Black Start Generator & Synchronisation System

The same Nigerian industrial power plant that depends on its steam turbine generators also requires a black start capability — the ability to restart the entire power system from a complete shutdown without relying on external grid power. This critical function was served by ageing SDMO diesel generators that had been in operation well beyond their designed service life, with reliability declining steadily.

The existing black start diesel generators had deteriorated to the point of unreliability, leaving the plant critically vulnerable during grid outages or turbine trip events. Without a functioning black start capability, any complete power loss could result in prolonged shutdowns — the steam turbines cannot self-start and require external power to initiate their startup sequence, including lube oil pumps, control systems, and auxiliary drives.

The plant needed both a reliable black start generation solution and a synchronisation system capable of seamlessly managing the complex electrical transitions between diesel generators and steam turbine generators as the plant returned to normal operation. Any mismatch in voltage, frequency, or phase during synchronisation could cause severe damage to both generators and connected equipment.

MIMAH delivered a two-phase solution. In the first phase, we supplied and installed three 1500KVA black start diesel generator sets, providing a combined 4,500KVA of startup capacity — sufficient to power the plant's complete auxiliary systems and initiate the steam turbine startup sequence with comfortable margin. Exhaust systems were installed, fuel lines terminated, and power cables connected to the plant's distribution network.

In the second phase, MIMAH designed and supplied a comprehensive synchronisation panel system comprising three purpose-built modules: a DG sync set for paralleling the diesel generators, a turbine sync set for connecting the steam turbines to the busbar, and a combined turbine-DG sync set for managing the critical load transfer transition as generation shifts from diesel to steam power. Each panel was engineered to ensure precise matching of voltage, frequency, and phase angle before closing synchronisation breakers.

The three 1500KVA black start generator sets have been fully installed, with exhaust, fuel, and electrical terminations completed and tested. The plant now has reliable black start capability that can restore power following any complete outage event — a critical safety and business continuity requirement.

The synchronisation panel system has been delivered to site and is in the final stages of installation and commissioning. Once operational, the plant will have fully automated synchronisation between its diesel generators and steam turbine generators, enabling smooth and safe power transitions that protect both equipment and production continuity.