
519.
0012
8.83
348.
2419
1.09
28.5
969
6.75
147.
5978
.11
126.
2334
.48
386.
4147
.63
33.7
11.
7239
.77
122.
83So
urce
: In
done
sia
Pow
er, P
JB D
ata
Tota
l
Syst
em F
ault
or Ir
regu
lar
Freq
uenc
y
Inst
rum
enta
tion
and
Con
trol
3 - 85 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (3) S m a of For ge for 2003, 2004 and 2005 at E ch Pow Station u m ry ced Outa a er
Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Oct
.) at
Gre
sik
P/S
Num
ber o
f Uni
t Tro
uble
(Tim
es)
PLT
GU
-Blo
ck 1
PLT
GU
-Blo
ck 2
PLT
GU
-Blo
ck 3
PLT
UTr
oubl
e Ite
ms
GT1
.1G
T1.2
GT1
.3S
T1To
tal
GT2
.1G
T2.2
GT2
.3S
T2To
tal
GT3
.1G
T3.2
GT3
.3S
T3To
tal
U-1
U-2
U-3
U-4
Tota
l1.
Inst
rum
enta
tion
and
Con
trol
1512
217
1)Fu
el G
as S
uppl
y P
ress
. Trip
23
42
111
12
43
23
120
2)M
FT T
rip2
20
11
21
34
3)Fi
re A
larm
Trip
01
21
42
20
4)Lo
ss o
f Fue
l Trip
00
01
1
5)Lo
ss o
f Fla
me
Trip
00
01
1
6)O
ther
s1
12
11
22
62
11
15
11
2.Tu
rbin
e / G
ener
ator
58
33
1)Tu
rbin
e1
12
12
14
11
11
2)A
uxili
arie
s1
11
31
12
21
12
3)G
ener
ator
01
11
30
0
3.H
RSG
and
Aux
iliar
ies
1930
170
1)H
RS
G3
1518
1011
930
81
716
0
2)A
uxili
arie
s1
10
11
0
4.R
elay
Tro
uble
00
01
21
4
5.6k
V B
us T
roub
le5
51
11
12
0
6.U
PS S
yste
m T
roub
le1
12
20
0
7.Sy
stem
Fau
lt or
Irre
gula
r Fre
quen
cy4
910
0
1)S
yste
m T
roub
le3
35
16
22
14
90
2)Fr
eque
ncy
Hig
h/Lo
w1
12
13
11
0
8.O
ther
s0
11
11
13
0
79
2211
4919
1820
663
209
1710
565
52
214
Sou
rce
: Ind
ones
ia P
ower
, PJB
Dat
aTo
tal
Final Report 3 - 86
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (4) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station
Trou
ble
Item
Uni
t-1U
nit-2
Uni
t-3U
nit-4
Uni
t-5U
nit-6
Uni
t-7To
talU
nit-1
Uni
t-2To
tal
Uni
t-1U
nit-2
Uni
t-3U
nit-4
Uni
t-5U
nit-6
Uni
t-7To
tal
Uni
t-1U
nit-2
Tota
l
4212
240.
0471
.75
1)Fu
rnac
e D
raft
Pre
ssur
e H
igh/
Low
22
37
04.
074.
488.
4717
.02
0.00
2)D
rum
Lev
el H
igh/
Low
63
21
45
210
15.6
814
.08
8.88
2.52
29.5
931
.67
102.
420.
00
3)M
FT T
rip4
15
57
1216
.51
3.52
20.0
337
.70
34.0
571
.75
4)M
ill T
rip1
12
041
.92
2.58
44.5
00.
00
5)O
ther
s1
11
11
27
07.
281.
5511
.15
4.63
11.5
219
.94
56.0
70.
00
2. T
urbi
ne /
Gen
erat
or14
830
0.72
151.
14
1)Tu
rbin
e1
41
28
22
6.92
125.
140.
2740
.14
172.
4711
.65
11.6
5
2)A
uxili
arie
s2
13
55
62.2
725
.78
88.0
513
8.86
138.
86
3)G
ener
ator
12
31
18.
5031
.70
40.2
00.
630.
63
3. B
oile
r and
Aux
iliar
ies
3411
1976
.69
696.
36
1)B
oile
r/Tub
e Le
ak9
64
827
47
1156
4.01
363.
4222
0.91
498.
5916
46.9
321
1.01
485.
3569
6.36
2)A
uxili
arie
s1
15
70
188.
6887
.33
53.7
532
9.76
0.00
100
82.2
30.
00
1)S
yste
m T
roub
le2
21
16
04.
1812
.80
11.2
312
.10
40.3
10.
00
2)Fr
eque
ncy
Hig
h/Lo
w1
11
14
010
.17
17.1
54.
639.
9741
.92
0.00
5. O
ther
s1
12
06.
2317
.47
23.7
00.
00
Tota
l20
2516
177
98
102
1615
3185
6.08
648.
3333
4.86
599.
4233
.63
96.8
754
.19
2,62
3.38
399.
2252
0.03
919.
25
Sou
rce
: Ind
ones
ia P
ower
, PJB
Dat
a
1. In
stru
men
tatio
n an
d
Con
trol
4. S
yste
m F
ault
or
Irre
gula
r Fre
quen
cy
PLT
U: P
aito
n P
/SN
umbe
r of U
nit T
rips
(Tim
es)
Tota
l Shu
tdow
n (O
utag
e) H
ours
(Hou
rs)
Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 a
t Sur
alay
a an
d Pa
iton
Pow
er S
tatio
ns
PLT
U: S
ural
aya
Pow
er S
tatio
n P
LTU
: Pai
ton
P/S
PLTU
: Sur
alay
a P
ower
Sta
tion
3 - 87 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (5) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station
Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (
~ M
ay) a
t Per
ak P
/SN
o. o
f Uni
t Tro
uble
s (T
imes
)To
tal S
hutd
own
(Out
age)
Hou
rs (H
ours
)
Trou
ble
Item
sP
LTU
3PL
TU4
Tota
lP
LTU
3P
LTU
4To
tal
1.5
535
0.82
350.
82
1)Fl
ame
Out
Trip
22
213
0.43
130.
4313
0.43
2)D
rum
Lev
el H
igh/
Low
3)M
TF T
rip
4)C
ontro
l Val
ve T
roub
le2
22
217.
2221
7.22
217.
22
5)O
ther
s1
11
3.17
3.17
3.17
2.Tu
rbin
e / G
ener
ator
1313
877.
4087
7.40
1)Tu
rbin
e3
47
757
.35
618.
6067
5.95
675.
95
2)Au
xilia
ries
32
55
69.2
860
.67
129.
9512
9.95
3)G
enra
tor
11
171
.50
71.5
071
.50
3.Bo
iler a
nd A
uxili
arie
s16
166,
023.
416,
023.
41
1)B
oile
r / T
ube
Leak
66
1212
2,92
6.66
2,87
9.94
5,80
6.60
5,80
6.60
2)B
oile
r Cas
ing
/ Bur
ner T
roub
le3
33
191.
6419
1.64
191.
64
3)Au
xilia
ries
11
125
.17
25.1
725
.17
4.
1)S
yste
m T
roub
le
2)Fr
eque
ncy H
igh/
Low
5O
ther
s
1717
3434
3,37
0.35
3,88
1.28
7,25
1.63
7,25
1.63
Sou
rce
: Ind
ones
ia P
ower
, PJB
Dat
a
Tota
l
Syst
em F
ault
or Ir
regu
lar F
requ
ency
Tota
l
Inst
rum
enta
tion
and
Cont
rol
Tota
lP
LTU
-Blo
ck 1
PLTU
-Blo
ck 1
Final Report 3 - 88
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (6) Summary of Forced Outage for 200 , 2004 nd 200 at Each Power Station 3 a 5
Sum
mar
y of
For
ced
Out
age
for 2
004
and
2005
(~ S
ep.)
at T
anju
ng P
riok
P/S
Num
ber o
f Uni
t Tro
uble
s (T
imes
)To
tal S
hutd
own
(Out
age)
Hou
rs (H
ours
)P
LTG
U-B
lock
1PL
TGU
-Blo
ck 2
PLT
GU
-Blo
ck 1
PLT
GU
-Blo
ck 2
Trou
ble
Item
sG
T1.1
GT1
. 2G
T1.3
ST1
.4To
tal
GT2
.1G
T2.2
GT2
.3ST
2.4
Tota
lG
T1.1
GT1
.2G
T1.3
ST1.
4To
tal
GT2
.1G
T2.2
GT2
.3S
T2.4
Tota
l
1.25
1136
241.
5247
.58
289.
10
1)Fu
el G
as C
ontro
lTr
oubl
e2
13
21
14
717
.69
0.12
17.8
122
.77
2.70
1.48
26.9
544
.76
2)C
ontro
l Val
veTr
oubl
e3
31
14
16.1
616
.16
3.85
3.85
20.0
1
3)Fl
ame
Out
Trip
11
125
.87
25.8
725
.87
4)M
FT T
rip3
33
25.1
125
.11
25.1
1
5)V
acuu
m L
ow2
21
13
32.9
732
.97
1.85
1.85
34.8
2
6)Fi
re A
larm
Trip
11
197
.70
97.7
097
.70
7)O
ther
s2
51
412
22
15
171.
9110
.34
9.15
4.50
25.9
03.
248.
992.
7014
.93
40.8
3
2.Tu
rbin
e / G
ener
ator
1527
4221
4.76
161.
4237
6.18
1)Tu
rbin
e1
15
18
12
710
185.
1660
.96
121.
320.
1518
7.59
0.42
4.62
11.7
916
.83
204.
42
2)A
uxili
arie
s1
12
22
46
1.72
2.80
4.52
45.4
127
.25
72.6
677
.18
3)G
ener
ator
41
54
17
113
186.
0816
.57
22.6
531
.17
7.40
30.7
12.
6571
.93
94.5
8
3.13
1326
99.2
539
.68
138.
93
1)S
yste
m T
roub
le2
44
103
14
412
224.
3814
.18
73.2
191
.77
15.9
32.
409.
3210
.50
38.1
512
9.92
2)Fr
eque
ncy
Hig
h/Lo
w1
23
11
43.
933.
557.
481.
531.
539.
01
4.O
ther
s1
12
02
0.90
0.37
1.27
1.27
1610
1712
5510
918
1451
106
69.2
821
5.36
190.
6381
.53
556.
8071
.40
65.4
282
.37
29.4
924
8.68
805.
48
Sou
rce
: Ind
ones
ia P
ower
, PJB
Dat
a
Tota
l
Syst
em F
ault
orIrr
egul
ar F
requ
ency
Tota
l
Inst
rum
enta
tion
and
Con
trol
Tota
l
3 - 89 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (7) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station Su
mm
ary
of F
orce
d O
utag
e fo
r 200
3, 2
004
and
2005
(~D
ec.)
at M
uara
Kar
ang
P/S
No.
of U
nit T
roub
les
(Tim
es)
Tota
l Shu
tdow
n (O
utag
e) H
ours
(Hou
rs)
Trou
ble
Item
sG
T1.1
GT1
.2G
T1.3
ST1
.0To
tal
GT1
.1G
T1.2
GT1
.3ST
1.0
Tota
l1.
5757
996.
5499
6.54
1)Fu
el G
as S
uppl
y Tr
ip2
22
138.
1113
8.11
138.
11
2)G
as S
uppl
y P
ress
ure
Low
21
21
66
13.1
011
.27
15.5
415
.48
55.3
955
.39
3)Fl
ame
Out
Trip
21
33
31.5
823
.85
55.4
355
.43
4)Fi
re A
larm
Trip
31
26
655
.28
48.7
060
.78
164.
7616
4.76
5)E
xhau
st T
empe
ratu
re H
igh
57
1212
99.2
166
.05
165.
2616
5.26
6)Ig
nitio
n Tr
oubl
e1
11
20.9
520
.95
20.9
5
7)C
ontro
l Val
ve T
roub
le1
11
11.7
211
.72
11.7
2
8)Lo
ss o
f Exc
itatio
n8
412
1217
7.47
58.0
723
5.54
235.
54
9)V
acuu
m L
ow4
44
54.7
754
.77
54.7
7
10)O
ther
s2
21
510
1022
.15
17.5
66.
8548
.05
94.6
194
.61
2.Tu
rbin
e / G
ener
ator
2525
1,10
8.36
1,10
8.36
1)Tu
rbin
e2
11
1014
1493
.58
0.14
50.2
225
2.25
396.
1939
6.19
2)Au
xilia
ries
77
763
8.28
638.
2863
8.28
3)G
ener
ator
13
44
18.0
555
.84
73.8
973
.89
3.H
RSG
and
Aux
iliar
ies
33
84.2
884
.28
1)H
RS
G
2)Au
xilia
ries
12
33
0.75
83.5
384
.28
84.2
8
4.10
1010
2.58
102.
58
1)S
yste
m T
roub
le4
22
88
55.6
43.
0043
.79
102.
4310
2.43
2)Fr
eque
ncy
Hig
h/Lo
w2
22
0.15
0.15
0.15
5.12
1225
5.45
255.
45
1)R
elay
Tro
uble
27
312
1217
.74
190.
1547
.56
255.
45
6O
ther
s1
45
520
4.48
80.8
528
5.33
285.
33
2630
1640
112
112
545.
1969
7.86
350.
391,
239.
102,
832.
542,
832.
54S
ourc
e : I
ndon
esia
Pow
er, P
JB D
ata
Tota
l
Syst
em F
ault
or Ir
regu
lar F
requ
ency
Tota
l
Inst
rum
enta
tion
and
Con
trol
Tota
l
Rel
ay T
roub
le
PLT
GU
-Blo
ck 1
PLTG
U-B
lock
1
Final Report 3 - 90
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (8) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station
Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Dec
.) at
Mua
ra K
aran
g P/
SN
umbe
r of U
nit T
roub
les
(Tim
es)
Tota
l Shu
tdow
n (O
utag
e) H
ours
(hou
rs)
PLT
UPL
TUTr
oubl
e Ite
ms
12
34
5To
tal
12
34
5To
tal
1.74
1,44
2.80
1)Fl
ame
Out
Trip
65
1114
.74
79.5
794
.31
2)Fu
el O
il S
uppl
y P
ress
. Trip
22
2.51
2.51
3)Fu
el O
il P
ress
. Low
35
879
.71
43.4
812
3.19
4)D
rum
Lev
el H
igh/
Low
11
13
1.25
108.
872.
1711
2.29
5)Tr
ippe
d du
e to
BM
S T
roub
le2
12
518
.87
1.03
20.6
140
.51
6)M
W M
eter
and
Tur
bine
Spe
ed M
eter
Abn
orm
al4
412
.41
12.4
1
7)V
accu
m L
ow1
46
113.
0357
.01
19.1
679
.20
8)A
ir Fl
ow L
ow3
14
18.0
13.
5921
.60
9)C
onde
nsat
e Lo
st F
low
44
35.4
935
.49
10)O
ther
s1
74
46
226.
9212
6.84
377.
2110
1.32
309.
0092
1.29
2.Tu
rbin
e / G
ener
ator
331,
286.
71
1)Tu
rbin
e4
12
18
214.
7348
.75
27.5
428
.50
319.
52
2)A
uxili
arie
s4
26
39
2472
.44
23.8
914
0.73
135.
7745
8.99
831.
82
3)G
ener
ator
11
135.
3713
5.37
3.B
oile
r and
Aux
iliar
ies
321,
849.
58
1)B
oile
r/Tub
e Le
ak2
32
11
917
7.20
209.
7913
7.82
4.55
25.4
355
4.79
2)A
ir H
eate
r Tro
uble
11
81
314
111.
3317
.77
539.
3624
.70
193.
4388
6.59
3)A
uxili
arie
s3
11
13
917
7.15
5.33
43.5
229
.25
152.
9540
8.20
4.In
vert
er T
roub
le2
221
.33
21.3
3
5.1
11
313
.73
6.45
2.02
22.2
0
6.1
12
124.
5316
.87
141.
40
7.2
11
46.
781.
758.
8017
.33
8.1
13.
363.
36
9.O
ther
s1
13
15
1124
.25
28.6
760
.80
29.0
384
.97
227.
72
2427
2929
5316
281
6.67
786.
851,
373.
5858
1.48
1,45
3.85
5,01
2.43
Sour
ce :
Indo
nesi
a Po
wer
, PJB
Dat
a
Tran
sfor
mer
Tro
uble
Tota
l
Inst
rum
enta
tion
and
Con
trol
LS o
r Rel
ay T
roub
le
Syst
em T
roub
le
Freq
uenc
y H
igh/
Low
3 - 91 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (9) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station Su
mm
ary
of F
orce
d O
utag
e fo
r 200
3, 2
004
and
2005
(~ N
ov.)
at T
amba
k Lo
rok
P/S
Tota
l Shu
tdow
n (O
utag
e) H
ours
(Hou
rs)
for P
LTU
PLTG
U-B
lock
1PL
TGU
-Blo
ck 2
PLTG
U-B
lock
1P
LTG
U-B
lock
2Tr
oubl
e Ite
ms
GT1
.1G
T1.
3
2GT1
.3S
T1.0
Tota
lGT2
.1G
T2.2
GT2
.ST
2.0
Tota
lTU
1TU
2TU
3To
tal
GT1
.1G
T1.2
GT1
.3ST
1.0
Tota
lG
T2.1
GT2
.2G
T2.3
ST2.
0To
tal
TU 1
TU 2
TU 3
Tota
l
1.In
stru
men
tatio
nan
d C
ontr
ol55
4017
112
555.
6929
1.61
145.
4799
2.77
1)Lo
ss o
f Fla
me
1
11
33
2.83
0.40
0.58
3.81
3.81
2)Ig
nitio
n Tr
oubl
e1
12
11
24
4.10
20.7
524
.85
4.25
9.97
14.2
239
.07
3)IP
C/P
DC
/DC
C/D
CS
Trou
ble
BCS
Trou
ble
218
207
75
51
1138
2.31
191.
2819
3.59
69.0
869
.08
59.0
020
.60
0.75
80.3
534
3.02
4)Fi
re P
rote
ctio
nTr
oubl
e4
31
82
210
19.6
222
.07
3.32
45.0
12.
622.
6247
.63
5)Ex
haus
t Vac
uum
Trou
ble
Vacu
um L
ow2
22
68
31
414
81.0
581
.05
1.26
6.59
7.85
14.8
55.
7220
.57
109.
47
6)H
PU T
roub
le6
62
28
88.1
888
.18
42.7
342
.73
130.
91
7)O
ther
sO
ther
s1
21
1317
21
211
161
12
3527
.02
13.6
51.
4780
.87
123.
017.
3765
.77
2.85
75.3
115
1.30
1.17
43.3
844
.55
318.
86
2.Tu
rbin
e / G
ener
ator
1818
844
134.
2514
5.04
373.
4165
2.70
1)Tu
rbin
eTu
rbin
e2
24
13
11
610
44.2
08.
0052
.20
1.13
10.3
41.
4534
.88
47.8
010
0.00
3)Au
xilia
ries
Auxi
liarie
s2
17
101
910
13
37
274.
129.
5218
.01
31.6
52.
9253
.67
56.5
980
.12
106.
3645
.51
231.
9932
0.23
2)G
ener
ator
Gen
erat
or2
24
11
21
17
48.5
01.
9050
.40
32.2
28.
4340
.65
141.
4214
1.42
232.
47
3.B
oile
r and
Aux
iliar
ies
2010
1444
85.4
431
.89
563.
0868
0.41
1)H
RS
GBo
iler /
Tub
e Le
ak1
11
1720
16
310
28
1040
0.12
0.12
0.83
84.3
785
.44
6.45
24.0
01.
4431
.89
65.5
645
4.64
520.
2063
7.53
2)Au
xilia
ries
Auxi
liarie
s2
11
44
25.8
13.
2713
.80
42.8
842
.88
4.Sy
stem
Fau
lt or
Irreg
ular
Fre
quen
cy4
15
10.0
826
.57
36.6
5
1)Sy
stem
Tro
uble
Syst
em T
roub
le1
11
12
3.80
3.80
26.5
726
.57
30.3
7
2)Fr
eque
ncy
Hig
h/Lo
wFr
eque
ncy
Hig
h/Lo
w3
33
6.28
6.28
6.28
5.C
able
/ R
elay
Trou
ble
63
615
39.6
81.
8037
.94
79.4
2
1)El
ectri
cal T
roub
leC
able
Tro
uble
31
11
62
13
21
312
31.3
81.
404.
502.
4039
.68
1.60
0.20
1.80
25.8
05.
2831
.08
72.5
6
2)R
elay
Tro
uble
21
33
4.53
2.33
6.86
6.86
6O
ther
s1
33
29
14
514
0.15
46.8
713
.59
1.60
62.2
10.
372.
853.
2265
.43
1612
1173
112
915
844
7611
1916
4623
412
8.92
122.
6472
.73
563.
0688
7.35
55.8
511
3.30
9.43
294.
9847
3.56
191.
9029
0.40
664.
171,
146.
472,
507.
38
Sour
ce :
Indo
nesi
a Po
wer
, PJB
Dat
a
Turb
ine
/ Gen
erat
or
HR
SG a
ndA
uxili
arie
s
Oth
ers
No.
of U
nit T
roub
les
(Tim
es)
Tota
l
Tota
l
Syst
em F
ault
orIrr
egul
ar F
requ
ency
Inst
rum
enta
tion
and
Con
trol
Elec
tric
al T
roub
le
PLTU
PLTU
Tota
l
Final Report 3 - 92
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (10) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station
Sum
mar
y of
For
ced
Out
age
for 2
003,
200
4 an
d 20
05 (~
Dec
.) at
Gra
ti P/
SN
o. o
f Uni
t Tro
uble
s (T
imes
)To
tal S
hutd
own
(Out
age)
Hou
rs (H
ours
)PL
TGU
-Blo
ck 1
PLTG
-Blo
ck 2
PLTG
U-B
lock
1PL
TG-B
lock
2Tr
oubl
e Ite
ms
GT1
.1G
T1.2
GT1
.3ST
1.0
Tota
lG
T2.1
GT2
.2G
T2.3
Tota
lG
T1.1
GT1
.2G
T1.3
ST1.
0To
tal
GT2
.1G
T2.2
GT2
.3To
tal
1.92
5614
872
7.73
657.
601,
385.
33
1)Fl
ame
Out
Trip
33
51
1214
316
3345
46.7
883
.88
110.
408.
1324
9.19
87.1
817
4.15
293.
5855
4.91
804.
10
2)Te
mpe
r. C
ontro
lTr
oubl
e20
2629
7511
74
2297
84.5
710
6.05
151.
4534
2.07
28.9
058
.00
9.17
96.0
743
8.14
3)Fi
rel A
larm
Trip
11
120
.65
20.6
520
.65
4)C
ontro
l Val
ve T
roub
le1
12
218
.42
90.0
010
8.42
108.
42
5)O
ther
s2
21
13
7.40
7.40
6.62
6.62
14.0
2
2.Tu
rbin
e / G
ener
ator
3318
5138
6.48
407.
9979
4.47
1)Tu
rbin
e2
31
612
13
37
1956
.98
70.3
711
.87
19.9
715
9.19
6.72
35.5
812
0.47
162.
7732
1.96
2)A
uxili
arie
s8
21
415
34
722
119.
6919
.20
8.08
69.7
321
6.70
40.4
087
.83
128.
2334
4.93
3)G
ener
ator
31
26
44
103.
902.
983.
7110
.59
116.
9911
6.99
127.
58
3.H
RSG
and
Aux
iliar
ies
66
5.00
5.00
1)H
RSG
42
66
3.50
1.50
5.00
5.00
2)A
uxili
arie
s
4.El
ectr
ical
Fau
lt3
25
521
.59
22.9
044
.49
44.4
9
5.1
14.
284.
28
1)S
yste
m T
roub
le
2)Fr
eque
ncy
Hig
h/Lo
w1
11
4.28
4.28
4.28
6.O
ther
s1
6970
7023
.22
1,62
4.94
1,64
8.16
1,64
8.16
3641
4184
202
3024
2579
281
311.
9234
5.29
380.
561,
733.
882,
771.
6516
9.82
494.
1444
6.12
1,11
0.08
3,88
1.73
Sou
rce
: Ind
ones
ia P
ower
, PJB
Dat
a
Tota
l
Syst
em F
ault
or Ir
regu
lar
Fre q
uenc
y Tota
l
Inst
rum
enta
tion
and
Con
trol
Tota
l
3 - 93 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-12 (11) Summary of Forced Outage for 2003, 2004 and 2005 at Each Power Station Su
mm
ary
of F
orce
d O
utag
e fo
r 200
3, 2
004
and
2005
(~ O
ct.)
at B
ali P
/Ss
Tota
l Shu
tdow
n (O
utag
e) H
ours
(Hou
rs)
Pesa
ngga
ran
Gili
man
ukPL
TG P
esan
ggar
anPL
TG G
ilim
anu k
Trou
ble
Item
sG
T1G
T2G
T3G
T4To
tal
GT1
Tota
lG
T1G
T2To
tal
GT1
GT2
GT3
GT4
Tota
lG
T1To
tal
GT1
GT2
Tota
l1.
42
1117
12.0
926
.13
31.8
1
1)Lo
ss o
f Fla
me
2)Ig
nitio
n Tr
oubl
e1
11
1.83
1.83
3)M
ark
V T
roub
le7
77
12.0
112
.01
4)Fi
re P
rote
ctio
n Tr
oubl
e1
11
0.57
0.57
5)A
ir P
ress
ure
Low
11
13.
603.
60
6)C
ard
Trou
ble
11
21
11
14
4.50
3.42
7.92
0.43
0.43
15.6
815
.68
7)O
ther
s1
12
23
25.7
025
.70
2.29
2.29
2.Tu
rbin
e / G
ener
ator
244
735
394.
5015
.72
87.3
5
1)Tu
rbin
e2
55
416
11
51
623
107.
5672
.63
133.
5627
.92
341.
675.
585.
5851
.67
26.5
578
.22
2)Au
xilia
ries
33
33
69.
749.
7410
.14
10.1
4
3)G
ener
ator
32
51
16
37.8
75.
2243
.09
9.13
9.13
3.2
23
718
.94
15.8
08.
12
1)C
able
Tro
uble
11
11
22.
622.
624.
574.
57
2)R
elay
Tro
uble
11
11
33
516
.32
16.3
211
.23
11.2
38.
128.
12
4.4
26
13.1
53.
47
1)S
yste
m T
roub
le1
21
44
0.62
11.0
01.
5313
.15
2)Fr
eque
ncy
Hig
h/Lo
w2
22
3.47
3.47
5.O
ther
s1
11
8.02
8.02
910
79
3510
1019
221
6616
9.49
89.4
213
8.51
49.2
844
6.70
61.1
261
.12
85.0
542
.23
127.
28
Sou
rce
: Ind
ones
ia P
ower
, PJB
Dat
a
PLT
G P
emar
o nTo
tal
No.
of U
nit T
roub
les
(Tim
es)
Tota
l
Syst
em F
ault
or Ir
regu
lar
Freq
uenc
y
Inst
rum
enta
tion
and
Con
trol
Pem
aron
Cab
le /
Rel
ay T
roub
le
Final Report 3 - 94
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Note; Annual generation energy for the year 2005 is up to October. Source; PJB & INDONESIA POWER data
The trend and relationship between annual generation energy and annual inflow for each objective power station are shown in the following figures.
3 - 95 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
0
500
1,000
1,500
2,000
2,500
3,000
3,500
1995 1997 1999 2001 2003 2005Year
Gen
erat
ion(
GW
h)
020406080100120140160180200
Inflow
(m3/s
)
GenerationInflow
Saguling Annual Generation/Inflow
-200400600800
1,0001,2001,4001,6001,8002,000
1995 1997 1999 2001 2003 2005Year
Gen
ertio
n(G
Wh)
0
50
100
150
200
250
300
350
400
Inflo
w(m
3/s)
GenerationInflow
Cirata Annual Generation/Inflow
0
100
200
300
400
500
600
700
1995 1997 1999 2001 2003 2005Year
Gen
erat
ion(
GW
h)
0
20
40
60
80
100
120
140
Inflo
w(m
3/s)
GenerationInflow
Soedirman Annual Generation/Inflow
0
100
200
300
400
500
600
2001 2002 2003 2004 2005Year
Gen
ertio
n(G
Wh)
0
20
40
60
80
100
120
Inflo
w(m
3/s)
GenerationInflow
Sutami Annual Generation/Inflow
Final Report 3 - 96
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
3.2.2.3. Annual Energy Consumption for Station Service (approximately recent 5 years) Annual energy consumption for the station service and consumption ratio for each objective power station is shown in the following table.
Annual Station Service Energy Consumption & Percentage
The energy consumption ratio for the power station use is almost the same level in comparison with that of Japan5. The station use ratio probably depends on the unit operation hours and the load factor. In this viewpoint, Cirata and Soedirman’s operation hours are rather shorter than Sutami and Saguling, and the station use ratios of Cirata and Soedirman are relatively high ratio consequently. Station use for Sutami shows the lowest one and the reason of the lowest station use is that Sutami’s operation hours are rather longer and load factor is bigger and also cooling water is supplied directly from the penstock instead of cooling supply pump.
3.2.2.4. Annual Operation Hours, Average Power Output and Load Factor
(1) Saguling
Annual operation hours for each unit are shown in the following table.
Annual Operation hour Year Unit 1 Unit 2 Unit 3 Unit 4 2000 5198.2 4958.72 5081.93 4468.04 2001 6094.6 5680.11 5229.15 6425.44 2002 2833.57 4711.75 3750.0 6347.9 2003 1664.02 4116.45 3459.62 4998.94 2004 4762.84 4772.79 2627.59 4184.22 2005 4427.41 4399.53 3121.65 4999.52
For the year 2005 is up to October. Source; INDONESIA POWER data 5 According to “Outline of Power Demand and Supply in 2004, released by Agency of Resources and Energy, Japan”, the average station
use ratio for hydropower stations including pumped storage P/S is 0.46 % for 10 power utilities companies in Japan.
3 - 97 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Annual average output and load factor for each unit is shown in the following table.
Annual Average Output (MW) & Load Factor (%) Year Unit 1 Unit 2 Unit 3 Unit 4 Mean
The trend of annual operation hours, average output and load factor are shown in the following figures.
0
1000
2000
3000
4000
5000
6000
7000
2000 2001 2002 2003 2004 2005Year
Hou
r
Unit1 Unit2Unit3 Unit4
Saguling Operation Hour
0
20
40
60
80
100
120
140
2000 2001 2002 2003 2004 2005Year
Out
put(M
W),L
oad
Fact
or(%
)
OutputLoad Factor
Saguling Annual Average Output and Load Factor
Final Report 3 - 98
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
(2) Cirata
Annual operation hours for each unit are shown in the following table.
Annual Operation Hour Year Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 Unit 82000 405 2140 1642 1720 2583 2333 2495 2314 2001 1549 1704 1165 2437 3240 3657 3451 3483 2002 1992 1490 1123 1562 2574 2353 2777 2837 2003 1782 1863 0 1618 1951 1567 1778 2059 2004 1826 1799 2100 1762 2300 1926 1828 1748 2005 2024 2015 1759 1723 2372 2095 1854 963
Note: Annual operation for the year 2005 is up to September. Source; PJB data Annual average output and load factor for each unit are shown in the following table.
Source; PJB data The trend of annual operation hours, average output and load factor are shown in the following figures.
0
500
1000
1500
2000
2500
3000
3500
4000
2000 2001 2002 2003 2004 2005Year
Hou
r
Unit1 Unit2 Unit3Unit4 Unit5 Unit6Unit7 Unit8
Cirata Annual Operation Hour
3 - 99 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
50
55
60
65
70
75
80
85
2000 2001 2002 2003 2004 2005Year
Out
put(M
W),L
oad
Fact
or(%
)
OutputLoad Factor
Cirata Annual Average Output and Load Factor
The annual load factor of Cirata varies approximately 60 ~ 65%. From the viewpoint of turbine efficiency, units are operated under rather inefficient mode.
Attempt to improve the turbine operating efficiency by higher load operation of the units seems to be necessary. In this case, paying close attention is needed to the influence on LFC function.
(3) Soedirman
Annual operation hours for each unit are shown in the following table.
For the year 2005 is up to October Source; INDONESIA POWER data
Annual average output and load factor for each unit is shown in the following table.
Final Report 3 - 100
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Annual Average Output (MW) & Load Factor (%) Unit 1 Unit 2 Unit 3 Mean Year Output Load Factor Output Load Factor Output Load Factor Output Load Factor
The trend of annual operation hours, average output and load factor are shown in the following figures.
0500
100015002000250030003500400045005000
1995 1997 1999 2001 2003 2005Year
Hou
r
Unit1 Unit2Unit3
Soedirman Annual Operation Hour
40
50
60
70
80
90
1995 1997 1999 2001 2003 2005Year
Out
put(M
W),
LOad
Fac
tor(
%)
OutputLoad factor
Soedirman Annual Average Output and Load Factor
Annual operation hours for each unit are well balanced. The load factor trends to decrease year by year. This means that total turbine efficiency
3 - 101 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
trends to lower side because of decrease of operating power output.
The reason why the average power output has been decreased is desirable. And attempt to improve the turbine operating efficiency by means of higher load operation is proposed.
(4) Sutami
Annual operation hours for each unit are shown in the following table.
The trend of annual operation hours, average output and load factor are shown in the following figures. The load factor is kept at 75 ~ 80 % level, although the load factor trends to decrease slightly year by year. Annual operation hours are kept more than 5,000 hours. This means the units are operated under higher efficiency zone and availability is relatively high.
Final Report 3 - 102
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Operation hours of Unit 3 are relatively shorter than those of other units. It is recommended to consider the balance of operation hours from the viewpoint of better maintenance.
3.2.2.5. Annual Start & Stop Frequency
(1) Saguling
Number of annual start and stop frequencies for each unit are shown in the following table.
Annual Start and Stop Frequency Year Unit 1 Unit 2 Unit 3 Unit 4 2000 205 198 188 158 2001 199 163 178 183 2002 74 151 227 163 2003 101 159 260 246 2004 245 229 240 152 2005 158 174 245 177
Note; Annual start & stop for the year 2005 are up to October. Source; INDONESIA POWER data
3 - 103 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
The trend of annual start and stop frequency is shown in the following figure.
0
50
100
150
200
250
300
2000 2001 2002 2003 2004 2005Year
Freq
uenc
y
Unit1 Unit2Unit3 Unit4
Saguling Annual Start and Stop Frequency
(2) Cirata
Number of annual start and stop frequencies for each unit are shown in the following table.
Annual Start and Stop Frequency Year Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 Unit 8 2000 130 337 247 307 351 320 340 347 2001 122 222 49 297 312 339 331 325 2002 288 218 153 282 333 333 330 298 2003 280 302 0 253 292 286 320 291 2004 265 272 229 242 306 274 258 240 2005 238 239 222 211 238 218 223 110
Till end of Oct. in 2005 Source; PJB data
The trend of annual start and stop frequency is shown in the following figure.
0
50
100
150
200
250
300
350
400
2000 2001 2002 2003 2004 2005Year
Freq
uenc
y
Unit1 Unit2 Unit3 Unit4Unit5 Unit6 Unit7 Unit8
Cirata Annual Start and Stop Frequency
Final Report 3 - 104
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
(3) Soedirman
Number of annual start and stop frequencies for each unit are shown in the following table.
Annual Start & Stop Frequency Unit 1 Unit 2 Unit 3 Year
For the year 2005 is up to October Source; PJB POWER data
The trend of annual start and stop frequency is shown in the following figure.
3 - 105 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
0
50
100
150
200
250
300
2001 2002 2003 2004 2005Year
Freq
uenc
y
Unit1 Unit2Unit3
Sutami Annual Start and Stop Frequency
3.2.2.6. Typical Daily Operation Pattern
(1) Saguling
Units operation is usually corresponding to peak load and units start/stop operation is requested by P3B Gandul Dispatching Center. Also units output is controlled manually according to LFC (Load Frequency Control) system signal (This system is probably not a full automatic load frequency control.)
The generator output is controlled following LFC signal. Pt = Po + N Pr Pt; Actual generator output Po; Base output requested by the dispatching center Pr; Changeable output decided by the power station N; coefficient value (<1) Po signal is sent from the dispatching center and adjusted manually by the power station operator Pr is adjusted manually by the power station operator. N signal is automatically sent from the dispatching center Therefore actual generator output is automatically changed according to the “N Pr” signal and manually changed according to the “Po” signal.
Presently designated peak hours are from 17:00 to 22:00 hour. The power grid frequency usually fluctuate approximately ±0.3 Hz and sometimes ±0.5 Hz and generator’s output is changed manually by LFC signal. The power grid condition seems to be rather insufficient and generator’s output is often changed by LFC signal. This operation probably means that Saguling stands in an important position and contributes a lot to the power grid stability. Due to the above fluctuation, Saguling, the hydropower station being large installed capacity
Final Report 3 - 106
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
and its excellent corresponding characteristic for the load fluctuation contributes to the stability of the power grid system.
Recheck of the governor function such as free governor operation is recommended and recheck of the constant values of the governor is also recommended, if necessary.
Typical operation pattern is shown in the following figure.
0
100
200
300
400
500
600
0 6 12 18 24Time
Out
put(M
W)
Unit1 Unit2Unit3 Unit4Total
Source ; INDONESIA POWER data (2005.8.15)
Saguling Daily Operation Pattern (Load Curve)
(2) Cirata
Units operation is usually corresponding to peak load and units start/stop operation is requested by P3B Gandul Dispatching Center. Also units output is controlled manually according to LFC (Load Frequency Control) system signal (This system is probably not a full automatic load frequency control.) LFC condition is the same as Saguling. Presently designated peak hours are from 17:00 to 22:00 hour. The power grid frequency usually fluctuates of approximately ±0.3 Hz and sometimes ±0.5 Hz and generator’s output is changed manually by LFC signal. The power grid condition seems to be rather insufficient and generator’s output is often changed by LFC signal. This operation probably means that Cirata stands in an important position and contributes a lot to the power grid stability.
Recheck of the governor function such as free governor operation is recommended and recheck of the constant values of the governor is also recommended, if necessary.
Typical operation patter is shown in the following figure.
3 - 107 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
0
100
200
300
400
500
600
700
0 6 12 18 24
Time
OU
tput
(MW
)
Unit1 Unit2 Unit3
Unit4 Unit5 Unit6
Unit7 Unit8 Total
Source; PJB data (2005.09.15)
Cirata Daily Operation Pattern (Load Curve)
(3) Soedirman
Units operation is usually corresponding to peak load and units start/stop operation is requested by P3B Ungalan Dispatching Center. Also unit output is controlled manually 50% or 100% load following Dispatching Center request. The unit operation load is usually 50%. Typical operation pattern is shown in the following figure.
0
20
40
60
80
100
120
140
160
180
200
0 6 12 18 24Time
Out
put(M
W)
Unit1 Unit2Unit3 total
Source; INDONESIA POWER data (2005.1.15)
Soedirman Daily Operation Pattern (Load Curve)
Final Report 3 - 108
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
(4) Sutami
Units operation is basically corresponding to peak load, although one (1) unit is operated for a whole day. During the rainy season, sometimes full load operation is carried out for all day long. Units start/stop operation and unit output are requested by P3B Surabaya Dispatching Center. In case of big inflow, Sutami proposes P3B to increase number of operation units and/or increase the units output to minimize the spilled water from the dam. Typical operation pattern is shown in the following figure.
0
10
20
30
40
50
60
70
80
0 6 12 18 24Time
OU
tput
(MW
)
unit1 unit2unit3 total
Source; PJB data (2005.8.28)
Sutami Daily Operation Pattern (Load Curve)
3.2.2.7. Routine Management (check items, frequency, etc.) For all power stations, all areas in the powerhouse and switchyard are kept very clean and good arrangement. Any harmful rust and/or peeling of paint on all equipment were not observed. Emergency exit indications are installed at all stairs for safety. For all power stations, inspection items and period/timing such as daily, weekly, monthly, and yearly etc. are carefully decided for all equipment. For example of Saguling, inspection items and schedules cover all equipment in the powerhouse and switchyard classified as electrical, mechanical, control and instrument equipment and inspection is carried out steadily based on the inspection check list and schedule. Other power stations are almost the same situation. Inspection schedule and tabulated check items for Saguling and Cirata are shown in Appendices HY-8 and HY-9. For daily inspection and patrol, the equipment is basically checked visually and machine’s temperature, pressure, etc are recorded. In case of Sutami, data recording is carried out every hour about the unit output, reactive power, machine’s temperature, pressure for the cooling system and oil pressure system etc.
3 - 109 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Also notice of important points and criteria are described on the log sheets. In case of Cirata, data recording is carried out every half hour about the unit output, reactive power, machine’s temperature, pressure, etc. and also unit in parallel time and off parallel time are recorded in the log sheet. Also notice of important points and criteria are described on the log sheets. Other power stations are almost the same situation. Daily log sheets for Cirata and Sutami are shown in Appendices HY-10 and HY-11. For all power stations, design documents, drawings, operation manuals, and test records and so on are stored in the library. In case of Soedirman, trend management is carried out for every unit relating to bearings temperature, stator windings temperature, and generator air coolers temperature. The trend management sheet of Soedirman is shown in Appendix HY-12. Generally, the number of labels indicating the equipment/machine name, abbreviation number for whole equipment seems to be insufficient. Valve No. and valve open/close indicating tags are not found out for every power station. Indication of normal range for the various meters such as pressure gauges, oil level gauges, and temperature meters seems to be insufficient. Regarding the environmental activity, every power station is carrying out based on the ISO 14001.
Indication of the equipment name and/or machine’s abbreviation number is quite important to avoid miss operations and/or miss judgments. Therefore it is desirable to adopt the above indications for safety work. For the meters, indication of standard value or normal range is desirable if possible. For maintenance work, description of the criteria is important in the recording sheets for easier judgment during maintenance work. Measurement and recording of the unit operation sequence time (for instance “preparation finished, inlet valve full open, start the machine, excitation, in parallel” and vice versa) from starting to stopping is one of the useful check records to judge the machine condition. (IP informed that at the Saguling P/S these sequence time is recorded by the computer system.) The machine’s temperature is recorded closely for every power station and trend management is advised to continue closely for bearing temperature, stator winding temperature, and generator cooling air temperature etc.
Following items are found out individually for each power station.
(1) Saguling
1) Condition of Routine Management
The generator air cooler is stored as the spare part to avoid the long time outage due to
Final Report 3 - 110
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
the air cooler trouble caused by the deterioration of reservoir water quality.
2) Condition of the Machine Temperature Bearings, air cooler and stator winding temperature record in June 6, 2005 are shown in the following table.
Temperature Record of Machine (°C) Item Unit 1 Unit 2 Unit 3 Unit 4 Setting (alarm/trip)
Source; INDONESIA POWER data From the above data, all units are operated normally.
(2) Cirata
1) Condition of Routine Management
The spare parts are managed by MIMS (Mincom information maintenance system) built up in PJB Company. Regarding the maintenance, following manuals which describe detailed items, are prepared under the conception of preventive and predictive maintenance. ・Instrucsi Kerja Pemeliharaan Preventive . (Instruction Preventive Maintenance Work) ・Instrucsi Kerja Pemeliharaan Predictive ... (Instruction Predictive Maintenance Work) ・Laporan Preventive Maintenance............................. (Report Preventive Maintenance) ・Laporan Predictive Maintenance............................... (Report Predictive Maintenance) ・Schedule Dan Ruang Lingkup Pemeliharaan Preventive Dan Predictive TH.2005 .. (Schedule and column scope Preventive and predictive maintenance Year 2005)
2) Condition of the Machine Temperature
Bearings, air cooler and stator winding maximum temperature record in September 2004 are shown in the following table.
Temperature Record of Machine (°C)
Item Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 Unit 6 Unit 7 Unit 8Gen. guide beag. 56(55) 59(57) 55(55) 53(56) 65(57) 67(66) 46(50) 63(64)Thrust beag. 68(69) 72(69) 67(68) 71(68) 65(63) 66(66) 64(65) 68(63)Turbine beag. 55(59.5) 61(56) 60(60) 53(57) 65(58) 62(59) 62(60) 60(62)Stator winding 78 82 76 85 82 85 88 91 Gen. air cooler 30(36) 59(39) 70(44) 101(43) 32(32) 37(34) 48(32) 49(35)
Source; PJB data
3 - 111 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
From the above data, followings are found out.
- Bearing - Thrust bearing temperature seems rather higher than our experience in Japan because European manufacturers were used to select the bearing temperature design value at 75°C or more.
- Generator air cooler outlet - Temperature is rather high for Unit 2 and Unit 7. Temperature is abnormally high only one day in September (20th) and (8th) for Unit 3 and unit 4 respectively. Other day's data is normal. Temperature has risen high suddenly since the middle of September (24th) for Unit 8.
- Stator winding - Temperature is kept normal range for all units.
Concerning the machine temperature management, comparison between actual gathered data and design data and/or commissioning test data is quite important. When once abnormal data is observed, urgent confirmation of machine's condition and measurement system are necessary. Description of its cause in the recording sheet is also important and the calibration of the detector should be carried out, if necessary. Regarding the machine temperature, long term trend management is important and it is better that the result of the trend management is reflected on the periodical inspection items.
(3) Soedirman
1) Condition of Ordinary Management
Heat spot check was carried out for the connection point of 154 and 13.8 kV main circuits in 2002 and this check was found out to be useful method. Heat spot checker was procured in 2005 and the periodical heat spot check was planned after that. During the generator is under operation, inspection of inside of the generator housing is prohibited by the reason of danger. (In Japan, inside of generator housing is usually inspected even if generator is operating.)
Even if the generator is under operation, inside inspection of the generator housing is desirable because inside inspection is one of the useful inspections to find out abnormal condition by bad smell, abnormal noise and etc. (For instance, in case that partial discharge occurs on the winding, abnormal smell (ozone smell) can be felt. And this is one of the useful methods to find out the winding abnormal.) For this inspection, it is quite important that work safety is secured.
2) Condition of the Machine Temperature
The bearings, stator winding and air cooler temperature test record during the annual inspection and general inspection in 2004 are shown in the following table.
Final Report 3 - 112
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Temperature Record of Machine (°C) Item Unit 1 Unit 2 Unit 3 Criteria
Gen. guide bearing. 66.5 66.0 59.8 <80 Thrust bearing. 74.5 78.0 73.5 <80 Turbine bearing. 55.6 56.0 55.6 <75 Stator winding 66.9 76.0 63.6 Gen. air cooler 30.8 28.4 31.2
Source; INDONESIA POWER data
From the above data, followings are found out.
- Bearing - Thrust bearing temperature seems rather higher than our experience in Japan because European manufacturers were used to select the bearing temperature design value at 75°C or more.
- Generator air cooler outlet - Temperature is kept normal range for all units.
- Stator winding - Temperature is kept normal range for all units.
Concerning the machine temperature management, comparison between actual gathered data and design data and/or commissioning test data is quite important. When once abnormal data is observed, urgent confirmation of machine’s condition and measurement system are necessary. Description of its cause in the recording sheet is also important and the calibration of the detector should be carried out, if necessary. Regarding the machine temperature, long term trend management is important and it is better that the result of the trend management is reflected on the periodical inspection items.
(4) Sutami
1) Condition of Routine Management
As mentioned in Section 3.2.2.7, there is no comment in particular.
2) Condition of the Machine Temperature
The temperature record during the continuous operation of three (3) units in 31/Dec./ 2004 is shown in the following table.
3 - 113 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Temperature Record of Machine (°C) Item Unit 1 Unit 2 Unit 3
Actual Condition 54.8 54.5 55.1 Dry Out Running 50 50 52
Upper bearing.
Alarm/Trip 60/65 60/65 60/65 Actual Condition 56.0 54.5 55.8 Dry Out Running 51 52 54
Thrust bearing.
Alarm/Trip 60/65 60/65 60/65 Actual Condition 51.9 46.8 47.1 Dry Out Running 46.5 47 55
Lower bearing.
Alarm/Trip 60/65 60/65 60/65 Actual Condition 49.5 54.8 56.5 Dry Out Running 49.5 51 52
Actual Condition 33.2 37.8 33.9 Dry Out Running 53? 33 30
Generator air cooler (outlet aide)
Alarm/Trip 50/60 50/60 50/60 Source; PJB data
Concerning the machine temperature management, comparison between actual gathered data and design data and/or commissioning test data is quite important. When once abnormal data is observed, urgent confirmation of machine's condition and measurement system are necessary. Description of its cause in the recording sheet is also important and the calibration of the detector should be carried out, if necessary. Regarding the machine temperature, long term trend management is important and it is better that the result of the trend management is reflected on the periodical inspection items.
3.2.2.8. Condition of Periodical Maintenance Management (actual situation of periodical inspection, period of inspection, result of inspection,
history of incident and repair, etc.) Interval of periodical inspection is as mentioned below.
Annual inspection; every 8,000 hours unit operation (AI) General inspection; every 20,000 hours unit operation (GI) Major overhaul; every 40,000 hours unit operation (MO)
IP informed that at the Saguling P/S, interval of the periodical inspections are usually carried out every year for AI, every 3 years for GI and more than every 10 years for MO respectively. Basically periodical inspection is classified as above three (3) categories. However other type inspections such as major inspection (MI) and simple AI etc. are carried out sometimes. In Japan, regarding the hydro power stations, inspection interval is extended from the reliability and economical viewpoints. Periodical inspection in Japan is carried out one time for every three years and inspection duration takes about within one week taken account of
Final Report 3 - 114
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
influence on power grid system and degrading level of equipment. And concerning the interval of overhaul, more than ten (10) years are adopted including the large scaled pumped storage power stations.
Actually periodical inspection in Indonesia is carried out almost every year for all hydro power stations. However serious issues which request annual detailed inspection have not been identified. Therefore it is recommended to extend the interval of periodical inspection taken account of importance level of the power station and degrading level of machine. Overhaul of the machine is not always necessary by the reason that operation hours of the unit reach the scheduled inspection timing. (and also economical point of view) At the Soedirman power station, overhaul of the units has not been conducted up to now because the units have been kept in good condition. This judgment is agreeable.
As far as referring to the inspection reports, inspection items of AI and GI for all power stations are almost same. Inspection is carried out in detail items for the equipment. Performance test is quite important after the inspection; however performance test items seem to be rather insufficient. As a sample case, AI inspection items and performance test items in Cirata is shown in the following table. Cavitation pitting at runner vane is sketched for all power stations. In Saguling, cavitation pitting volume is also evaluated. Detail description of repairing work is not mentioned in the report. (For instance; repair welding volume at the runner vane) One of the evaluation method of stator winding performance such as Polarity Index (PI) test and Tan (δ) test are carried out in some power stations and not carried out in others.
Except the abnormal case, it is not necessary to inspect the bearing pad surface at AI. Polarity Index (PI) test and Tan (δ) test are useful for the evaluation of stator winding. Therefore it is desired to conduct the both tests during the periodical inspection. It is better to add the performance test items after inspection. “Measurement of relationship between guide vane opening level and output” is advisable to confirm the turbine performance during performance test conducted after inspection. During GI, execution of load rejection test is desirable to confirm the governor performance if it is acceptable from both of the power grid side and the power station facility side. Any performance test record is not described in the some inspection report. Test result is important not only to confirm the machine performance but also to compare the previous performance. Therefore description of the performance test record in the report is advisable.
3 - 115 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Sample of the Inspection Items for AI (Cirata AI) Inspection item
Turbine Generator Main circuit Instrument Bearing Stator winding Main circuit breaker Meter & relay Shaft seal (support) Voltage transformer (Main turbine) Spiral case (wedge) Current transformer (Main generator) Guide vane Rotor pole Excitation transformer (Governor) Draft tube Balance weight Motor control center (Inlet valve) Runner Slip ring Static Excitation system (Excitation system) Governor Cooling fan Power distribution center (Sequence control) Inlet valve Brake Ring (Protection relay) Aux. equipment Rotor coil Damper winding Coil support Brush Brake system Guide bearing Thrust bearing Air cooler Oil cooler Aux. equipment Performance test item Bearing heat run Output test Trip test
Source; PJB data
Following items are found out individually for each power station.
(1) Saguling
1) History of Incident and Repair
History of scheduled outage, forced outage and their causes are shown in the following table.
Final Report 3 - 116
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Table 3.2-13 Cause of Scheduled Outage/Forced Outage & Outage Hour (Saguling)
Year Scheduled
outage hour
Forced outage hour
Cause of outage
Unit 1 4.5 0.27 3.50 1.92
(12/08) Air cooler maintenance (7/31) Over current relay. STR1 fault (10/20) Air cooler leak (10/30) 86-2 trip (DC power supply fault)
Unit 2 1.67 696.7
0.27 2.00 1.72
(8/20) Repair air cooler #5,6,7 (9/03-10/02) Repair upper bearing oil cooler and predictive maintenance (GI?) (7/31) Over current relay. STR1 fault (10/26) Air cooler #1 repair (10/30) 86-2 trip (DC power supply fault)
Unit 3 718.45 247.37
0.50 0.25 1.92 0.23
AI?(3/03-4/02) (10/04-10/14) Upper bearing oil cooler repair (3/30) Excitation ground fault (5/22) Current relay fault (10/30) 86-2 trip (DC power supply fault) (12/24) 86-5 trip thrust bearing temp. high
2001
Unit 4 105.12 6.27 6.48
0.08 1.92 0.77 1.08 1.98
(8/13-8/17) Predictive maintenance (9/12) Air cooler repair (10/30-10/31) Excitation system repair (10/25) 86-5 trip (10/30) 86-2 trip (DC power supply fault) (12/22) Automatic sequence system Fault (12/27) Automatic sequence system Fault (12/27) Automatic sequence system Fault
Unit 1 47.0 31.0 4531.58
(1/05-1/07) Air cooler repair (1/09-1/10) Air cooler repair (6/26-12/31) MTr repair
Unit 2 54.5 1749.22
0.87
(5/25-5/27) Oil cooler replace and penstock valve verification (6/26-9/07) MTr repair (9/19) 86-2 STR-2 temp. high
Unit 3 149.25 13.83 224.75 2.0
2.83
(4/10-4/16) Oil cooler repair (8/08-8/09) MTr repair (8/21-8/30) Upper bearing repair (9/19) Station service transformer inspection (9/19) 86-1 trip Str-2 over current relay
(1/29) Guide vane seal change & air cooler (5/07-5/08) Governor oil pressure tank repair (10/05-10/09) Maintenance (AI?) (3/07) MTr-2 T87(differential relay) operate (10/22) Governor protection relay malfunction
Source; INDONESIA POWER data
Increase of forced outages caused by the same reason is observed. These may be due to the malfunction of the detector or control module trouble. It is important to replace the related component as soon as possible.
Final Report 3 - 118
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
2) Interval for Periodical Inspection
The record of interval for the periodical inspection is shown in the following table. Record of Periodical Inspection
Unit No. 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005Unit 1 MO AI AI Unit 2 GI MO AI AI Unit 3 AI AI AI GI AI AI GI AI AI MO AI Unit 4 MO GI AI AI AI MO AI
AI; Annual Inspection Source; INDONESIA POWER data GI; General Inspection MO; Major Overhaul
The interval for each inspection is approximately every year for AI, every 3 ~ 4 years and every 8 ~ 9 years respectively.
3) Required Days for Periodical Inspection
Required days are 5 ~ 13 days for AI, 25 ~ 30 days for GI and 84 ~ 146 days for MO respectively. AI is sometimes simplified called as predictive maintenance.
(2) Cirata
1) History of Incident and Repair
History of scheduled outage, forced outage and their causes is shown in the following table.
Table 3.2-14 Cause of Scheduled Outage/Forced Outage & Outage Hour (Cirata)
(01/11/29-3/25) Stator winding repair (4/11-4/12) Generator system repair (10/04-10/06) Air admission, shaft seal repair (3/27) Trip; field failure (11/13) Trip; over current trip
AI(8/29-9/08) (3/05-3/6) Failure start; synchro. DC fault (4/04-4/05) Trip; IV pre. tank P&L<min. (4/05) Trip; IV pre. tank P&L<min. (8/20) Trip; IV pre. tank P<min. (8/26) Failure start; turbine oil cooler leak
Unit 8 3652.06 (12/08-05/6/02) Stator winding repair
Source; PJB data
Increase of forced outages caused by the same reason is observed. These may be due to the malfunction of the detector or control module trouble. It is important to replace the related component as soon as possible.
2) Interval for Periodical Inspection
The record of interval for the periodical inspection is shown in the following table.
The major inspection has not been carried out yet for unit 5 ~ 8 since the commissioning. This probably means units operation is kept in good condition. The interval for the inspection is approximately 4,000 hours for AI and 20,000 hours for GI respectively. For unit 3, from 2002 to 2004 any periodical inspection was not carried out because of the outage from Jun. /2003 to Mar. /2004 due to the generator winding repair work.
3 - 123 Final Report
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
Record of Periodical Inspection 1988 1989 1990 1991 1992 1993 1994 1995 1996
Classifi AI AI AI GI AI AI Unit 1 Op.hour 3609 3885 4915 16977 11024 4493 Classifi AI AI AI GI MO AI AI Unit 2 Op.hour 5393 3809 3899 17669 23244 4269 3730 Classifi AI AI AI AI AI GI Unit 3 Op.hour 1854 4150 3944 5153 9906 29009 Classifi Unit 4 Op.hour
1997 1998 1999 2000 2001 2002 2003 2004 2005 Classifi MI AI AI GI AI AI AI Unit 1 Op.hour 40115 ? 3294 3813? Classifi GI AI AI MI AI AI Unit 2 Op.hour 11940 3847 2292 22071 Classifi AI MI AI AI Unit 3 Op.hour 7621 42718 2571 Classifi MI AI AI AI GI AI Unit 4 Op.hour Classifi AI AI AI GI AI Unit 5 Op.hour Classifi AI AI AI GI AI Unit 6 Op.hour Classifi AI AI AI GI AI Unit 7 Op.hour
Not Available
Classifi AI AI AI GI AI Unit 8 Op.hour
Till to end of Oct. in 2005 Source; PJB data Classifi; Classification of inspection Op.hour; Operation hour between inspection and previous inspection
3) Required Days for Periodical Inspection
Required days are about 18 days for AI, 40 days for GI and 60 days for MI respectively. The major overhaul was carried out for unit 2 in 1993 and required days were approximately seven (7) months. There were the long period outages for the stator winding repair for units 1, 2, 3, 4 and 8.
Cirata office considers shortening of the required days to about half duration for AI. This effort is useful to improve the unit operation availability.
(3) Soedirman
1) History of Incident and Repair
There is nothing any serious trouble for the units and the original equipment is, on the whole, still used since the commissioning.
Final Report 3 - 124
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
History of scheduled outage, forced outage and their causes is shown in the following table.
Table 3.2-15 Cause of Scheduled Outage/Forced Outage & Outage Hour (Soedirman)
Year Scheduled outage hour
Forced outage hour Cause of outage
Unit 1 184 1.90
AI(7/25-8/02) (1/17) Governor in manual order
Unit 2 201.03 0.25
AI(8/28-9/05) (9/23) Governor trouble
1995
Unit 3 220 AI(9/18-9/27) Unit 1 131
0.77 AI(7/25-7/30) (1/07) Pressure switch trouble
Unit 2 98 AI(8/26-8/30)
1996
Unit 3 268 0.38
AI(9/16-9/27) (3/24) Governor in manual order
Unit 1 103.17 AI(7/21-7/25) Unit 2 82.25 AI(8/25-8/28)
Unit 1 205.4 GI(9/05-9/15) Unit 2 130.0 AI(7/15-7/20)
2005
Unit 3 113.27 1.95
AI(8/01-8/06) (5/07) Excitation fault
Source; INDONESIA POWER data
2) Interval for Periodical Inspection
The record of interval for the periodical inspection is shown in the following table.
Record of Periodical Inspection Year 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
Unit 1 AI AI AI AI AI AI GI Unit 2 AI AI AI AI GI AI AI Unit 3 AI AI AI AI AI GI AI
AI; Annual Inspection Source; INDONESIA POWER data
6 month maintenance inspection
GI; General Inspection MO; Major Overhaul
The Interval for AI is almost one year. The major overhaul has not been conducted up to now because all units have been kept in good condition since the commissioning. During 1999 ~ 2002, the inspection were simplified and the 6 month maintenance inspection was carried out instead of AI in the relevant period. Simplified inspection took only thirty (30) hours duration. However AI is resumed recently.
3) Required Days for Periodical Inspection
Required days are 5 ~ 6 days for AI, and 9 ~ 11 days for GI respectively in recent years.
Final Report 3 - 126
The Study on the Improvement Measures for Electric Power Generation Facilities in Java-Bali Region in the Republic of Indonesia
(4) Sutami
1) History of Incident and Repair
There is nothing any serious trouble for the units and the original equipment is, on the whole, still used since the commissioning. History of scheduled outage, forced outage and their causes is shown in the following table.
Table 3.2-16 Cause of Scheduled Outage/Forced Outage & Outage Hour (Sutami) Year Scheduled
outage hour Forced outage
hour Cause of outage
Unit 1 112.88 AI (7/02-7/08) Unit 2 133.12 GI (7/16-7/20)
2001
Unit 3 119.4 AI (7/23-7/27) Unit 1 129.75 AI (7/01-7/06) Unit 2 129.39
0.38 0.13
AI (7/08-7/13) (2/27) Lock out relay 86-3 operated (3/30) Ditto
2002
Unit 3 132.65 0.72 21.08
AI (4/08-4/12) (10/16) 11 kV disconnecting switch coil trouble (11/29) Main strainer valve broken
Unit 1 144 2
GI (8/20-8/26) (4/13) Main valve opening operation stuck
Unit 2 138.71 11
AI (7/07-7/11) (11/14) Circuit breaker (ABB) support loosen
2003
Unit 3 192 GI (7/24-7/31) Unit 1 120 AI (823-8/29) Unit 2 96 AI(7/12-7/16)
2004
Unit 3 744 MO (9/27-11/04) Unit 1 72 AI (7/04-7/07) 2005 Unit 2 48 AI(7/18-7/20) Unit 3 96 AI(7/11-715)
Source; PJB data
At Sutami, forced outage hours are very small. This means that very good operation and maintenance are carried out by the operation and maintenance staff.
2) Interval for Periodical Inspection
The record of interval for the periodical inspection is shown in the following table.
Record of Periodical Inspection
Year 2001 2002 2003 2004 2005 Unit 1 AI AI GI AI AI Unit 2 GI AI AI AI AI Unit 3 AI AI GI MO AI
AI; Annual Inspection Source; PJB data GI; General Inspection MO; Major Overhaul
The planned interval for the periodical inspection is shown in the following table.
