Workshop on the 1st Asean Advanced Engineering

Course
Sharing Experience on Power System Protection.
Jogjakarta March 10, 2003
 GENERATED POWER FOR JAWA
BALI
Year : 2001 - 2004
100%

90%

80%

70%

60%

50%

40%

30%

20% SURALAYA

10%
SURALAYA
0%
2001 2002 2003 2004

Slaya Oil Gas HSD Geo Hydro PJBII IPP

 GENERAL DESCRIPTION OF SURALAYA SPP
General Description

No. DESCRIPTION UNIT 1 UNIT 2 UNIT 3 UNIT 4 UNIT 5 UNIT 6 UNIT 7

1 Power Output

a. Coal Fuel ( MW ) 400 400 400 400 600 600 600

b. HFO Oil Fuel (MW) 400 400 175 175 - - -

2 Commercial Operation 1985 1986 1989 1989 1997 1997 1997

3 Power System Stabilizer OFF OFF OFF OFF ON ON ON

4 Load Frequency Control None None None None ON ON ON

5 Present Ramping Rate ( MW/menit ) 5 5 5 5 10 10 10

6 Speed Droop Setting 4,6 % 4,6 % 4,6 % 4,6 % 7,6 % 9,5 % 9,5 %
Free Governoor
7 Operation Mode Load Limit
(Boiler-Turbine Coordinate)

8 Boiler Manufacture Babcock Wilcock ( Radiant Boiler Natural Circulation Tower )

9 Turbin Manufacture Mitsubishi Heavy Industri ( Tandem Compund Quadraple Exhaust Reheat Condensing )

10 Generator Manufacture Mitsubishi Electric Company ( Brushless Exciter with PMG )

11 Generator Transformer Manufacture Mitsubishi Electric Company ( OFAF cooling Off Load Tap Changer )
 PT Indonesia Power’s Power Plants Location

UP Suralaya UP Priok UP Semarang UP Perak Grati

Steam Coal PP GT, CCGT & Diesel PP CCGT & SPP SPP & CCGT
3,400 MW 1,469.16 MW 864.08 MW
1,562.77 MW

Jakarta
Installed
Capacity 9,094
Bandung
Semarang MW
Banjarnegara
Surabaya

Grati

Denpasar

UP Saguling UP Kamojang UP Mrica UP Bali

Hydro Geothermal Hydro GT & Diesel
797.96 MW 360 MW 305.44 MW 335.07 MW
 STEAM CYCLE IN
SURALAYA STEAM POWER
PLANT
169 k, 538 C 10 k, 330 C

MAIN DRUM HP BY PASS T U R B I N E S

HP IP G
LP 1 LP 2
SUPER 40 k, 336 C
REHEATER HEATER condenser
39 k, 538 C
SEA
ECONOMIZER LP BY PASS
BOILER FUEL 12 k, 109 C
COND.
174 k
251 C PUMP

HP HEATER 8 COND
DEAERATOR LP HEATER 4 POLISH
DEMIN
HP HEATER 7 PLANT
ASH LP HEATER 3
FWT
180 k, 142 C 28 k. 40 C
HP HEATER 6
LP HEATER 2
DESAL PLANT

BFP LP HEATER
GLAND ST
COND
LP HEATER

SUBFP
 CAPABILITY CURVE SPECIFICATION
Applicable for Unit No 5 to 7
Generator Mitsubishi Electric
600

Gas Pressure 5 kg/cm2

Capability Curve

POWER OUTPUT : 767 MVA

Voltage : 23.000 Volts
OVER EXCITATION

PF 0,85
400

Current : 19.253 A
Power Factor : 0,85
Phase :3
200

Frequency : 50 Hz
MEL
No of pole :2
MVAR

0 MW
200 400 600 Cooling System : Hydrogen at
Steady 5kg/cm2
state limit
Ecxitation Voltage : 590 V
UNDER EXCITATION
200

Ecxitation Current : 4965 A

PF 0,95
Stator Winding : Y
Turbine Limit Insulation = Class F
400

EXCITER
CAPABILITY CURVE
Brushless type , Output : 3300 KW,
Voltage 590 V current 5593 A
 SURALAYA SPP
1 2 3 4 5 6 7
A
Station Use Bus-
500 kV bars

to GANDUL to CILEGON

1 2 3 4 5 6
A

150 kV
B

to CILEGON To SALIRA
 HOT START-UP
START UP CURVE OF SURALAYA POWER PLANT

TEMP Pres s TURBINE

oC (kg/cm2)
% HOT START UP SPEED

600

2
500 200 100 4
180
1
400 160 80

140
300 120 60
100

200 80 40
60 3 3000

100 40 20 2000
20 1000

0 2 4 6 8 10 12 14 16
hours
Legend :
1. Main steam pressure (kg/cm2)
2. Main steam temperature (oC)
3. Turbine speed (rpm)
4. Generator Loading
 START-UP TIME OF SURALAYA SPP

DURATION OF
CONDITION MAX START-UP START-UP TIME START UP COST
UNIT No. TYPE st STOP
Turbin 1 Metal Temp. per YEAR up to 100% LOAD (in Million Rp. )
( hour )
0
COLD < 190 C >36 hours 3 times 17 hours 221

1-4 WARM 0
190 C - 370 C
0
8 - 36 hours 2 times 12 hours 170
0
HOT > 371 C < 8 hours 1 time 7.9 hours 102
0
COLD < 190 C > 36 hours 3 times 17 hours 324

5-7 WARM 0
190 C - 370 C
0
8 - 36 hours 2 times 12 hours 218
0
HOT > 371 C < 8 hours 1 time 7.9 hours 155
Estimated Time to Restart Power plants following
blackout
FATEST START-UP TIME OF SURALAYA AFTER BLACK-OUT
BACK FEEDING (INCOMING POWER SUPPLY) AFTER BLACK-OUT
< 1 hours 1 - 8 hours 8 - 36 hours > 36 hours
No. DESCRIPTION
With With-Out With With-Out With With-Out With With-Out
By-Pass By Pass By-Pass By Pass By-Pass By Pass By-Pass By Pass

A. UNIT 1-4 (Max 2 Unit Start)

Condensor Damage, Turbin Damage, Steam Drum Boiler
1 Consequence Minimum Impact Drop (long firing), Back-Up Time Battery LOW

2 Start up Criteria HOT START-UP WARM COLD

3 Auxiliary Boiler Start Not Used 2 2 2

By Pass not
By Pass not

By Pass not

By Pass not
Available

Available

Available
Available
4 Start-Up Unit 5,3 5,3 9,9 14,2
5 Ramping 0% to 100% Load 4,1 4,1 4,1 5
TOTAL TIME (HOURS) 9,4 11,4 16 21,2
B. UNIT 5-7 (3 Unit Start)
Condensor Damage, Turbin Damage (Lub Oil Pump not
1 Consequence Minimum Impact running), Air Heater Damage, Steam Drum Boiler Drop (long
firing), Back-Up Battery Time LOW

2 Start up Criteria HOT START-UP WARM COLD

3 Auxiliary Boiler Not Used Not Used Not Used Not Used
Available
Available

Available

Available
By Pass

By Pass

By Pass

By Pass
4 Start Unit 3,8 7,9 7,9 12
5 Ramping 0% to 100% Load 4,1 4,1 4,1 5
TOTAL TIME (HOURS) 7,9 7,9 12 17
 ANTICIPATION AGAINTS
BLACKOUT
• Established internal supply to avoid any damages
which may be occurred upon blackout
• Established routine check and test any essential
supply which maintain protection to the apparatus.
• Set-up islanding operation to speed up recovery
• Set-up initial HOUSE LOAD operation if
islanding operation fail to establish
 BLACKOUT ON 24 OCTOBER
1988
The main cause of failure Atwas
13.13 the
WIT air supply for instrument

control system suspended due to the mishandling during

construction. In 1988 only Power Plant Unit No.1 and No.2
being commercial operation Unit No. 3 under testing and
commissioning and Unit no.4 still under construction. To
complete the construction some pipe of conveying air to the
instruments control system should be modified, but
unexpected accident happened though the engineer has been
carefully plan check and instruct necessary action to cut and
reconnect any intended pipe.
All Suralaya generators (at that moment Unit No. 1 and 2 mean
800 MW in operation) tripped out and then caused cascaded
tripping to others generators. This failure put Java-Bali in
blackout immediately since at that time the overall loads around
 BLACKOUT ON 17 AUGUST
1991
The main cause of failureAtwas flash over happened around
00.22 WIT

the body of 500 kV circuit breaker No. 4 at Suralaya

Substation. Following those phenomena while breaker try to
isolate itself, the interrupting driving part was broken down
and the ruins were touch the other parts of substation put all
breaker in substation immediately off then cuts all circuits
towards Suralaya substation.

All Suralaya generators (at that moment Unit No. 2,3 and 4
mean 1200 MW in operation) tripped out and then caused
cascaded tripping to others generators. This failure put Java-
Bali in blackout immediately since at that time the overall loads
only 3635 MW.
 BLACKOUT ON 13 APRIL 1997

The main cause of failure was 500 kV lines between Suralaya-

Gandul tripped out due to unexpected line to ground fault
occurrence. Following this phenomena all Suralaya generators
faced loss of load and immediately put all generators off.
All Suralaya generators (at that moment Unit No. 1,2,3,4 loaded
around 1500 MW in operation) tripped out and then caused
cascaded tripping to others generators, this failure put Java - Bali
in to blackout
The special intention to this occurrence was the recovery time very
long since at that time it was difficult to restart Saguling HPP as
main source to energize 500 kV network.
 BLACKOUT ON 12 SEPTEMBER
2002
The main cause of failure was 500WITkV lines between Cibinong-
At 17.52

Gandul not successfully isolated failure caused cross country

outage along the 500 kV lines between Cilegon and Cibinong.
Following this phenomena those two circuits from Cilegon to
Suralaya interrupted power to all auxiliaries in Suralaya and
immediately put all generators off.
All Suralaya generators (at that moment Unit No. 1,3,4,5,6 and 7
loaded around 2895 MW in operation) tripped out and then caused
cascaded tripping to others generators. This failure put Western
part of Java partially in blackout since at that time the 500 kV link
to the east part was interrupted.
 BLACK-OUT ON 12 SEPTEMBER 2002
( chronological event at SURALAYA SPP )
Time EVENTS CONDITIONS

All Suralaya plants (Unit no 1-7 except No.2 whose
out for maintenance) being in normal condition,
17:30
operated at 2895 MW ( 85% of Total Capacity of
3400 MW )
Unit 1 = 390 MW, Unit 2 = Overhaul
Unit 3 = 390 MW, Unit 4 = 390 MW
Unit 5 = 600 MW, Unit 6 = 525 MW
Unit 7 = 600 MW

EHV lines in Cibinong to Saguling tripped out. Those were

Abnormal Frequency detected
17:52 unterrupted the interconnection system from west to center
Power Freq ramp up
and east Java-Bali

17:55 UNIT No. 1 TRIP Generator and Turbin TRIP

- UNIT 2 OFF LINE Overhaul

17:58 UNIT No. 3 TRIP Caused by DRUM LEVEL HIGH (Boiler)

17:57 UNIT No. 4 TRIP Caused by Furnace Draft > Max (Boiler)

18:02 UNIT No. 5 TRIP Caused by Main Steam Temp High (Boiler)

18:03 UNIT No. 6 HOUSE LOAD Loaded by station Use 24 MW

18:03:29 UNIT No. 6 TRIP Turbine Over Speed

18:04 UNIT No. 7 HOUSE LOAD Loaded by station use 26 MW

18:05 UNIT No. 7 TRIP No Flame of any Burner detected , (Boiler trip)

18:05 All voltages (150 and 500 kV) were out of service Suralaya Black-Out
SURALAYA CONDITION JUST AFTER BLACKOUT
UNIT No. STATE OF THE PLANT ACTION TO BE TAKEN

Ready to restart (finally boiler found

UNIT 1 SAFE. Nothing happened
leakage)

UNIT 2 Overhaul

Restart and synchronized at 02 : 45, 13

UNIT 3 SAFE Nothing happened Sept 2002 02:45, but TRIP again at 08:00
due to another Black-Out.

Restart up to roll-out but Trip again due to

UNIT 4 SAFE. Nothing happened
another Black-Out

- Eccentricity on Rotor Turbin found

abnormal (JOP & T/G No Power Supply)
UNIT 5 Inspection needed prior to restart
- Air Heater blocked
- Condenser leakage

- Eccentricity on Rotor Turbin found

UNIT 6 abnormal (JOP & T/G No Power Supply) Inspection needed prior to restart
- Air Heater blocked.

- Eccentricity on Rotor Turbin found

abnormal (JOP & T/G No Power Supply)
UNIT 7 Inspection needed prior to restart
- Air Heater blocked

NOTE : 12 September 2002 was the first black out occurred to Unit no. 5 up to 7
 RESTORATION OF SURALAYA
AFTER BLACK-OUT ON 12 SEPTEMBER 2002

SURALAYA FIRING SYNCHRONIZED

ACTION
Unit No. Date Time Date Time
First BLACK-OUT 12 September at 17:55 First Back Feeding arrived after 2 hours
First SST “ON” 12 Sept 2002 at 20:12 12 minutes

2 nd BLACK-OUT 13 September at 08:02 Second Back Feeding arrived after 38

Second SST “ON” 13 Sept 2002 at 08:40 menit

12 Sept 20:25 Firing aborted due to boiler leakage

UNIT 1
13 Sept 21:17 14 Sept 04:07 WARM Start Recovery Time 6 jam 43 mnt
UNIT 2 14 Sept 09:45 14 Sept 18:40 WARM Start Recovery Time 8 jam 55 mnt

12 Sept 23:15 12 Sept 02:45 HOT Start Recovery Time 9 jam 35 mnt
Turbin has been trip at roll out due to the
13 Sept 10:45
UNIT 3 failure in lubrication system
Start Up has been performed after
03 Okt 02:00 04 Okt 17:00 repairing on turbine bearing & Impeller of
Main Oil Pump (MOP)
13 Sept 01:00 Trip again due to second Black-Out
UNIT 4
HOT Start Recovery Time 23 hours 12
13 Sept 11:45 13 Sept 18:12
minutest
UNIT 5 15 Sept 18:04 16 Sept 06:54 COLD Start Recovery Time 3 days
COLD Start Recovery Time 54 hours and
UNIT 6 13 Sept 10:25 14 Sept 03:33
33 minutes
Rolled up aborted due to high turbine
12 Sept 20:15
vibration
UNIT 7
COLD Start Recovery Time 55 hours 43
14 Sept 19:51 15 Sept 04:43
minutes
 RECOVERY PROCESS FOLLOWING
BLACKOUT
• Since there was no power enough to restart from station use while
turbine speed down to zero which normally took 45 minutes, back
feeding should returned at a proper time (less than 60 minutes) to
ensure that restarting enable as soon as possible.
• Since Auxiliary Steam is necessary to fire plants No 1 to 4 , it could be
supplied by remaining steam which still held in any steam drum of
boilers. If any unit can be restarted within 2 hours all units then can
easily be restarted, but if none of them could not be started or
restarted after 2 hours there will be no auxiliary steam enough to
restart any plant. In this situation Auxiliary Boiler should be started
and this will take at least 2 hours to produce auxiliary steam which
the amount also be limited. Only up to two plants can be started at the
same time.
 RECOVERY PROCESS FOLLOWING
BLACKOUT
(continued)
• After back feeding return to Suralaya Start-Up for plants No
1 to 4 still limited to two units due to limitation on start up
transformer capability an the auxiliary steam produced on
auxiliary boiler.
• When back feeding applied to Plants No 5 to 7 all plants can
be restarted since atomizing process used instruments air.
• If HOUSE LOAD success to establish, resynchronize to the
grid should be taken less than two hours since control system
will recall for tripping due to Low Power Turbine Limit
action.
 Scenario to Perform Island Load of Suralaya SPP

PREVIOU NEW (modified by Jan 2003)

Same Mechanical Over-speed Protection
55S
55 Hz
Hz Action (Turbine Trip)

Same 53,75 Hz Electrical Turbine Over-speed Protection Control (OPC

53,75 Hz Action  Turbine Speed Control to hold Generator still ONL

51,5 Hz Unit 7 HOUSE LOAD

by Over Freq Relay (OFR) Unit 7 (new Relay)
Setting Time : Instantaneous
With permissive All Feeder Suralaya-Gandul OPEN

Same
50 Hz Action 50 Hz NORMAL OPERATION

SURALAYA ISLAND OPERATION

Set by Over Freq Relay (OFR) GITET Suralaya
48,3 SURALAYA ISLAND OPERATION 48,3 All Feeder towards Suralaya are OPENED
Hz Unit 2,3 tripped out Hz To make stable LOAD Generator
Unit 1 OR Unit 4 feed 150 kV IBT of Suralaya ISLAND LOAD should be between 700 – 900 MW
Unit 5, 6 & 7 feed 500 kV Gandul & Cilegon Baru Unit 2,3 TRIP
Unit 6 HOUSE LOAD
Keep 2000 MW still ONLINE
Flow chart of performing Suralaya Island Operation
48,3 Hz SCHEME 51,5 Hz SCHEME
BEGIN
BEGIN

Fre q =
Freq = 51,5 Hz
48,3 Hz

PMT
NO
PMT GANDUl 1
NO TRIP ?
GANDUl 1
TRIP ?
YES

YES

PMT NO
GANDUl 2
TRIP ?
PMT NO
GANDUl 2
TRIP ? YES

YES

Unit 1 NO
ONLINE ?
SINKRON

YES

OPEN PMT OPEN PMT Unit 4

NO YES
UNIT 2 UNIT 3 Unit 5 ONLINE ?
ONLINE ? SINKRON
SINKRON
NO
YES

Unit 7 NO
ONLINE ? Unit 5 NO
SINKRON ONLINE ?
SINKRON

YES YES

OPEN PMT
UNIT 6
OPEN PMT
UNIT 7

NO ACTION NO ACTION
END
END
 CONCLUSIONS
• Even to restart only one plant, it is necessary for SURALAYA to have
back feeding from the grid immediately after blackout occurred
• Maximum Back-Feeding Time needs to avoid Suralaya SPP from any
damages should be less than 60 minutes. This will minimize damages to
the main apparatus ( I.e Turbine, Air Heater & Condenser etc )
• If back feeding recover more than 2 hours should Aux Boiler be started
providing auxiliary steam to assist firing process.
• Due to the complexity of control activities HOUSE LOAD only be kept
less than 2 hours. Any action to resynchronize to the grid should initiate
immediately to avoid further tripping.
 CONCLUSIONS
(continued)

• From the very beginning of operation, Suralaya has

been faced with various blackout conditions. Most of
them caused by external failure.
• Except the blackout on 12 September 2002, blackout
phenomena sensed and initiated by decreasing power
frequency before any tripping taken place, so UFR
might hold an island operation.
• On the last blackout power frequency course was
unexpected. It first went up so not any UFR could hold
island operation and then immediately went down
following plants tripped out by over-speed protection
apparatus.
 ONE LINE DIAGRAM OF UNIT 1-4 STATION USE

Start-Up Bus “A” To Unit 2,3 & 4 (Typical)

Start-Up Bus “B”

SST 1 (35/46 MVA) SST 2 (35/46 MVA)

Gen Trf Standby` In-service

UST 1
Unit No.1
35/46 MVA

M
M

6 kV Motors on Bus "A" 6 kV Motors on Bus “B"

BFP 1A, 1B = @ 5,3 MW BFP 1C = 5,3 MW
CWP 1A = 1,5 MW ID Fan 1A, 1B= @ 2,3 MW
FD Fan 1A = 1,4 MW CWP 1B = 1,5 MW From UST 1B From SST 2A
PAF 1A = 1,3 MW FD Fan 1B = 1,4 MW
GRF 1A, 1B = @ 1,2 MW PAF 1B = 1,3 MW Essential Bus
CEP 1A = 0,63 MW CEP 1B = 0,63 MW Aux. Boiler Bus

MILL 1A,1B = @ 0,5 MW MILL 1C,D,E = @ 0,5 MW Essential

LVS Load =  2 MW LVS Load =  2 MW Load M
Aux. Boiler
Connected Load “A”= 21 MW Connected Load “B”=  MW Gen-Set 1-2 FD Fan
400 kW Load
 ONE LINE DIAGRAM OF UNIT 5-7 STATION USE
UNIT 7 (Typical for 5 & 6) COMMON for Unit 5,6,7
Start-Up Bus A

Start-Up Bus B
SST 3
36/56 MVA
SST 4
36/56 MVA
GT Unit 7
M
UST 7A
UST 7B SU-BFP 7
36/56 MVA
36/56 MVA 6 MW

Gen Unit 7

M M

Gas Turbine 10.5 kV Motors on Bus

"A" 10.5 kV Motors on Bus
16,5 MW CWP 7A = 2,8 MW “B"
Essential Bus
ID Fan 7A = 2 MW CWP 7B = 2,8 MW
FD Fan 7A = 0,9 MW ID Fan 7B = 2 MW
PAF 7A = 1,8 MW FD Fan 7B = 0,9 MW
CEP 7A = 2,1 MW PAF 7B = 1,8 MW
3,3 kV Load = 3,1 MW CEP 7B = 2,1 MW
Gen-Set Essential Load
LVS Load =  3,5 MW 3,3 kV Load = 3,1 MW
1800 kW
Connected Load “A”= 24 LVS Load =  4,25 MW
MW Connected Load “B”= 25
(Included SUBFP) MW
(Included SUBFP)
 Emergency Power Supply
Installed Output Starting Time
Emergency Power Mode of State of
No. Cap. Voltage up to Functions
Supply Operation Conditions
( kW ) (V) Loading
Auto Start & Emergency Power
Diesel Genset 1-2
1 1 x 500 380 Loading by 30 seconds Supply Essential Bus Standby
( New 2002 )
Undervoltage Unit 1-2
Auto Start & Emergency Power
Diesel Genset 3-4
2 1 x 400 380 Loading by 30 seconds Supply Essential Bus Standby
( since 1988 )
Undervoltage Unit 3-4
Auto Start & Eemrgency Power
Diesel Genset 5-7
3 1 x 1800 400 Loading by 30 seconds Supply Essential Bus Standby
( since 1997 )
Undervoltage Unit 5-7
Manually Emergency Power
Gas Turbine 45 minutes
4 1 x 17500 10.500 Started Supply 10,5 kV Bus Unit Standby
(since 1999) (Fast)
by Operator 5-7
 MAIN SOURCE TO START-UP UNIT No. 1-7
1. Power Consumption (Full Load Operation)
CONNECTED Load Normal Load
System LOAD (Bus A+B) Factor Power
UNIT
Voltage (kV) Factor (MW) (MVAR) (MVA)
(MW) (MVA) (% )
AUX. BOILER 6 1 1,2 80 0,85 0,85 0,5 1
UNIT 1-4 @ 6 40 45 50 0,85 20 13 24
UNIT 5-7 @ 10,5 50 52 56 0,85 28 17 33

2. AUXILIARY STEAM : Used to maintain vacuum on Condenser Unit 1-4,

Atomizing Burner, Gland Seal Turbine, Igniter (first fired). Normal operation
supplied Individually by its boiler. When blacked-out happened, transferred to
Auxiliary Boiler ( 60 T/hr) which has capability to supply only two boiler.
3. MAKE UP – WATER additional water supplied by desalination plant .
Normally it was stored on Reserve Water Tank

4. Diesel fuel oil (HSD) Igniter : Perform first firing prior to use coal firing
system or marine fuel oil firing system
 Required Power to Start-Up :
CONNECTED Load Demand Load
Motor
Operation Factor Power
ITEM Qty
Voltage ( kV )
Acceleration LOAD (Bus A+B)
Factor (kW) (kVAR) (kVA)
Time (Seconds) (kW) (kVA) (% )
1. UNIT 1-4 (for 1 unit)
a. Low Voltage LVS LOAD 1 0,38 1800 2250 80 0,80 1876 1389 2334
b. Auxiliary Boiler Start-Up 1 6 & 0,38 1000 1250 80 0,80 800 600 1000
c. Cooling Water Pump (CWP) 1 6 4 1500 1875 95 0,80 1425 1069 1781
e. Condesate Extraction Pump (CEP) 1 6 4 630 788 85 0,80 536 402 669
f. Boiler Feed Po. (BFP) 1 6 4 6342 7928 90 0,80 5708 4281 7135
g. Induced Draft Fan (IDF) 1 6 28 2255 2819 50 0,80 1128 846 1409
h. Force Draf Fan (FDF) 1 6 25 1393 1741 50 0,80 697 522 871
i. Primary Air Fan (PAF) 1 6 10 1322 1653 50 0,80 661 496 826
j. 1 ea. MILL to produce 100 MW 1 6 3 522 653 95 0,80 496 372 620
TRANSFER SST to UST at 80 MW
Power to Start-Up one plant of 400 MW 13325 9975 16646
Total Power to Start-Up 4 plants of 400 MW 39976 29926 49937

2. UNIT 5-7 (for 1 unit)

a. Low Voltage LVS LOAD 1 0,4 1800 2250 80 0,80 1876 1389 2334
b. Cooling Water Pump (CWP) 1 10,5 4 2835 2835 95 0,78 2700 2166 3461
c. Closed Cooling Water Pump (C3WP) 1 3,3 4 580 1160 95 0,88 552 294 625
d. Condesate Extraction Pump (CEP) 1 10,5 3,7 2126 2126 84 0,90 1796 891 2005
e. Start-Up Boiler Feed Po. (SU-BFP) 1 10,5 3,9 5960 5960 90 0,89 5342 2746 6006
f. Induced Draft Fan (IDF) 1 10,5 23,2 4302 4302 48 0,71 2061 2066 2918
g. Force Draf Fan (FDF) 1 10,5 20,4 1728 1728 50 0,76 865 731 1133
h. Primary Air Fan (PAF) 1 10,5 8,9 1824 2280 53 0,80 971 728 1214
i. 1 ea. MILL to produce 125 MW 1 3,3 3 800 1000 84 0,81 671 482 826
TRANSFER SST to UST at 80 MW
Power to Start-Up one plant of 600 MW 16834 11493 20523
Total Power to Start-Up 3 plants of 600 MW 50502 34478 61568

TOTAL POWER for START-UP 7 UNIT SURALAYA 90478 64404 111505

 Minimum power required to avoid
any serious damage to the plants
System CONNECTED Load Demand Load
ITEM Qty Voltage LOAD (Bus A+B) Factor Power Source of Supply
Factor (kW) (kVAR) (kVA)
( kV ) (kW) (kVA) (%)
1. UNIT 1-4 (Total 4 unit) 8817 6181 10778
a. Essential Apparatus 4 0,38 4 x 500 4 x 588 40 0,85 800 497 942 Gen-Set 2 x 500 kW
b. Turbine protection 4 0,38 4 x 612 4 x 720 25 0,85 612 379 720 Grid
c. Boiler protection 4 0,38 4 x 680 4 x 800 20 0,85 544 337 640 Grid
d. Station protection 4 0,38 4 x 1156 4 x 1360 25 0,85 1156 716 1360 Grid
e. Circ. Water System 1 0,38 850 1000 25 0,85 213 132 251 Grid
f. Circ. Water Pump 4 6 4 x 1560 4 x 1950 88 0,80 5492 4119 6865 Grid

2. UNIT 5-7 (Total 3 unit) 13185 11122 17556

a. Emergency apparatus 1 0,4 1800 2250 80 0,80 1440 1080 1800 Gen-Set 1800 kW
b. Turbine protection 3 0,4 3 x 1700 3 x 2000 25 0,85 1275 967 1600 Gas Turbine
c. Boiler protection 3 0,4 3 x 1700 3 x 2000 20 0,85 1275 967 1600 Gas Turbine
d. Station protection 3 0,4 3 x 1700 3 x 2000 25 0,85 1275 967 1600 Gas turbine
e. Circ. Water system 1 0,4 1700 2000 25 0,85 425 1543 1600 Gas Turbine
f. Circ. Water Pump 3 10,5 3 x 2835 3 x 3543 88 0,80 7495 5600 9356 Gas turbine

MINIMUM POWER NEEDED TO AVOID DAMAGE 22002 17304 28334

 Inrush Current Characteristic
(Motor Starting Analyze)

2,500
2,375 CEP start SU-BFP start
2,250 Is = 7,14 x In ID Fan start
Is = 8,49 x In Is = 9,26 x In
2,125
2,000
Current (Amperes) at 10,5 kV

1,875
FD Fan start
1,750
CWP start Is = 9 x In
1,625
1,500
Is = 4,82 x
In
1,375
1,250
1,125
1,000
875
750
625 C3WP

500
375
250
125
0

Time (Second)
Station Service Transformer Bus Drop Voltage Simulation by ETAP
3.0.1)

CWP
start
CEP start
SU-BFP start
FD Fan start
ID Fan start

82% Vn UNDER VOLTAGE RELAY LIMIT

(27)
 COLD START-UP
TEMP Press TURBINE
oC (kg/cm2)
% COLD START UP SPEED

600

500 200 100 2

180

400 160 80

140
300 120 60 4
100

200 80 40
60 3 3000

100 40 20 1 2000

20 1000

0 2 4 6 8 10 12 14 16 Hours

Legend :
1. Main steam pressure (kg/cm2)
2. Main steam temperature (degree C)
3. Turbine speed (rpm)
4. Generator Loading
 WARM START-UP
START UP CURVE OF SURALAYA STEAM POWER PLANT

TEMP Press TURBINE

oC (kg/cm2)
% WARM START UP SPEED

600
2

500 200 100 4

180
400 160 80
140
300 120 60
100
200 80 40
60 3000
3
100 40 20 2000
1
20 1000

0 2 4 6 8 10 12 14 16 Hours

Legend :
1. Main steam pressure (kg/cm2)
2. Main steam temperature (oC)
3. Turbine speed (rpm)
4. Generator Loading