Diesel Power Plant installation for BALCO

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Overview

Bharat Aluminium Company (BALCO) Korba, Chattisgarh, a unit of Vedanta Group, is a leading manufacturer of aluminium products. The customer needed a reliable power solution for continuous running of their smelter which, if interrupted by a power supply failure of more than an hour, could lead the molten metal to solidify which would lead to an expensive re-building process. Beating stiff competition, Jakson was chosen as a reliable partner to provide the emergency power to back up black start of 135 MW captive power plant at Korba. With the commissioning of the project in 2011, BALCO became first in the industry to go for black start system for 21 MVA capacity for their 4 x 135 MW power plant catering to huge power demand for the smelter. The project included Supply of 7 nos. 3000 kVA 6.6 KV DG Sets installed in a DG building erected by Jakson, LT-HT Control Panels, Transformer , Crane, BOT Civil Electrical & Mechanical work.

About the Client

Bharat Aluminium Company Ltd. (BALCO) is an Indian aluminium company. The company was founded in 1965 as Government of India Public Sector Undertaking. It was acquired by Vedanta Group in the year 2001. BALCO was the first public sector enterprise in India which started producing aluminium in 1974. Major operations of BALCO are in the town of Korba (Chhattisgarh), whereas its mines supplying high grade Bauxite are situated at Kawardha and Mainpat.

Business Need

The client wanted to commission a 21 MVA Diesel Power Plant for its smelter unit in Korba. A smelter unit is an installation for smelting a metal from its ore. The process of smelting involves heating the ore at very high temperatures to extract a metal and needs constant operations without any power failure to maintain required temperatures. To ensure the smelting operations of the plant did not suffer during a power failure, the client decided to operate a diesel power plant that could provide uninterrupted power to the smelter.

Solution

Jakson provided a turnkey engineering solution that included design, supply, installation, testing & commissioning of 12 numbers of 3000 KVA 6.6 KV diesel gensets with all accessories. The plant had to operate at 80% load factor to provide power.

The project included the following key activities:

  • All generator sets synchronised in auto and manual mode with power command controller and master synchronizer
  • Live phasing out on 6.6KV between DG bus and Grid bus for synchronisation of 12 x 3000 kVA DG sets with Grid
  • Complete system for Grid synchronisation in reverse and forward direction
  • SCADA PLC system
  • Start/ Stop/ AMF operation in black out condition
  • Load management
  • Remote monitoring and operation from Central Control room (CCR)
  • All outgoing VCB’s and B/C and tie breakers operation
  • Complete civil works including Power house Building
  • Related auxiliary work
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COVID 19 UPDATE

Dear Stakeholders

The outbreak of the COVID -19 pandemic is a cause of concern for all of us. In these extraordinary circumstances, we at Jakson, are closely monitoring this rapidly evolving scenario and have put in place a slew of measures to ensure business continuity, employee safety so as to minimise impact of any disruptions. We remain deeply committed to our customers/stakeholders/employees and would like to update you on some of these actions:

  • Cross Functional Team - A cross functional team comprising members across various functions has been set up to monitor the situation. This team interacts every day to review customer orders, project sites status, supply chain constraints, review updates and take up risk mitigation actions.
  • Limiting Business Trips – While outstation travel has been suspended temporarily, we are encouraging use of video conferencing/skype etc to provide business continuity.
  • Risk Mitigation Plans – We are closely working with our business teams and developing specific contingency plans to minimise disruptions to all our customers.
  • Work from Home for Employees – For the safety of our employees, we are encouraging work from home, while at the same time ensuring sufficient access to data & technology. We also have a skeleton staff presence by rotation supporting the operations wherever its possible
  • Social Distancing – At our offices, strict guidelines are in place to use teleconferencing / video conferencing facilities so as to limit face to face contact. Individual meetings, as and when situation improves, will be limited to 4 people with adequate precautions of maintaining distance. We have a visitor policy for all Jakson facilities and we are encouraging use of alternative communication methods till such time situation normalises.
  • Hygiene & Safety - We are ensuring that we provide a healthy and clean environment to all our employees & visitors wherever premises are not in lockdown. All our facilities are maintaining the highest standards of EHS, keeping premises clean & disinfected, ensuring availability of hand sanitisers in sufficient quantities and providing all employees with masks.
  • Regular Employee Communications - We are ensuring regular employees communications, that update them on the dos and don’ts of keeping safe and healthy. There are also regular advisories on the evolving situation so as to ensure, all guidelines from the govt & ministry of health are complied for from time to time.
  • Employee Motivation - In these testing times, we continue to assure our employees and their families, of our commitment & support irrespective of anticipated business disruptions.
  • Stepping up CSR Activities - We are fully cognisant of the global & India impact of this pandemic and are therefore gearing up to commit a heightened level of participation and support to society through our CSR initiatives. We will keep you updated on these initiatives as well.



Jakson has a rich heritage of 70 years, which has been built on principles of strong commitment, trust & relationship. We wish to reiterate this and remain committed in the belief that together we will tide over the current situation.

We thank you for your association and support.


Warm Regards,

Sameer Gupta, CMD & Sundeep Gupta, VCMD