Alaoji 1074MW Combined Cycle Power Plant

Black Start Procedure

(Refer to the Alaoji Black Start Concept and Description of the Alaoji Electrical
System, attached).

Introduction
Today, due to the high quality of power generation equipment design, advanced materials,
and precise numerical control manufacturing, producing excellent power plant equipment
and fast acting electrical protection, a Power Plant Black Site due to equipment failure would
be a rare occurrence, however all generation plants must be ready for such an occurrence
and equip themselves with the knowledge and analytical techniques to prepare procedures
and practices, to be able to quickly ascertain why an event has occurred and to be in a
position, whilst liaising with the Grid Control Engineers, to immobilise defective equipment,
quickly reinstate the high voltage grid system and return available transmission and
generating plant to service.

The operator must be fully aware, that the business of managing a power plant is to produce
and sell generation under the umbrella of exacting operating procedures and safety rules, it
is a business which must make profits to cover all operating costs, provide for technological
improvements and future expansion, it is not merely running a plant.

The Grid System Electrical Protection and Power Plant Electrical and Mechanical Protection,
will safeguard the plant and equipment from major damage, however the power plant
respective Operations and Maintenance Engineers must have an in-depth knowledge of the
design detail of the generation plant and equipment, its inherent protection and the differing
scenarios which would or could cause the protection to operate.

Plant management and plant engineers alike should be equipped with the knowledge to
recognise specific plant failure and have procedures in place to resolve any occurrence.
They should be in a position to quickly immobilise the defective equipment for correction
under the auspices of the Safety Permit to Work System and return the un-affected
equipment to service as quickly as possible. To ensure all operations and maintenance
engineers fully understand and develop this knowledge, albeit provided in the operations and
maintenance procedures, recovery from all failure scenarios listed and logically delineated in
the plant operations and maintenance procedures, should be discussed, examined and
practiced, until all fully understand and are confident, that they have the broad and exacting
knowledge, to quickly recover from any system failure scenario. Power Plant Management
should never leave anything to chance.

Following plant take-over and development of quiescent operation, periodic debates on this
subject with differing scenarios are strongly recommended to avoid stagnation and to be
prepared at any time to manage such circumstances of plant failure.

In the event of a black site, due either to an electrical fault, or under-frequency condition
caused by generation or plant system failure, the power plant electrical system having
tripped due to operation of the main protection, rendering the whole plant DEAD, the cause
of the failure will clearly be apparent from the alarm and protection provisions provided by
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the Gas Turbine Distributed Control System (DCS) and by the High Voltage Switching
Software.

By remaining alert and fully informed, the more experienced plant operator will have the
current and inherent knowledge of the control and protection systems, and will be in a
position to quickly diagnose the cause of an incident and commence correction, adhering
strictly to the ‘Black Start Procedure’, with which he will be fully familiar.

Failure of the generating plant and the transmission system as previously referred, would be
a rare occurrence, however the plant management operations and maintenance personnel
should be fully trained, have the knowledge and equipment to be prepared to contain this
type of incident, be able to reinstate the plant and if necessary, re-energise the Alaoji 330kV
Grid System and assist in its return to normal operation as soon as is possible following such
an event.

The Black Start procedure assumes the plant is ‘DEAD’, all plant and equipment is shut
down. The high voltage grid system may also be ‘DEAD’.

The procedure guides the plant engineers through progressive reinstatement of the
generating plant and re-establishing power generation to meet site demand, re-charging the
Plant High Voltage Transmission Lines, the remote Transmission and Distribution
Transformers, and power export to meet and to maintain System Frequency and Voltage,
whilst continuing constant liaison with the Grid Control Engineers who manage the
Transmission System.

Adhering strictly to the Black Start Procedure, it is essential to develop a strong and stable
rotating power base from which to re-establish the transmission and distribution systems.
Alaoji has this potential with its large gas turbine generators which provide substantial
rotating, electrical stability and mechanical mass, to repress transformer inrush current and
recharge the 330kV Grid Transformers.

A description of the Alaoji Electrical System has been written and is available for reference
with drawing E0-0EE001, Overall System One Line Diagram.

Preparations for Black Start

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As referred above, the initial condition of the Plant Electrical AC System is assumed as
DEAD, ie., at zero AC voltage. The dc Control System Voltage will be maintained from the
Station Batteries. The 330kV System is also assumed as DEAD.

The power plant electrical system will be re-energised and progressively returned to service
in Black Start mode and the 330kV Power Evacuation System will be charged and re-
established from re-instatement of the first Gas Turbine Generator.

Before commencement of the Electrical System Restoration, the whole electrical system will
be checked as healthy and all outgoing circuits fed from both the 11kV busses will be
opened. The 330kV Transmission Lines 1 and 2, Circuit Breakers 0-0ESW-BKR-1 and 0-
0ESW-BKR-2 and 330kV Tie Breaker 0-0ESW-BKR-3, will also be checked as open on the
SCADA Transmission Network Console and the Transmission and Distribution Systems
Mosaic, as referred in the Modus Operandi.

A quick inspection will be made of the 330kV Sub Station, the plant AC 11kVand 415v
switchgear, the dc switchgear and the station batteries, prior to commencement of the plant
restoration operations.

Black Start Generator #1, will be pre-start checked and started. Following checking the
running condition of the machine as satisfactory, the generator circuit breaker 1-1EGN-BKR-
0010 will be closed on to the 11kV Main Busses 1 and 2, 1-0EAP-SWG-0100 and 2-0EAP-
SWG-0100, with the Tie Breaker 1-0EAP-BKR-0101 closed, to charge both of the 11kV Bus
Bars. (At a later stage as plant is reinstated, Black Start Diesel Generator #2, will be started
and synchronised to the re-established system). The generation on each diesel generator
can be adjusted to share the load, and more so to provide additional generation capacity
and system stability proportionately to maintain system frequency, as the system is re-
established to avoid one machine being overloaded.

Initially, the Station and Gas Turbine auxiliary distribution boards with respect to the gas
turbines will be returned to service, such that all ac and dc systems are available to re-start
the plant.

Gas Turbines #1 and #2 are started from the 1-0-EAP-MCC-0100 6.9kV Cranking and Soft
Start MCC and Gas Turbines #3 and #4, are started from the 2-0-EAP-MCC-0100 6.9kV
Cranking and Soft Start MCC. The two Cranking MCC’s are respectively fed from 750kVA
11/6.9 kV Cranking MCC Transformers, 1-0EAP-TFM-0010 and 2-0EAP-TFM-0010, each
fed from either end of the 11kV Main Busses 1 and 2. Power Oil is provided from the Gas
Turbine Power Oil Pump to control the Gas Inlet Valves and the Variable Inlet Guide Vanes.

All 415v Gas Turbine Auxiliaries are fed from the 415 Volt Distribution Boards labelled GT
PCM, viz., 1-0EAP-SWG-1000; 2-0EAP-SWG-1000; and 415v Essential Busses 1-0EEP-
SWG-1000 and 2-0EEP-SWG-1000.

As given, the Cranking MCC 11kV/6.9kV Transformers 1-0EAP–TFM-0010 and 2-0EAP–

TFM-0010, provide the power base to start and run the Gas Turbine Generators 1 and 2, to
synchronous speed in rotation and to synchronise the generators to the re-established
system provided by the Black Start Generators, from which to establish the generated
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voltage to re-energise the Gas Turbine Generator, Unit and Generating Transformers, re-
establishing a heavy rotating Mechanical Mass and Electrical MVA Capacity to charge the
330kV Transmission System and remote Grid Transformers without stalling. Progressive re-
establishment of the power transmission system and distribution networks will evolve.

As the Gas Turbine Generators are started, run up to synchronous speed and synchronised
to the system, generation and supply will be re-established and developed by supplying the
generation requirements to the instruction of the Grid Control Engineers. Healthy system
stability will be re-established, such that the diesel generators can be shut down.

Modus Operandi

Refer to the Overall System One-Line Diagram E0-0EE001 – A.

A black start of the Alaoji Electrical System will be necessary following de-energising of the
whole plant electrical system, normally due to a system electrical fault, in which all electrical
equipment is rendered DEAD. A Generating System ‘Black Out’ could also be caused by an
immediate general loss of fuel, especially gas where no plant storage is maintained (closure
of the gas incoming main stop valve).

An electrical fault will be immediately indicated by the SCADA Electrical Control System
alarms and printout. The circuit breakers which have tripped will be clearly shown on the
SCADA System Mosaic as a flashing discrepancy, enabling any defective equipment to be
quickly identified and isolated. This will enable the remaining plant to be returned to service
as quickly as possible. Any operating discrepancy occurring on the Gas Turbine Generator,
viz., electrical, mechanical or, instrumentation and control systems, will be indicated on the
Distributed Control System facia and on the continuous printout.

Immediately following the event of a Plant Black Site, first and foremost, the Operations
Staff, following the Black Start Procedure, must check that the Gas Turbine Generator and
Steam Turbine Generator units, direct current lubricating oil pumps are running and
circulating oil to the machine bearings, that the respective bearing temperatures are normal
and that the machines are ready to be placed on Turning Gear, otherwise hand turning of the
Steam Turbine must immediately commence. The respective Steam Turbine Generator
hydrogen cooling dc Systems should be checked as running and controlling the generator
hydrogen temperature.

To safely and systematically return the electrical system to service from a Black Site
condition, by re-energising in a logical and constructive manner, the following the Black Start
Procedure will be adhered to.

The two 11kV Black Start Generators viz., 1-OEEP GEN-0001 and 2-OEEP GEN-0001,
located on the drawing at each end of the plant common 11kV Main 2000A, 500MVA
Busses, 1,1-OEAP-SWG-0100 and 2,2-OEAP-SWG-0100, will be maintained ready for
immediate Start on loss of 11kV ac Volts on the 11kV Main Busses 1 and 2 indicating a
Black Site has occurred.

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To affect immediate availability, the Black Start Generators will be test run on a weekly basis
initiated by operation of the No Volt Relay located on the 11kV Unit Board.

Two 11kV/6.9kV 750kVA AN/AF, Soft Cranking Transformers, viz., 1-OEAP-TFM-0010 and 2-
OEAP-TFM-0010, again located one either end of the 11kV 2000 Ampere, 500MVA, Main
Busses, feed the 6.9kV Cranking MCC’s of Gas Turbine Generator Units 1-1 and 1-2 and
Gas Turbine Generator Units 2-1 and 2-2, viz., 1-0-EAP-MCC-0100 and 2-0-EAP-MCC-
0100.

Each Gas Turbine has an individual 1000 kW Cranking Motor controlled by the machine
starting software. This equipment is operated each time there is a Unit Start, however to
ensure a successful Black Start, all the equipment, albeit normally static with generating
units in service, must be pre-start checked as fully available during each operating shift.
Although the DCS will indicate any equipment discrepancy, there is no room for
complacency in power plant operations and maintenance.

Should all Steam Turbine Generators and Gas Turbine Generators have been running prior
to the system Blackout, then during the run down of the machines, essential checks should
be quickly made on the DCS Print Out to ensure the respective machine dc Lubricating Oil
and Hydrogen Sealing Pump have automatically started maintaining bearing lubrication,
cooling and the hydrogen seal, pending reinstatement of the ac Lub Oil Pump, Bearing
Cooling Water Pump, Cooling Fans and respective machine Turning Gear. It is essential that
having established lubricating oil flow that turning of the Steam Turbine shafts be re-
established without delay. (Eccentricity can be measured by placing a dial gauge on the
exposed shaft.)

The Steam Turbine AC lubricating, sealing and cooling oil pumps, and turning gear, will be
returned to service as soon as is possible to prevent the hot turbine shaft from hogging due
to expansion caused by the hotter temperature in the upper half of the cylinder, the rotor
should not remain stationery for any length of time, and pending restoration of the 415v AC
Supply, the turbines will be hand turned. (Is this available) Due to turbine being hot, hand
turning will initially be continuous, however if the turning gear has not been re-energised,
hand turning will be changed to periodic as the shaft cools, guided by marking 180° chalk
marks where the turbine shaft is exposed to ensure symmetrical straightening and that
bending remains in one plane. Compound bending must be avoided, since straightening of
the rotor will be very difficult, perhaps necessitating removal of the turbine spindle and the
blading, to facilitate controlled heat treatment in the differing bending planes.

In preparation for re-establishing generation, on loss of the station electrical system, with
respect to the GT PCM 11kV Bus Bars 1.1 0EAP-SWG-0100 and 2.2 0EAP-SWG-0100
having been rendered DEAD, all 11kV outgoing circuit breakers will be opened to allow the
first Black Start Generator to be started to re-energise the GT PCM 11kV Main Bus Bars 1.1
0EAP-SWG-0100 and 2.2 0EAP-SWG-0100 in parallel, the interconnecting 11kV Circuit
Breaker 1-0EAP-BKR-0101 having remained closed.

All transformers may have tripped on under-voltage protection, necessitating controlled

return to service.

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A daily operation task will be to pre-start check the Black Start Generators #1 and #2, to
ensure their immediate healthy availability. (A procedure will be written).

Having started the first Black Start Generator, the 11kV Generator Circuit Breaker can be
closed to charge the 11kV Bus Bars 1.1 0EAP-SWG-0100 and 2.2 0EAP-SWG-0100 as
given above.

At this stage of re-energising the site, it would be prudent to provide some load on Black
Start Generator #1, to secure a measure of system stability, before starting and
synchronising Black Start Generator #2, to the lightly loaded 11kV System. To accommodate
respective transformer in-rush current, both Black Start Diesel Generators should be in
service before energising plant auxiliary transformers related to return to service of the Gas
Turbine Generators.

At this interim phase of the plant return to service, it would be prudent to concentrate on Gas
Turbine Generators 1 or 2, pending re-establishing the first Gas Turbine Generator in
service, followed in sequence by the second Gas Turbine Generator to create a rotating
power base to sustain the developing auxiliary load, the charging current and loading of
successive plant auxiliary transformers.

These operations will necessitate energising the Control Building 11 kV Supply to re-
energise the four Site 11kV Feeders 0-0EAP-SWG-0100.

Having re-energised the GT PCM 11kV Bus Bars 1.1-0EAP-SWG-0100 and 2.2-0EAP-
SWG-0100, the initial preparations to re-energise the plant will necessitate energising the
415v Bus Bars GT PCM 415v GT/BOP Bus 1 through 1-0EAP-BKR-1001 and GT PCM 415v
GT/BOP Bus 2 through 2-0EAP-BKR-1001.

6.9kV Soft Start for Gas Turbines #1 and #2, is provided from GT PCM 1-0EAP-TFM-0010
and 2-0EAP-TFM-0010 Cranking MCC Transformers feeding Cranking MCC’s 1-0EAP-
MCC-0100 and that for Gas Turbines #3 and #4, is provided from GT PCM 2-0EAP-TFM-
0010 and 2-0EAP-TFM-0010 Cranking MCC Transformers feeding Cranking MCC’s 1-0EAP-
MCC-0100.

The GT PCM 415v Essential Busses 1-0-EEP-SWG-1000 and 2-0EEP-SWG-1000 are fed
directly from 415v Busses GT PCM 1-0EAP-SWG-1000 and 2-0EAP-SWG-1000. These
415v Busses feed the Control Building Battery Chargers providing 125v dc and 240v ac Un-
interrupted Power Supplies.

The GT PCM 415v GT/BOP Bus 1 and 2, 2.5MVA Transformers 1-0EAP-TFM-0100 and 2-
0EAP-TFM-0100 also feed the 415v Essential Busses 1-0EEP-SWG-1000 and 2-0EEP-
SWG-1000. From these 415v Essential Busses, four Battery Chargers located in the Control
Building, viz., 1-0EEP-CHR-1000, 1-0EEP-CHR-2000, 2-0EEP-CHR-1000, 2-0EEP-CHR-
2000 provide charging current to the Station Batteries, 1-0EEP-BAT-1000 and 2-0EEP-BAT-
2000 and also feed the 125v dc Switchboards 1-0EEP-SWB-1000 and 2-0EEP-SWB-1000
which feed Power Panels 1-0EEP-PNL-1000, 1-0EEP-PNL-2000, 2-0EEP-PNL-1000, 2-
0EEP-PNL-2000 respectively.

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Also located in the Control Building and fed from the 125v dc system, two Invertors dc to ac,
providing 240v ac Uninterrupted Essential supplies to both Gas Turbine and Steam
HRSG/Turbine Generator Units, through a static switch to 1-0EEP-UPS-1000, 1-0EEP-UPS-
2000 and 2-0EEP-UPS-1000, 2-0EEP-UPS-2000.

In case of failure of the 125dc to 240v ac invertors, a manual bypass is provided which feeds
240v ac from the 415v Essential Bus through 415/240v ac Bypass Transformers, 1-0EEP-
TFM-1000 and 2-0EEP-TFM-1000.

In the event of a system black-out at Alaoji, with the exception of the Generator Circuit
Breakers, all other system circuit breakers will remain closed. These closed circuit breakers
will be opened in preparation for return to service of the system and will be progressively
closed as the equipment is returned to service in the order provided in this procedure.

The only equipment solidly connected to the 330kV Main and Reserve Bus Bar are the
Measurement and Protection CCVT’s both rated at 1732/3000+1+1.

The modus operandi to return generation to service following a Black Site involves initial
preparation of the electrical system to be able to methodically re-energise the essential
services equipment and also to be used to systematically commission the plant electrical
system and services.

Check that distribution boards interconnecting circuit breakers remain open. Both LHS and
RHS of the distribution boards will be charged through their respective distribution
transformer and 415v Circuit Breaker when returning them to service. During setting up of
the electrical system, the distribution boards will remain supplied from their respective
incomer with the interconnecting circuit breaker remaining open.

Having re-established the electrical transmission and distribution systems for the gas
turbines, they may be returned to service as per grid control requirements.

With respect to the steam plant generation involving the Gas Supply System for the Duct
Burners, Steam Turbine Power Control Modules as follows will be checked as healthy, and in
respect of 1-0EAP-SWG-3000 415v ST/HRSG Bus 1- , and 1-0EAP-SWG-2000, 415v
ST/HRSG Bus 1–1 and 1-0EAP-SWG-3000, 415v ST/HRSG Bus 1-1 and 2-0EAP-SWG-
2000; 415v ST/HRSG Bus 2–1 and 2-0EAP-SWG-3000, 415v ST/HRSG Bus 2–2; 1-0EAP-
MCC-0200 11kV ST/HRSG MCC, 2-0EAP-MCC-0200 11kV ST/HRSG MCC and Cooling
Tower Area 1-0EAP-SWG-4000, 415v Cooling Tower SWG and Cooling Tower Area 2-0EAP-
SWG-4000, 415v Cooling Tower SWG.

The HRSG’S do not require any operations at the initial stage of a Black Site, the Boiler
water level will remain as is, apart from shrinkage as it cools, all drains should be closed to
retain water. If the outage is extended, as the water in the drums cools and the vapour
inside the steam spaces condenses, the steam and water vents should be opened such that
a vacuum will not be generated.

The water treatment plant will be shut down, however any drains open at the time of the
Black Out can be closed.
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Should the High Voltage Transmission System have remained healthy and available, then in
these circumstances, following complete loss of generation, the plant can be reinstated by
initially back-charging the Plant 330kV Sub Station from the Grid System, followed by
progressively returning the generating plant to normal service as given.

If however the High Voltage Transmission System has also failed and is dead, then in these
circumstances, the generating plant will be re-energised by establishing a rotating
generation base from which to charge and supply the Grid.

To facilitate maintenance inspection of either of the above 11kV/415v feed transformers to

the four Bus Bars as given above, should they be defective, the 415v Tie Breaker viz., 1-
0EAP-BKR-1002 located on GT PCM, between distribution boards 1-0EAP-SWG-1000; 2-
0EAP-SWG-1000 and that on the 415v Essential Busses, 1-0EEP-SWG-1000 and 2-0EEP-
SWG-1000, the unlabelled Tie Circuit Breaker, will be closed to maintain supply when the
respective 11kV Transformer Primary Winding unlabelled circuit breaker and the Low
Voltage 415v circuit breakers 1-OEAP-BKR-1001 or 2-OEAP-BKR-1001, viz., distribution
board circuit breakers, are respectively opened and isolated in preparation for preparing and
issuing an Electrical Permit for Work to perform the work as clearly given on the Permit for
Work document.

D.N. Sellars
11.05.11.