Aditya Aluminium CPP

BLACKOUT AND RESTORATION:

Black Start/Emergency DG
Unit 3 Startup
Unit 4 Startup
Coordination with Smelter
Annexure: Black Start DG start-up & Synchronisation with Grid

 ELECTRICAL TEAM RESPONSIBILITY FOR POWER RESTORATION:

 Check that Emergency DG sets have started & DG incomer breakers of all 6
Emergency MCC have closed in auto.
Responsibility- Electrical SIC and Electrical shift Supervisor
 Emergency power is available to following drives -----
EOP, MOP, JOP, Battery Charger, UPS, Illumination, Elevators, APH, Scanner fan,
All Turbine area Valves, MS Stop Valve, VAM, Pilot air compressor and
Compressor control panel.
Responsibility- Electrical SIC and Electrical shift Supervisor
 Check that all 7 numbers Black Start DG have started in Auto. Checking of Fuel
oil, Lube oil, Cooling System and Exhaust system of all DG sets are normal.
Responsibility- Electrical SIC/Babul Prasad/Sambit Pattanaik
 Ensure that all Station Transformers 220KV side breakers are open and all Station
Switchgear incomer breakers are open.
Responsibility- Switchyard SIC/Abinash Panigrahy
 Ensure that Black Start DG power is available to Station Switchgear 2A, 2B and
3A, 3B.
Responsibility-Electrical SIC/BKPanda/PKSatapathy
 Close DG incomer to Station 3B from DG control PC at Unit 3 EER room.
Responsibility- Electrical SIC/Ramakanta/PKSatapathy
 Close DG incomer to Station 3A locally.
Responsibility- Electrical shift Supervisor/BKPanda
 Close DG incomer to Station Switchgear 2B and Station switchgear 2A locally.
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
 Ensure availability of PT voltage in Station Switchgear 3A 3B 2A 2B.
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
 Ensure availability of PT voltage in unit switchgear 4A 4B, 3A 3B and 2A 2B
(through closing of Tie breakers from Station to Unit Switchgear).
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
 Close LT Switchgear incomer breakers of unit 4, 3 and 2 Unit PCC and Turbine
MCC.
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
  When Unit PCC of Unit 4, 3 and 2 are charged from Black Start DG then power is
available at incomer of Emergency MCC and transfer from Emergency DG to
Black Start DG will take place.
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
 Ensure running of all the mentioned drives of Emergency MCC 4, 3 and 2.
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
 Close LT incomer breakers of Station PCC 1&2 and Ensure availability of power to
Compressor MCC, Fuel Oil MCC, CT PCC 2, 3 and 4 and Air Conditioning PCC and
MCC.
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
 Ensure that power is available to Clarified Water PCC, DM Plant, PT MCC and Raw
Water PCC.
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
 Reset & Normalize ID VFD system and ESP LT Main Switch Board of Unit 4, 3 and
2 (ESP control room operator to be trained).
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
 One engineer will be present in Control Room 3&4 & in the control room 1&2
one LMS will be present during normalization.

 OPERATION TEAM RESPONSIBILITY- TO SYNCHRONIZE

THE UNITS 3&4:
 One desk engineer to rush to compressor house.
 Two operators to rush to CWPH.
 AHP operator to rush to FOPH. (Responsibility-Shift in Charge Unit 1&2)
 Check that all DC drives (DC JOP, AOP, scanner air fan) has started.
 Close MS valve of all Units.
 Isolate TG oil cooler from water side in all Units.
 Open Turbine and Main steam line drains in all Units.
 Open Vacuum breaker valve at 0.8 kg/cm2 (abs) to kill vacuum in all Units.
(Responsibility - Desk Engineers – All Units)
 After restoration of Power, start CWP 6 or 7 and 9 or 10.
 Take changeover from DC drives to AC drives in all Units.
 Start any 2 SACW & one SA Compressor and one IA Compressor from local.
(Responsibility-Shift in Charge Unit 1&2)
 Start UACW, DMCW, APH, and ID Fan of Unit 3&4 from Control room.
 Ensure mashal (torch) readiness for boiler light-up.
 After getting instrument air pressure start BFP to fill the boiler drum.
 Start CEP.
 Start one LDO Forwarding pump and put other in standby.
 Start 2 CT fans each of Unit 3 and 4.
 By the pressure & temp of the steam in boiler, open MS valve, charge PRDS,
charge seal steam & pull vacuum.
 Check whether Turbine has come in barring gear if not inform to mechanical
maintenance.
 Start FD Fan, Maintain airflow & purge the boiler & ready for light-up.
(Responsibility - Desk Engineers – Unit 3&4)
 Bypass the drum level protection both for boiler and turbine (again take it in
service when TG load reached 100 MW). (Responsibility – Station In Charge)
 Open service airline drain of boiler area to remove condensate.
 Reset SADC.
 Keep burner tilt at 50%.
 Boiler light-up.
 Once flame is established flame, attempt to take other guns.
 Charge LTPRDS and HFO tracing and atomizing line.
 Start one HFO Forwarding pump and keep others in standby.
 Start COP and observe that sufficient pressure has achieved.
 Charge HPBP & Keep LPBP in auto with set point 5 kg/cm2. (Responsibility - Desk
Engineers – Unit 3&4)
 Ensure DP across the TG should be by-pass.
 Variable VAC tripping should be by-pass.
 Check all the parameters defined in Rolling permissive in TMR page.
1. Reset Control oil emergency PB.
2. Check Turbine vibration.
3. Generator bearing vibration FJB
4. Generator bearing vibration RJB
5. Generator electrical protection
6. Condenser pressure high variable (Responsibility – Station In
Charge)
 Reset LPBP, reset Turbine from DCS.
 Change IP shaft temp. Force value according to HP shaft.
 Check TSE margin to 30K & Forcing of IP shaft temperature is done.
 Achieve Turbine rolling criteria.
 Turbine rolling directly to 3000 rpm.
 Open water side valve of TG oil cooler and maintain oil temperature 45 to 55
degree centigrade. (Responsibility - Desk Engineers – Unit 3&4)
 Dead Bus Synchronization
Responsibility- Electrical shift Supervisor/BKPanda/Ramakanta/Jyoti
(Total Time Taken from Black-out condition to unit 3 or 4 synchronization is
expected to be 120 minutes).
 Close all drains at according to load. (Responsibility - Desk Engineers – Unit 3&4)
 Charging of Aux Transformer of Smelter & loading up to 20MW by starting aux
equipment like ID Fan, Conversion Substation, Carbon, Cast House and
Compressors (Operation and EMD to co-ordinate with Smelter for load
management).
Responsibility- PKS/SP/GT/AKV/GP/SIC
 Charging of Station Transformer 2 and Synchronisation of incomer breaker of
Station Switchgear 2A and 2B and Changeover of load from DG to Unit 3 or 4
(whichever is generating).
 Responsibility-Abinash/BKP/Ramakanta
 Unit 4 Auxiliaries will remain on DG and Station Transformer 3 will not be closed
until resumption of Grid Power.
Responsibility-Abinash/BKP/Ramakanta
 Start balance equipment (CT Fans, CWP, FD Fans, PA fans Mills etc.) of Unit 3 and
4. (Responsibility - Desk Engineers – Unit 3&4)
 Charge Station Transformer 1 & 4 and proceed for startup of all other units
simultaneously.
Responsibility-Abinash/BKP/Ramakanta
 Ensure synchronization of second generator.
Responsibility-Abinash/BKP/Ramakanta/SIC
 Charging of two Rectiformers one by one.
Responsibility- PKS/SP/GT
 Loading of Unit 3&4 to full load in close co-ordination with Smelter KA ramp up.
(Responsibility – Station In Charge)
 Synchronise third unit and charge two more Rectiformers one by one, raise load
quickly by taking Coal Mills in service.
Responsibility- Shift in Charge/SIC/PKS/SP/GT
 Synchronise fourth unit and charge the fifth Rectiformer, raise load quickly by
taking Coal Mills in service.
Responsibility- Shift in Charge/SIC/PKS/SP/GT
 Synchronise fifth unit, raise load quickly by taking Coal Mills in service.
(Responsibility – Station In Charge)

 C&I TEAM RESPONSIBILITY:

 One Engineer to rush to compressor house
 After compressor start-up, One LMS, Technician & Engineer to be present in
control room 3&4.
 Ensure DP across the TG should be by-pass.
 Variable VAC tripping should be by-pass.
 Ensure that boiler & turbine tripping on drum level is bypassed and again
taken in service after TG load 100 MW reached.
 Check all the parameters defined in Rolling permissive in TMR page.
1. Control oil emergency PB reset.
2. HPIP shaft vibration front journal bearing.
3. HPIP shaft vibration RJB.
4. LP shaft vibration RJB.
5. Generator bearing vibration FJB.
6. Generator bearing vibration RJB.
7. Generator electrical protection.
8. Condenser pressure high variable.
 Change IP shaft temperature forced value according to HP shaft.
 MECHANICAL TEAM RESPONSIBILITY:
 One LMS to rush to Black Start DG Control room and to check the Fuel, Lube
Oil, Exhaust and Cooling System.
 Shift Engineer to rush to compressor house.
 After starting of compressor, the engineer should rush to Unit # 3&4 control
room.
 One LMS to go to the CW Pump House. After starting of CWP, the LMS should
rush to Unit # 3&4 control room.
 One LMS to go to the burner floor of Unit 3 and one to Unit 4 along with a
maintenance gang to support operation team for gun cleaning and to arrest
oil leakage.
 For MS valve opening one LMS & one maintenance gang to be available in
Unit 3&4.
 Rest Maintenance team both LMS & Engineer to be in contact with operation
for any support to operation. (Responsibility-Shift Engineer)

Black Out Restoration Time

750 750

600

390

240

50
1
0 1.5
0 2
0 2.5 3 3.5 4 4.5 5
1 2 3 4 5 6 7 8 9
Load(MW) 0 0 0 50 240 390 600 750 750
Time (Hrs) 1 1.5 2 2.5 3 3.5 4 4.5 5

Load(MW) Time (Hrs)

Coordination with Budhipadar Grid SubStation/OPTCL
Regarding nature of outage, defects, Emergency restoration in Grid, Start -up Power,
Probable time for revival of power, Charging of Grid substation, Closing of Aditya Feeders,
Synchronisation with grid, Stability of Grid, Quantity of Drawl, MW/MVAR Export/Import,
discussion with higher ups

Responsibility- Head CPP/Head Electrical/Jyoti

Coordination with SLDC

Regarding nature of outage, Source of Start -up power, Arrival of start- up power,
Emergency restoration, Charging of Grid, Quantity of Drawl, MW/MVAR Export/Import,
discussion with higher ups

Responsibility- Head CPP/Head Electrical

Coordination with WESCO

Regarding import export schedule, Quantity of Drawl, MW/MVAR Export/Import

Responsibility- PKS/Jyoti/Abinash

Regarding Policy matters/Power Unavailability/Discussion with Higher Ups

Responsibility- Head CPP/Head Electrical/PKS/SP

Annexure: Black Start DG start-up & Synchronisation with Grid

Pre-Condition for BSDG start-up,

1. Grid Bus -1 ( 220 KV ) – OFF

2. Grid Bus-2 ( 220 KV) – OFF
3. Line PT of ( Q2 – 2B Transformer Incomer) – OFF
4. Line PT of (Q7-3B Transformer Incomer) – OFF

Responsibility- Electrical SIC/SP/Babul Prasad

Auto Operation through PLC

1. All DGs selected in auto mode will start

2. First DG incomer breaker will close on dead bus
3. Other DGs will close their breaker after synchronization.
 4. After six DGs get synchronized, the outgoings feeder breaker (O/G-1) & (O/G-
2) for STN SWBD #2B & #3B DG Incomer will get closed through PLC.
Responsibility- Electrical SIC/SP/Babul Prasad

DG Incomer Closing at CPP-STN SWBD#2B and 2A

Step1: Operator will select screen “CPP-3 Panel Line Diagram” under “LINE
DIAGRAM” from SCADA Screen. “CPP AREA -3” will appear on SCADA
Screen.
Step2: Operator will give “CLOSE” command through SCADA button to 2B DG
Incomer breaker (Q1). Breaker will close on Dead Bus & DG will take the load
of the bus.
Step3: (Optional for 2A Switchgear operation) Operator will ensure the following
condition on CPP Area-3 SCADA screen
a. Breaker Q3 (2A Traformer Incomer) – OFF
b. Bus of 2A Section is OFF (i.e. Green colour).
Step4: (Optional for 2A Switchgear operation) Operator will give “CLOSE” command
through SCADA button to Q4 Breaker (New 2B Tie Feeder to 2A), Else Local
Closing may be done.
Step5: (Optional for 2A Switchgear operation) Operator will give “CLOSE” command
through SCADA button to Q5 Breaker (New 2A Tie Feeder to 2B), Else Local
Closing may be done.

Responsibility-Electrical SIC/PKS/BKP/Ramakanta/Jyoti

DG Incomer Closing at CPP-STN SWBD#3B and 3A

Step1: Operator will select screen “CPP-4 Panel Line Diagram” under “LINE
DIAGRAM” from SCADA Screen. “CPP AREA -4” will appear on SCADA
Screen.
Step2: Operator will give “CLOSE” command through SCADA button to 3B DG
Incomer breaker (Q6). Breaker will close on Dead Bus & DG will take the load
of the bus.
Step3: (Optional for 3A Switchgear operation) Operator will ensure the following
condition on CPP Area-4 SCADA screen
a. Breaker Q8 (3A Traformer Incomer) – OFF
b. Bus of 3A Section is OFF (i.e. Green colour).
Step4: (Optional for 3A Switchgear operation) Operator will give “CLOSE” command
through SCADA button to Q9 Breaker (New 3B Tie Feeder to 3A)
Step5: (Optional for 3A Switchgear operation) Operator will give “CLOSE” command
through SCADA button to Q10 Breaker (New 3A Tie Feeder to 3B)

Responsibility-Electrical SIC/PKS/BKP/Ramakanta/Jyoti

GRID POWER RESOTARATION:

CASE-I: Grid comes when
A) 220KV Bus is dead
B) DG Running on SS 3A/3B and SS 2A/2B only
C) Unit not synchronized

Step: 1, Closing of 220KV Line Breaker

Ensure that there is no disturbance in Grid and the Grid voltage and Frequency
is stable... Check Line1 and Line2 Incomer voltage and frequency in
Switchyard. Close the desired Line Breaker in dead bus mode from Switchyard
SCADA. Close the other Line breaker in Live Bus mode from Switchyard
SCADA.
Step: 2, Closing of ST-3 220KV Breaker and ST-2 220KV Breaker
Close ST-3 and ST-2 220KV breaker from Switchyard SCADA. Once ST-3 and
ST-2 is charged, Line PT of Q2 (ST 2B Transformer Incomer) Line PT of Q7 (ST-
3B Transformer Incomer) will be healthy, i.e. Grid supply is available, and
SCADA screen will appear message “GRID SYNC ENABLE”.
Step: 3, Closing of Station Incomer 3B/Station Incomer 2B Breaker.
BSDG will be synchronized at Station Incomer#3B and Station Incomer#2B
through GSU after giving “CLOSE” command through SCADA button to Q2
(2B Traformer Incomer) or Q7 (3B Traformer Incomer). Transformer Incomer
breaker will close after synchronization with DG Power. The DG will sense
Grid mode and all the DG run parallel with Grid at Load set point mode.
Step: 4, Closing of Station Incomer 3A/Station Incomer2A Breaker.
After parallel operation, Switch on SS-3A Incomer breaker from the GSU of DG
Set (Alternately Locally). Close SS-2A Incomer Breaker from the GSU
(Alternately Locally)
Step: 5, Tripping of DG Incomer 3B/2B and DG Incomer 3A/2A Breaker.
Give “OPEN” command to Q1 (2B DG Incomer breaker) or Q6 (3B DG Incomer
breaker) through SCADA button, Similarly Give Open Command to DG
Incomer, Q10 and Q5, 3A/2A Breaker. DGs will be unloaded. Trip Q4 and Q9
Breaker

Responsibility-Electrical SIC/PKS/SP/BKP/Ramakanta/Jyoti

CASE-II: Grid comes when

A) 220KV Bus is charged from self-generation
B) DG Running on Station 3A/3B only
C) Unit synchronized

Step: 1, Synchronisation of 220KV Line Breaker

Ensure that there is no disturbance in Grid and the Grid voltage and Frequency
is stable... Check the Line1 and Line2 Incomer voltage and frequency of both
the Lines in Line Synchronizing Panel in MCR of Unit 3 & 4. Select the desired
Line to be synchronized and Switch on Synchroscope. Match the Frequency of
Incoming machine and Bus by Raising/Lowering speed of existing Generators.
 Match the Voltage of Incoming machine and Bus by Raising/Lowering voltage
of existing Generators Close the desired Line Breaker through synchronous
permissive.. Switch on other Line Breaker directly.
Step: 2, Closing of ST-3 220KV Breaker
Close ST-3 220KV breaker from Switchyard SCADA. Once ST-3 is charged, Line
PT of Q7 (ST-3B Traformer Incomer) will be healthy, i.e. Grid supply is
available, and SCADA screen will appear message “GRID SYNC ENABLE”.
Step: 3, Closing of Station Incomer 3B Breaker.
BSDG will be synchronized at Station Incomer#3B after giving “CLOSE”
command through SCADA button to Q7 (3B Traformer Incomer). Transformer
Incomer breaker will close after synchronization with DG Power. The DG will
sense Grid mode and all the DG run parallel with Grid at Load set point mode.
Step: 4, Closing of Station Incomer 3A Breaker.
After parallel operation, Switch on SS-3A Incomer breaker from the GSU of DG
Set (Alternately Locally).
Step: 5, Tripping of DG Incomer 3B and DG Incomer 3ABreaker.
Give “OPEN” command to Q6 (3B DG Incomer breaker) through SCADA
button, Similarly Give Open Command to Q10, DG Incomer 3A. DGs will be
unloaded.

Responsibility-Electrical SIC/PKS/SP/BKP/Ramakanta/Jyoti

CASE-III: Grid comes when

A) 220KV Bus is charged
B) DG Running on Station 3A/3B and Station 2A/2B only
C) Unit synchronized

Step: 1, Synchronisation of 220KV Line Breaker

Ensure that there is no disturbance in Grid and the Grid voltage and Frequency
is stable... Check the Line1 and Line2 Incomer voltage and frequency of both
the Lines in Line Synchronizing Panel in MCR of Unit 3 & 4. Select the desired
Line to be synchronized and Switch on Synchroscope. Match the Frequency of
Incoming machine and Bus by Raising/Lowering speed of existing Generators.
Match the Voltage of Incoming machine and Bus by Raising/Lowering voltage
of existing Generators Close the desired Line Breaker through synchronous
permissive.. Switch on other Line Breaker directly.
Step: 2, Closing of ST-3 220KV Breaker and ST-2 220KV Breaker
Close ST-3 and ST-2 220KV breaker from Switchyard SCADA. Once ST-3 and
ST-2 is charged, Line PT of Q2 (ST 2B Traformer Incomer) Line PT of Q7 (ST-3B
Transformer Incomer) will be healthy, i.e. Grid supply is available, and SCADA
screen will appear message “GRID SYNC ENABLE”.
Step: 3, Closing of Station Incomer 3B/Station Incomer 2B Breaker.
BSDG will be synchronized at Station Incomer#3B and Station Incomer#2B
through GSU after giving “CLOSE” command through SCADA button to Q2 (
2B Transformer Incomer) or Q7 (3B Transformer Incomer). Transformer
 Incomer breaker will close after synchronization with DG Power. The DG will
sense Grid mode and all the DG run parallel with Grid at Load set point mode.
Step: 4, Closing of Station Incomer 3A/Station Incomer2A Breaker.
After parallel operation, Switch on SS-3A Incomer breaker from the GSU of DG
Set (Alternately Locally). Close SS-2A Incomer Breaker from the GSU
(Alternately Locally)
Step: 5, Tripping of DG Incomer 3B/2B and DG Incomer 3A/2A Breaker.
Give “OPEN” command to Q1 (2B DG Incomer breaker) or Q6 (3B DG Incomer
breaker) through SCADA button, Similarly Give Open Command to DG
Incomer, Q10 and Q5, 3A/2A Breaker. DGs will be unloaded. Trip Q4 and Q9
Breaker.

Responsibility-Electrical SIC/PKS/SP/BKP/Ramakanta/Jyoti