Proceedings of the International Conference on F-51

Electrical Engineering and Informatics

Institut Teknologi Bandung, Indonesia June 17-19, 2007

The Optimization of Suralaya Steam Power Plant Operation

With Equal Incremental Rates and Priority Method
Hartono1*
1
University of Sultan Ageng Tirtayasa, Jalan Raya Jakarta kM.04 Pakupatan, Serang, Indonesia

Currently, the largest cost to produce electricity at Suralaya Steam Power Plant is the cost of coal consumption, which affects the
selling price of electricity per kWh. Saving coal consumption is the strong motivation for Suralaya steam power plantto achieve
maximum operational efficiency. Suralaya Steam Power Plant have 7 units of coal fired power plants, connect in parallel order and
operate at maximum capacity, to ensure reliability to supply electricity to consumer as the main priority rather than efficiency.
An optimal combination in operating the plants and loading operation scheduling in the most economic fashion using equal
incremental rates method will save coal consumption significantly. The method will use second-order polynomial equations, and
linear approach by deriving the second-order polynomial equation. The solution from equal incremental rates method will yield the
most economical operation schedule of Suralaya steam power plantin order to save coal consumption. In this study, we utilize the
highest load at 3197 MW generated from 7,561,479,246 kcal/hour coal consumption. After optimization using the equal
incremental rates method, we found that coal consumption can be reduced to 7,486,155,768 kcal/hour, which means we save
75,323,478 kcal/hour of coal consumption. Since average coal energy is 5100 kcal/kg, the optimization using equal incremental
rates saves us 14.77 ton of coal per hour if compared to the real operation system of Suralaya steam power plant at the same time.

1. Introduction 2.2 Calculation Approach Using Linear Equation

Operating cost of the system is the largest portion of Maximum output is achieved at the point where the
planning cost, at nearly 70% of total cost. slope of the straight line starting from origin to another point
To optimize Suralaya steam power plant efficiency in coal on the curve is minimum, which is where the straight line
consumption, the author will look for a combination of Unit touches the curve. (13)
1, Unit 2, Unit 3, Unit 4, Unit 5, Unit 6, and Unit 7 of the
seven units of coal-fired plants so that we obtained 128 ΔH
ΔP
possible combinations, in order to achieve the most economic ΔC
operating combination at Suralaya steam power plant. ΔP

We will implement the equal incremental rates method, an

increment in heat value over coal consumption cost. Using
this approach, energy cost for several loading levels at one
plant unit will be linear segments.(8)

2. Basic Theory Fig. 3. The straight-line approach graph. (7) (13)

2.1 Characteristics of Power Generation Units
ΔH → the incremental of heat rate (MBTU/MWh)
ΔP
ΔC → the incremental of fuel cost (Rp/MWh)
ΔP
dCi
= λ ...............................................................(1)
dPi
Where λ is fuel cost incremental or equal incremental rates
(Rp/MWh).(9)
N
Fig. 1. Incremental heat rate characteristic.(9) . ∑ Pi = Pload
i =1
..........................................................(2)

2.3 The constraints of generation unit

Minimum and maximum limits, from operational
capactiy can be expressed as (11)
dCi = λ , for Pi min < Pi < Pi max.............................(3)
dPi
dCi ≤ λ ,for Pi = Pi max.......................................(4)
dPi
(9)
Fig. 2. Incremental fuel cost characteristic . dCi ≥ λ ,for Pi = Pi min.........................................(5)
dPi
* E-mail: artonid@yahoo.com

ISBN 978-979-16338-0-2 846

Proceedings of the International Conference on F-51
Electrical Engineering and Informatics
Institut Teknologi Bandung, Indonesia June 17-19, 2007

( ΔP
3. Plant Optimization Problem Solving Methods (k )
) between turbine’s output power and load power is
3.1 Equal Incremental Rates Method zero.
The Consumption of fuel in unit generation production
can be state in Eq. 6 - Eq. 8 (1) (9) 3.2 Priority Method
C i = α i + β i Pi + γ i Pi 2 ....................................(6) Priority method is a method of operating generator plant
n unit based on priority order, started with prioritized
Ct = ∑ Ci ..........................................................(7) generating unit followed by other units.(5)
i =1
n
Ct = ∑α i =1
i + β i * Pi + γ i * Pi 2 ...........................(8) 3.3 Data and Result of Computing Suralaya Steam
Power Plant.
Where : 1. Maximum and minimum operating limits allowed
Ct = Total coal consumption (MBTU/h). without
Ci = Plant unit coal consumption (MBTU/h). constraints.
α i , β i , γ i = Constants
n

∑P = P
i =1
i load
.....................................................(9)

To obtain Equal Incremental Rates, we have to derive

equation (3 - 6). (9)
dCi = λ............................................................(10)
dPi
2. Second-order polynomial equation data for Suralaya
From equation (6) we derive. (1) (9)
steam power plant units
λ = β i + 2γ i Pi ....................................................(11) C1 = 1225.98235528122 + 3.79786663310P1
The power to be supplied for each plant unit is calculated + 0.01028572890P12 MBTU/hours.
using the following equation. (1) (9) C2 = 1353.93776992769 + 0.88284394409P2
λ − β i .........................................................(12) + 0.01645659697P22 MBTU/hours
Pi =
2γ i C3 = 1139.72097160743+ 3.94933262469P3
If we have more than one generating plant units, we can + 0.00980239080P32 MBTU/hours
substitute equation (12) into equation (9) so that. (1) (9) C4 = 1201.37807947711 + 3.74302205963P4
+ 0.00778457458P42 MBTU/hours
n
λ − βi
∑
i =1 2γ i
= Pload .............................................(13) C5 = 1873.08742378295 + 1.06373865407P5
+ 0.00666016875P52 MBTU/hours
Hence the coal consumption can be calculated for each C6 = 1809.47153156598 + 2.93282769127P6
running plant unit as follows. (1) (9) + 0.00433233514P62 MBTU/hours
n
β C7 = 739.176241056230 + 4.512480873186 P7
Pload + ∑ i
i =1 2γ i ...........................................(14)
+ 0.004702796368P72 MBTU/hours
λ= n
1
∑i =1 2 γi
From the 127 possible operating combinations, we obtain the
most optimal steam power plant operating point.
Since generating unit has limitations. (9)
Δ P ( k ) ...............................................(15)
Δλ(k ) =
1
∑ 2γ
i

then actual coal consumption in MBTU/MWh is the sum of

equation (14) and equation (15). (9)
λ( k +1) = λ( k ) + Δλ( k ) ...........................................(16)
Where:
λ( k +1) = Actual coal consumption
λ(k ) = Coal consumption from initial calculation
Δλ(k ) = Coal consumption when power generated exceeds
or is less than the generating unit capacity.
Accuracy of calculation.(11)
ng
ΔP ( k ) = Pload − ∑ Pi ( k ) ......................................(17) Fig. 4. Suralaya steam power plant Characteristic curve
i =1

Error process ( ΔP ) needs to be iteratively calculated until Color definitions:

(k )

the desired output becomes more accurate and the difference Unit 1 = ■ Unit 3 = ■ Unit 5 = ■ Unit 7 = ■
Unit 2 = ■ Unit 4 = ■ Unit 6 = ■

ISBN 978-979-16338-0-2 847

Proceedings of the International Conference on F-51
Electrical Engineering and Informatics
Institut Teknologi Bandung, Indonesia June 17-19, 2007

From Figure 4 above we can see that the priority which
yields maximum saving on coal consumption cost is in the
following order: Unit 7, Unit 5, Unit 6, and Units 1, 2, 3, 4.
4. Results and Discussion
4.1 Optimization result analysis
= 1201.378 + (3.743 x 370) + (0.007 x 3702 )
= 3652 MBTU/hours
C5 = 1873.087 + 1.063P5 + 0.0065P52 MBTU/hours
= 1873.087 + (1.063 x 582) + (0.0065 x 5822 )
= 4748.1 MBTU/hours
C6 = 1809.471 + 2.932P6 + 0.004P62 MBTU/hours
= 1809.471 + (2.932 x 560) + (0.004 x 5602 )
= 4810.5 MBTU/hours
C7 = 739.176 + 4.512P7 + 0.004P72 MBTU/hours
= 739.176 + (4.512 x 608) + (0.004 x 6082 )
= 5221.2 MBTU/hours
Total coal consumption for Surayala steam power plant is
CTotal = C2 + C4 + C5 + C6 + C7
= 3999.5 + 3544.6 + 4693.5 + 4705.8 + 4961.1
= 22498 MBTU/hours

From Table 2 above, we can see that when Suralaya steam

power plants supplies 2500 MW power, we have 13 possible
operating combinations. Then from the calculation presented
at Table 2, we found that the most optimal and economical From Table 3 above we can see significant difference
operating point when Suralaya steam power plants supplies between coal consumption calculated using equal incremental
2500 MW was when Unit 1 and Unit 3 were not operated, rates and without optimization technique.
meanwhile Unit 2 supplies 282 MW, Unit 4 supplies 400 This means that if we didn’t use the optimization technique,
MW, Unit 5 supplies 608 MW, Unit 6 supplies 608 MW, and we would waste as much as 306 MBTU/hour of coal.
Unit 7 supplies 602 MW, produced from 22,192 MBTU/hour
of coal consumption. This is the most efficient coal 4.2. Comparing Optimization to Actual Results
consumption compared to the other 12 possible combinations.
If we compare this result to the combinations when all the
7 units are operating to supply 2500 MW of power, i.e. where
the units supply 217 MW, 224 MW, 220 MW, 291 MW, 541
MW, 608 MW, and 399 MW respectively, we’ll find that the
previous combination (where Units 1 and 3 are not operating)
was consuming less coal.
Analysis result proves that operating combination of
Suralaya steam power plant units is very influential to its
efficency. If we do not choose to run the optimal
combination, for example by operating all the 7 units at 2500
MW load, we will have over consumption of coal as much as
1033 MBTU/hour. If the equivalent energy by coal consumed
is 5100 kcal/kg then the excessive coal consumed will be 51
ton/hour.
Using the similar operating combination, where Units 1
and 3 are not operating and annual power supplied by each of
the other units without optimization techniques (for example
when Unit 2 supplies 380 MW, Unit 4 supplies 370 MW, Unit
5 supplies 582 MW, Unit 6 supplies 560 MW and Unit 7
supplies 608 MW), then the coal consumed by Suralaya steam
power plant which is supplied by Units 2, 4, 5, 6, 7 can be
calculated using the following second-order polynomial Table 4 above shows that in order to supply 2500 MW –
equation: 3197 MW power, we need to operate all the 7 units.
C2 = 1353.937 + 0.882P2 + 0.016P22 MBTU/hours Priority to operate generating plant unit continuously when
= 1353.937 + (0.882 x 380) + (0.016 x 3802 ) required falls to Units 4 and 3. On the other hand, priority not
= 4.065.8 MBTU/hours to operate when only low supply required are Units 1, 2, and
C4 = 1201.378 + 3.743P4 + 0.007P42 MBTU/hours

ISBN 978-979-16338-0-2 848

Proceedings of the International Conference on
Electrical Engineering and Informatics
Institut Teknologi Bandung, Indonesia June 17-19, 2007
5. Actual data on Table 4 can be considered when comparing
to results from optimization calculation.
Table 5 shows that the most optimal results for supplies
over 3000 MW up to 3197 MW can be achieved when Units
1-7 are operated. Priority of continuously operating units after
optimization are Units 7, 5, and 6. On the other hand, the
priority not to operate units when supplying low powers are in
the following order: Units 1, 3, 2, and 5.
Priority by Table 4 is different from priority by Table 5.
Priority of operating units according to Table 4 is in the
following order: 4 and 3, while according to Table 5 is 7, 5, 6.
In order to save coal consumption, priority of operating units
is in the following order: 7, 5, 6.
Actual operating condition from Table 4 will be compared to
the optimized condition from Table 4 and will be presented in
Table 6.
ISBN 978-979-16338-0-2
F-51
Table 6. compares actual data of coal consumption to
equal incremental rates optimization method at the same
amount of supply. The largest difference in coal consumption
is 1,258,835,595 kcal/hour, achieved when supplying 2447
MW of power.
Table 6. proves that supply of 1402 MW up to 3197 MW
using equal incremental rates optimization results in
significant reduction in coal consumption, compared to
currently operating combination at Suralaya steam power
plant.
5. Conclusion
Operating the Suralaya steam power plant unit using equal
incremental rates method can significantly reduce coal
consumption, compared to actual condition, from 1,142,406
kcal/hour up to 1,258,835,595 kcal/hour.
The priority to operate Suralaya steam power plant units
in determining the combination of operation will result in the
efficiency of coal consumption.
Operating higher capacity plant units (units 5, 6, 7) will
reduce coal consumption, compared to when operating small
capacities unit (units 1, 2, 3, 4).
In condition where low power supply, units with large
capacity (unit 5,6,7) should be operated continously to
maxsimum capacity meanwhile units with small capacity
(unit 1,2,3,4) should be not operated.
The most optimal operation schedule of Suralaya steam
power plant using equal incremental rates method at 3197
MW peak load supply, is to run all the 7 plant units with each
unit supplies 334 MW, 297 MW, 342 MW, 400 MW, 608
MW, 608 MW, 608 MW respectively. The total coal
consumption will be 7,486,155,768 kcal/hour, which yields a
reduced coal consumption by 75,323,478 kcal/hour, or
equivalent with 14.77 ton coal per hour.
849
Proceedings of the International Conference on F-51
Electrical Engineering and Informatics
Institut Teknologi Bandung, Indonesia June 17-19, 2007

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