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Location India

Sectors Manufacturing

The challenge

Rapidly provide black start power contingency for smelter after monsoon damage

Aluminium manufacturing facilities can’t be without power for more than four hours – if this happens then massive repair costs can be incurred.

Our customer faced this problem in 2014, when monsoon winds caused failure to the local grid and Captive Power Plant (CPP). In the event of failure, a black start power package is required. On this occasion though, the CPP had no black start contingency.

This couldn’t be allowed to happen again. With monsoon season a frequent blight upon the region, our customer needed a black start contingency to keep costs down and production rolling in the face of extreme weather.


Project fact file

8 Weeks

Time taken to install power

32 MW

Total power

The solution

A 32 MW / 6.6 kV power package

Aggreko won the initial contract, which was for a 6-month duration, and delivered a 32 MW / 6.6 kV package to the aluminium smelter unit. The project was complex and the requirements demanding. The system had to be capable of starting a 4.9 MW motor on DOL (direct on line) mode and controlling the voltage dip to less than 19.5% over a base load of 6 MW.
Our expert engineers and modular equipment made it happen though, and the aluminium facility had the power and backup they needed.


The Aggreko Difference

Come rain or shine - we're here for you

The Impact

Costs kept down as power stayed on and production kept rolling

Aggreko assessed the task and installed the power package to match precise customer specifications. The new critical black start power system was available at the smelter within 8 weeks. This rapid response helped to ensure continuous operations throughout the monsoon season and to minimise the risk of financial loss associated with catastrophic power failure


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