POW-03-02-GRE

Black Start of the Power Plant

Black Start of the Power Plant

Overview

In case Plant’s black out happens, there are 2 (two) available initial power generators to reinstate auxiliary
power:
1. Black Start Diesel 11KV capacity 1.25 MVA, 1.0 MW
2. Black Start Diesel 400volts capacity 350 KVA, 280 KW
A Black Start Diesel 11KV is priorities to start unit for establish 400volt power to start 2 or 3 units
Combustion Turbines
A Black Start Diesel 400V capacity is only able for starting up 1 unit Combustion Turbine.

Purpose and Scope

Purpose This chapter provides information on the procedures and standards for a power plant black
start

Scope This chapter applies to PT Gresik Power Indonesia, Linde Gresik

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Initial Checks

Location Action
1 Bailey Check control system status. If the control system power is off, all actions to
Room energize the breakers must be operated from local

2 BSD 11KV The biggest capacity to be start for suitable to start Combustion Turbine 2 or 3 units
and the auxiliaries in same time.
Follow PROCEDURE SCENARIO 1

3 BSD 400V In case BSD 11KV is not ready. The capacity is only suitable to start Combustion
Turbine 1 unit and the auxiliaries.
Follow PROCEDURE SCENARIO 2

PROCEDURE SCENARIO 1
[Black Start Diesel 11 KV]

Pre-Start Procedure

Step Location Action Initial

1 11kV Line up the MCC using Pre-start MCC and 11 kV line-up

2 11kV Verify that all lockout/tag outs are cleared prior for starting
3 11kV Check all breakers are in the correct position

Procedure

Step Location Action Initial

1 DCS/Local Reset Alarms of BSD 11KV to confirm ready to start
Panel
2 DCS/Local Push RUN BSD 11KV
Panel
3 DCS Ensure Open breaker at:
1. F-05 (=MH-1) and F-07 (=MH-2) and,
Ensure PTS breaker 52R-1 and 52R-2 open by contact PT Smelting Utility
2. F-02 CT-1 Breaker
3. F-03 ST-1 Breaker
4. F-04 ST-2 Breaker
5. F-08 CT-2 Breaker
6. F-09 CT-3 Breaker

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Step Location Action Initial

7. F-11 BSD 11KV Breaker
8. F-12 Bus-2 and Bus-3 Interconnection Breaker
9. F-13 Bus-1 and Bus-3 Interconnection Breaker
10. F-14 Ex-PLN Breaker
11. F-18 Genset 1 & 2 Breakers
12. 400V Transformer_2 of 1APC-XF-2
13. 400V MCC-2, 1APC-MCC-02 Breaker

4 DCS Push ONLOAD BSD 11KV to close F-11

5 DCS Ensure 400V circuit breaker of F10 is in close position

6 400V/ Energize 400V Transformer_1 of 1APC-XF-1

DCS 1. Ensure NGR-1 is On and NGR-2 is Off
2. Switch to Dead Bus selected
3. Switch to REMOTE to close from DCS or LOCAL to close from local
4. Close breaker 1APC-XF-1, 400V transformer
5. When it succeeded, switch DEAD Bus to OFF selected

7 DCS / Restart utilities equipment such as:

Local 1. Diesel instrument air compressor
2. Electrical instrument air compressor 1A
3. Ariel Gas Compressor start if ISAR natural gas pressure is less than 20 barg
4. A New Forwarding Pump

8 DCS / Start available 2 unit CTs prior in gas fuel and bring synchronized online
Local ‘* Prioritise CT-2 and CT-3 because 400V breaker is in Bus-2 to backup BSD 400V
’** This follows CT start up and shutdown procedure
9 CT 1st Combustion Turbine’s Generator to be online:
panel/DCS
1. Display screen in ISLAND, ISOCH, and SYNCHRONIZING ENABLE
DEAD BUS
2. Synchronize the CT to LIVE Bus. 11KV downstream bus will live once it
succeeded
3. At Plant Load Management Control select AVAILABLE and ISOCH mode
4. In DCS CT overview is ISLAND and ISOCH
CT nd
10 2 Combustion Turbine’s Generator to be online
panel/DCS
1. Display screen in ISLAND, DROOP, and SYNCHRONIZING ENABLE
LIVE BUS
2. Synchronize the CT to LIVE Bus
3. At Plant Load Management Control select AVAILABLE and NEXT mode

‘* 3rd Combustion Turbine’s Generator synchronize sequences are same with the 2nd
Combustion Turbine, but it is different at Plant Load Management Control as
AVAILABLE and NOT NEXT mode
11 11kV/ Supply Power to PT Smelting
PTS If first power up is Bus-2, sequences are:

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Step Location Action Initial

1. Close circuit breaker F-07
2. Order to PTS to close 52-R1 (11kV feeder)
3. Override 27-1 breaker, then close circuit breaker F-05
4. Order to PTS to close 52-R2 (11kV feeder)

If first power up is Bus-1, sequences are:

1. Close circuit breaker F-05
2. Order to PTS to close 52-R2 (11kV feeder)
3. Override 27-2 breaker, then close circuit breaker F-07
4. Order to PTS to close 52-R1 (11kV feeder)

* These breakers are not synch check, ensure it is only energized from one source bus
power

12 DCS Inform PTSC that 7MW is available and note time in the logbook

13 ASU Local 1. Start a Main Oil Pump and

2. Stop an Emergency Oil Pump
3. Wait 30 minutes for sufficient lubrication supply, prior turn manually and
start a ST-18 Turning Gear Motor
14 400V Close 400V MCC-2, 1APC-MCC-02 Breaker

15 3.3kV/ Ensure 3.3kV circuit breaker of F01 is in close position

DCS
16 3.3kV/ 1. Energize 3.3kV Transformer_1 of 1APD-XF-1
DCS 2. Ensure NGR-1 is On and NGR-2 is Off
3. Switch to SYNCH selected
4. Switch to REMOTE to close from DCS or LOCAL to close from panel
5. Close Breaker 1APD-XF-1, 3.3kV transformer
6. When it succeeded, switch SYNCH to OFF selected
17 DCS 1. Start P131 one of Direct Cooler Pump for sealing of BFP
2. Cycle condensate makeup pumps for make up condenser
3. Condensate pump of ST1/ST2 for make up De-aerator
18 BFP-3X/ Check seal water of Boiler Feed Water Pump properly supply by open seal drain
DCS valve
Start one of Boiler Feed Water Pump, BFP-3X
‘* Seal water of Boiler Feed Water Pump is able to be supplied from ST-1 or ST-2
Condensate Pump-A
19 DCS Put online only 1 reactor (only online 1 reactor / bus tie connection allowed)
 To online Reactor 1-3 is close breaker F-06, then synchronize close breaker
F-13
 To online Reactor 2-3 is close breaker F-10A, then synchronize close breaker
F-12
20 400V/ Ensure 400V circuit breaker of F17 is in close position
DCS

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Step Location Action Initial

21 400V/ Energize 400V Transformer_2 of 1APC-XF-2
DCS 1. Ensure NGR-1 is On and NGR-2 is Off
2. Switch to SYNCH selected
3. Switch to REMOTE to close from DCS or LOCAL to close from local
4. Close breaker 1APC-XF-2, 400V transformer
5. When it succeeded, switch SYNCH to OFF selected

22 3.3kV/ Ensure 3.3kV circuit breaker of F15 is in close position

DCS
23 3.3kV/ Energize 3.3kV Transformer_2 of 1APD-XF-2
DCS 1. Ensure NGR-1 is On and NGR-2 is Off
2. Switch to Dead Bus selected
3. Switch to REMOTE to close from DCS or LOCAL to close from panel
4. Close Breaker 1APD-XF-2, 3.3kV transformer
5. When it succeeded, switch DEAD Bus to OFF selected
24 DCS Ensure put online all Combustion Turbine and Sewatama Gensets to comply
supplying demand power
25 DCS Clear all alarms on the DCS and target of all Engines / Motors that have tripped

26 Local Reset & start HRSG-4

27 DCS Supply LP steam from let down HP steam.

When LP steam is re-established, note the time in the logbook
28 DCS Start one cooling water circulating pump, to re-establish the cooling water system

29 DCS Start the cooling tower fans on any cell that is in service
30 DCS Inform PTSC that electrical supply is back to normal and note the time in the logbook
31 Local/ Prepare a Power Steam Turbine for service, open the HRSG dampers and begin
DCS raising steam.
See Steam Turbine Start-Up
32 Local/ Prepare to start the ASU compressor turbine.
DCS See ASU start up
33 DCS Clear all alarms on the demineralisation plant and place one train in standby mode

34 DCS Reset the superheater panel and place the unit in standby mode
35 Local/ Thoroughly inspect all areas of the plant and DCS to ensure the plant is returned to
DCS the correct operating mode

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PROCEDURE SCENARIO 2
[Black Start Diesel 400 Volts]

Stage 1 - MCC Room

Procedure The procedure is followed for the first stage of the black start, which is from the MCC
room

Step Location Action Initial

1 MCC Open manually circuit breaker 1 APC-MCC-1

2 MCC Close 1APC-52-1 the BSD feeder breaker generator

(beside of the battery charger control panel)
3 LOCAL Start Diesel Instrument Air Compressor (1CAA-CMP–1C)

4 BSD On the local BSD control panel, turn (clockwise) the START switch to manual run

5 BSD On the local BSD control panel, check that 50 Hz and 400 V are displayed
6 BSD Close 1APK-SKD-1 a local BSD breaker

7 Bailey Check control system status :

room / a. Network Switch
GHH
turvis b. Bailey
room c. OPC Computer
d. IO Server Computer

8 Inst. If instrument air header pressure is less than 6.2 barg, Start instrument air compressor
Comp 1A (1CAA–CMP-1A)
9 DCS/ Ensure fuel supply are ready
Local 1. Ensure ISAR pressure control valve 1FGA-ISAR-PCV01 is in auto 20.5 barg
2. If control system status (point no. 7) was failure, open an ISAR bypass
control valve
3. Or start Ariel Compressor 1A as demand required
4. Start one of Liquid Forwarding Pumps

10 Local CT Select only one unit CT to be started

*Prior CT2 or CT3 to be started where the CT2 generator and 400V are in Bus-2

11 MCC-1 Switch OFF:

distributio  Enclosure Fan Breakers of undedicated CTs start
n panel
 Lube Oil Cooler Fan Breakers of undedicated CTs start

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Step Location Action Initial

12 DCS Open breaker F-05 (=MH-1) and F-07 (=MH-2) and,
Ensure PTS breaker 52R-1 and 52R-2 open by contact PT Smelting

13 11 KV Ensure all 11KV Generators breakers open

14 CT panel Press RESET button

15 CT panel Select CT prior start in gas mode

16 CT panel Press START button the selected CT and ensure run up until ready to load.
If it failed attempt to start the other ready CT then go to step 8

17 CT panel Ensure at Generator display screen is ISLAND, ISOCH, and SYNCHRONIZING

ENABLE DEAD BUS

18 CT panel / Synchronizing the CT to DEAD Bus

DCS When it succeeded, 11kV bus downstream will live
19 DCS - At plant load management control select AVAILABLE and ISOCH mode, and
- In CT view DCS is ISLAND and ISOCH

20 11KV/DC Close F10 to supply 400 V transformer

S
22 400V/ Energize 400V Transformer_1 of 1APC-XF-1
DCS 1. Ensure NGR-1 is On and NGR-2 is Off
2. Switch to Dead selected
3. Switch to REMOTE to close from DCS or LOCAL to close from local
4. Close breaker 1APC-XF-1, 400V transformer
5. When it succeeded, switch DEAD Bus to OFF selected

23 MCC-1 Ensure 1 APC-MCC-1 breaker is OPEN and CHARGED

24 BSD In the local synchronizing panel at the diesel generator, turn ON the synchronize-scope
switch

25 BSD Check the voltage and frequency on both 110 voltmeters and 50 Hz.
Adjust BSD voltage and frequency to synchronize
(If the synchronization-scope rotates SLOW then the governor may need to be adjusted
to increase the diesel speed)

If BSD frequency is bellow 50Hz, then

a. Change CT mode from Isoch to Droop on Bailey
b. Adjust manually CT speed and CT voltage
(The synchronize-scope will rotate clockwise slowly)

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Step Location Action Initial

26 BSD When the synchronize-scope indicator is in the 11 to 12 o’clock position (as shown),
manually close a Switch at the local synchronizing panel

400 V (once it succeeded at 400 volt supply circuit breaker 1APC-MCC-1 will close and
MCC 1APC-52-1 will open)

27 BSD Ensure that the RED light is illuminated within the synchronize-scope panel to indicate
a successful breaker voltage.

28 BSD Switch off synchronize-scope

29 400 V Lock the BSD feeder breaker from the diesel generator into the OFF position (beside
of the battery charger control panel)

30 11 kV If first power up is Bus-1, sequences are:

1. Close circuit breaker F-05 (=MH-1)
2. Order to PTS to close 52-R2 (11kV feeder)
3. Override 27-2 breaker, then close circuit breaker F-07
4. Order to PTS to close 52-R1 (11kV feeder)

If first power up is Bus-2, sequences are:

1. Close circuit breaker F-07 (=MH-2)
2. Order to PTS to close 52-R1 (11kV feeder)
3. Override 27-1 breaker, then close circuit breaker F-05
4. Order to PTS to close 52-R2 (11kV feeder)
* These breakers are not synch check, ensure one source power only was energized

31 DCS Inform PTSC that 5MW is available and note time in the logbook

32 11KV Close F-01, 3.3 kV breaker in bus-1

33 3.3kV/ Energize 3.3kV Transformer_1 of 1APD-XF-1

DCS 1. Ensure NGR-1 is On and NGR-2 is Off
2. Switch to Dead Bus selected
3. Switch to REMOTE to close from DCS or LOCAL to close from panel
4. Close Breaker 1APD-XF-1, 3.3kV transformer
5. When it succeeded, switch DEAD Bus to OFF selected

34 DCS Start P131-A or P131-B for seal water of Boiler Feed Water Pump

If ASU 400 Volt power is not ready and must supply condensate, then:
1. Start one of Condensate Pump-1A or -2A of ST1 or ST2 for water seal of
Boiler Feed Water Pump is running
2. Swap seal water supply of Boiler Feed Water Pump from condensate pump

35 DCS Start cycle make up pump to supply condenser from demine tank

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Step Location Action Initial

36 BFP-3X/ Check seal water of Boiler Feed Water Pump supplied properly by opening outlet seal
DCS drain valve
Start one of Boiler Feed Water Pump, BFP-3X

37 Local Ensure fuel supply pressure for start another CT is satisfy

38 DCS / Start available CTs and bring on-line

Local
39 Local Check that all scanner-cooling fans have restarted (HRSG 1,2,3)

40 DCS / Start available Gas Engine and bring on-line

Local * Start radiator cooling fans
41 Local Reset & start HRSG-4
42 DCS Supply LP steam from let down HP steam. When LP steam is re-established, note the
time in the logbook

43 DCS/ Put online only 1 reactor (only online 1 reactor / bus tie connection allowed)
11 KV  To online Reactor 1-3 is close breaker F-06, then synchronize close breaker F-
13
 To online Reactor 2-3 is close breaker F-10A, then synchronize close breaker
F-12

44 DCS/ Close Breaker F-17, 400V circuit breaker Bus-3

Local
45 400V/ Energize 400V Transformer_2 of 1APC-XF-2
DCS  Ensure NGR-1 is On and NGR-2 is Off
 Switch to SYNCH selected
 Switch to REMOTE to close from DCS or LOCAL to close from local
 Close breaker 1APC-XF-2, 400V transformer
 When it succeeded, switch SYNCH to OFF selected

46 DCS/ Ensure one of P131 Direct Cooler Pump is running

Local Ensure seal water of Boiler Feed Pump line is from sweet water line.
To swap seal water are :
 Open drain valve of outlet seal water boiler feed water pump to conform seal
water satisfy
 Put sweet water seal supply in parallel
 Check sweet water rotameter is rotating
 Close condensate seal water supply
 Ensure seal water outlet of boiler feed water pump is satisfy supply
 Close drain valve of outlet seal water boiler feed water pump

47 DCS/ Close Breaker F-15, 3.3kV circuit breaker Bus-3

Local
48 3.3kV/ Energize 3.3kV Transformer_2 of 1APD-XF-2 by:
DCS 1. Ensure NGR-1 is On and NGR-2 is Off
2. Switch to SYNCH selected
3. Switch to REMOTE to close from DCS or LOCAL to close from panel

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Step Location Action Initial

4. Close Breaker 1APD-XF-1, 3.3kV transformer
5. When it was succeeded, switch SYNCH to OFF selected

49 DCS Start one Cooling Water Circulating Pump, to re-establish the cooling water system

50 DCS Start the Cooling Tower Fans on any cell that is in service

51 DCS Inform PTSC that electrical supply is back to normal and note the time in the logbook
52 Local/ Prepare a Power Steam Turbine for service, open the HRSG dampers and begin raising
DCS steam.
See Steam Turbine Start-Up

53 Local/ Prepare to start the ASU compressor turbine.

DCS See ASU start up

54 DCS Clear all alarms on the demineralisation plant and place one train in standby mode

55 DCS Reset the Superheater panel and place the unit in standby mode.

56 Local/ Thoroughly inspect all areas of the plant and DCS to ensure the plant is returned to the
DCS correct operating mode.

Chapter Information
About this Chapter

Issue Revision Date Written Reviewed Authorised

1 0 November Dwi Ngesti Saefuddin Jauhari Susila Hadi Seputra
2005 Suwarji

2 1 April Farisol Eko Rully Meilasih Rudi Cahyono

2010 Pamuji Rudi Cahyono
Trihandoyo

3 2 Nov 2014 Amanda Agus Salim Firman Suryadi

Editasia Indra Pamungkas Adrianus Adityawardhana
Trihandoyo
Tri Kukuh Raharjo

4 3 Nov 2017 Retnawati Agus Salim Rully Meilasih

Survia Indra Pamungkas
Trihandoyo
Tri Kukuh Raharjo

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Change History

Issue Revision Description of Change

Nov 2014 2 ST#1 and ST#2 Condensate Pump 1A and 2A power supply have taken from MCC#1
and also the condensate discharge have been modified to supply seal water of boiler
feed water pump to speed up boiler feed water supply to customer and HRSG
By these modify, Black Start Diesel has been capable to supply power to both the
condensate pumps
Boiler Feed Water Pump power still utilize 3.3 KV transformer outgoing 11 KV bus#1
and bus#3

Nov 2017 3 Installed a Black Start Diesel 11KV, 1.25MVA, 1.0MW has capable to start 3 units
Combustion Turbine in same time or 2 units Combustion Turbine and Boiler Feed
Water Pump with seal water from Condenser Pump to speed up supply Boiler Water to
PT Smelting to prevent Boiler Drum dry level.

Audit

To be developed.

Learning and Assessment Guide

POW-03-02-GRE : Black Start of the Power Plant

Prerequisite(s) About Power Generation Process

As a result of You will You will be Refer to the Date when Initial & date
completing this learn this assessed by: following: coached when assessed
chapter you will be by:
able to:
State the items need to Self-study Multi-choice
be checked and test and on ________ ________
prior to start up coaching job check

Demonstrate the pre- Self-study Multi-choice

start up procedure prior and test and on ________ ________
to black start up coaching job check

Demonstrate the black Self-study Multi-choice

start up of and test and on ________ ________
the power plant coaching job check

________ ________

________ ________

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All tasks assessed on: Learner Assessor

________
(Date) ________ ________
(Signed) (Signed)
Other references Coaching Checklist Printable version of this chapter
Assessment Checklist PowerPoint presentation

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