ArchivesConceptual Design & Plant Philosophy

Glass Factory 6 MW HFO Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Glass Factory 6 MW HFO Power Plant2018Chtoura, LebanonGlasspackPower PlantHFO power plant based on four Hyundai engines delivering 24/24 power to a glass factoryExecution of the preliminary and conceptual design

Project Background & Objectives

The Glass Factory 6 MW HFO Power Plant project was initiated to build a dedicated, highly stable captive power generation facility to support intense industrial manufacturing operations in Chtoura, Lebanon. Commissioned by Glasspack, this high-reliability project focused on establishing an independent HFO power plant based on four Hyundai engines capable of delivering continuous, 24/24 power to a glass factory. Within this critical heavy industrial operational framework, PDP Energy was selected to direct the crucial early phase of the facility. The primary company-specific objectives centered on the execution of the preliminary and conceptual design, setting up the core electrical and thermal baseline architecture to protect manufacturing lines against grid instability.

Project Challenges

Designing a 24/7 heavy fuel oil (HFO) generation asset inside an active industrial glass manufacturing campus presents significant thermal, mechanical, and power quality hurdles. Glass production requires absolute thermal and electrical continuity; even a brief voltage dip can freeze raw materials in the furnaces, resulting in catastrophic equipment failure and massive financial losses. PDP Energy had to resolve intense technical challenges, including balancing structural layout constraints for four massive Hyundai engine blocks, optimizing complex heavy fuel handling and pre-heating subsystems, and designing robust fault-ride-through capabilities to handle abrupt industrial motor load variations without disrupting the plant’s delicate operating balance.

Project Outcomes

Operating as the primary conceptual engineering partner, PDP Energy successfully finalized the complete preliminary and conceptual design package for the heavy industrial power asset. The project effectively established an optimized, highly resilient technical framework tailored for high-demand captive industrial operations. By delivering precise mechanical configurations and synchronized load management blueprints, PDP Energy paved the way for the secure installation of the 6 MW power plant, ensuring the manufacturing facility gains complete energy self-sufficiency, maintains uninterrupted production cycles, and isolates its core machinery from external grid disruptions.

All Projects

Port of Beirut 10 MW Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Port of Beirut 10 MW Power Plant2005Beirut, LebanonPort of Beirut authoritiesPower PlantDiesel emergency power plant and infrastructure supplying power to container terminal cranesActed as client representative during all project phases

Project Background & Objectives

The Port of Beirut 10 MW Power Plant project was initiated to build an elite, highly reliable captive power solution to support the massive maritime operations at Lebanon’s primary shipping hub in Beirut, Lebanon. Commissioned directly by the Port of Beirut authorities, this critical infrastructure asset was planned to serve as a high-capacity Diesel emergency power plant and infrastructure supplying power to container terminal cranes. Within this high-demand, high-security logistics framework, PDP Energy was selected to protect the stakeholders’ interests throughout the entire lifecycle of the development. The primary company-specific objectives centered on fulfilling the extensive Client Representative role during all project phases, ensuring the physical deployment perfectly aligned with international standards and successfully secured independent energy backup for the port’s heavy cargo machinery.

Project Challenges

Designing and integrating a heavy-duty 10 MW emergency diesel power plant to drive utility-scale container terminal cranes presents severe spatial and mechanical engineering hurdles. Port cranes demand massive, near-instantaneous surge currents when lifting heavy cargo loads, creating extreme voltage fluctuations and severe mechanical stress on power generation equipment. PDP Energy had to navigate complex technical constraints, engineering a highly coordinated electrical layout capable of absorbing these sudden load variations without triggering system blackouts. Furthermore, providing independent oversight across all project phases required meticulous vetting of contractor blueprints, validating rapid automatic transfer switching mechanisms, and enforcing strict safety protocols to ensure construction proceeded seamlessly without disrupting active, 24/7 maritime shipping schedules.

Project Outcomes

Operating as the dedicated client representative, PDP Energy successfully concluded its comprehensive engineering audits, multi-trade design reviews, and construction monitoring services. The project effectively guaranteed that the entire power facility and integrated distribution grid were executed to the highest engineering standards, ensuring long-term operational durability and structural safety. By delivering rigorous independent engineering supervision across all phases, PDP Energy cleared the path for the secure deployment of the 10 MW emergency asset, ensuring the port maintains complete power autonomy, isolates its mission-critical crane networks from municipal grid deficits, and safeguards the continuity of international trade.

All Projects

Lebanese American University 8 MW Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Lebanese American University 8 MW Power Plant2016Beirut, LebanonLAUPower PlantDiesel emergency power plant and electrical infrastructure for campus expansionWorked on conceptual design, preparation of tender documents, and supervised construction

Project Background & Objectives

The Lebanese American University 8 MW Power Plant project was initiated to build an elite, highly reliable captive power solution to support the extensive campus expansion of the Lebanese American University in Beirut, Lebanon. Commissioned directly by LAU, this critical infrastructure asset was planned to serve as a high-capacity Diesel emergency power plant and electrical infrastructure network to safeguard continuous academic, medical, and administrative operations against volatile municipal grid deficits. Within this high-demand institutional development context, PDP Energy was selected to spearhead all technical and oversight phases. The primary company-specific objectives centered on delivering a complete project lifecycle roadmap, where the engineering team worked on conceptual design, preparation of tender documents, and supervised construction of the 8 MW generation facility.

Project Challenges

Designing and integrating a heavy-duty 8 MW emergency diesel power plant within a dense, active urban university campus presents severe spatial, environmental, and network engineering hurdles. PDP Energy had to navigate complex technical constraints, including engineering strict acoustic containment, vibration isolation, and optimized exhaust filtration systems to comply with stringent urban environmental standards. On the electrical and automation side, integrating the new generation block with existing and expanding campus networks required precise synchronization. The design demanded highly advanced automatic transfer switching mechanisms, meticulous fault-ride-through protection configurations, and rigorous load-shedding schemes to guarantee instantaneous, safe backup transition to critical medical mainframes and university data centers without risking voltage dips or equipment damage.

Project Outcomes

Operating as the primary full-lifecycle engineering consultant and supervisor, PDP Energy successfully finalized the complete conceptual design package, comprehensive structural tender documentation, and independent field construction monitoring services. The project effectively established an unshakeable, high-performance energy foundation tailored for premier metropolitan educational assets. By delivering highly synchronized and resilient electrical blueprints alongside rigorous quality control on-site, PDP Energy cleared the path for the secure deployment of the 8 MW power plant, ensuring absolute energy redundancy, safeguarding vital institutional data integrity, and securing uninterrupted operations across the expanded campus.

All Projects

Sirakoro 100 MW Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Sirakoro 100 MW Power Plant2020Bamako, MaliMatelecPower PlantHFO power plant based on four-stroke MAN engines replacing a rented 98 MW diesel plantDetailed engineering of all balance of plant outside DG hall (mechanical, electrical, instrumentation)

Project Background & Objectives

The Sirakoro 100 MW Power Plant project was initiated as a massive, utility-scale infrastructure development to secure permanent energy independence and drastically expand grid capacity in Bamako, Mali. Commissioned by Matelec, this landmark energy transition facility focused on establishing a state-of-the-art HFO power plant based on four-stroke MAN engines replacing a rented 98 MW diesel plant. Within this sophisticated utility framework, PDP Energy was selected to lead the extensive engineering balance-of-plant phase. The primary company-specific objectives centered on executing the comprehensive Detailed engineering of all balance of plant outside DG hall (mechanical, electrical, instrumentation), setting up a highly optimized technical foundation for the massive power complex.

Project Challenges

Designing the distributed balance-of-plant infrastructure for a large 100 MW heavy fuel oil (HFO) utility facility introduces extreme mechanical, thermal, and control integration hurdles, especially when transitioning away from modular rental systems. PDP Energy had to navigate massive process constraints across extensive outdoor areas, including optimizing dense HFO handling, storage, and pre-heating networks alongside complex cooling water utility loops. Coordinating the fluid dynamics and pipe stress analysis for large-bore piping networks across multiple facility zones required absolute precision to withstand extreme thermal expansion and dynamic load variations. Furthermore, interfacing these distributed auxiliary systems seamlessly with the core generation hall and a high-capacity utility interface demanded flawless multi-trade coordination to prevent system imbalances, manage tight spatial limits, and engineer complex instrumentation loops to guarantee absolute grid stability.

Project Outcomes

Operating as the primary detailed engineering partner, PDP Energy successfully formulated and delivered the complete multi-disciplinary engineering packages for the comprehensive balance-of-plant systems. The project effectively established an elite technical reference for high-capacity, permanent fuel oil infrastructure in West Africa. By providing highly synchronized mechanical layouts, precise process schematics, and robust utility integration designs, PDP Energy cleared the path for Matelec to securely deploy the 100 MW energy asset, dramatically minimizing regional power deficits, lowering long-term operating costs by replacing rented equipment, and ensuring a stable, high-performance electricity supply for the national grid.

Project Gallery

All Projects

Banque du Liban 8 MW Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Banque du Liban 8 MW Power Plant2017Beirut, LebanonBDLPower PlantNew power plant and electrical network constructionConsulting and design

Project Background & Objectives

The Banque du Liban 8 MW Power Plant project was initiated to build an elite, highly reliable captive power solution for Lebanon’s central banking headquarters in Beirut. Commissioned directly by the central bank (BDL), this critical infrastructure asset was planned to safeguard continuous financial operations against grid failures and energy deficits. Within this high-security institutional framework, PDP Energy was selected to spearhead the specialized engineering and advisory phases. The primary company-specific objectives centered on providing comprehensive consulting and design for the new 8 MW power plant and its integrated electrical network construction, ensuring total system redundancy, stability, and immediate emergency response capabilities.

Project Challenges

Constructing a medium-scale 8 MW power plant within a dense, high-security urban environment presents severe spatial, environmental, and technical hurdles. The electrical network integration required syncing the new generation assets with existing complex corporate grids without risking even a millisecond of voltage disruption to critical banking mainframes and security infrastructure. PDP Energy had to overcome intense engineering difficulties by modeling precise fault ride-through protections, engineering strict acoustic and vibration isolation systems for the urban site, and planning flawless automatic transfer switching mechanisms to secure instantaneous backup transition under any grid collapse scenario.

Project Outcomes

Operating as the primary engineering consultant, PDP Energy successfully delivered the complete consulting and design package for the power generation facility and grid network. The project successfully established an unshakeable energy foundation for the nation’s financial core. By providing highly synchronized, resilient electrical blueprints, PDP Energy paved the way for the construction of a robust 8 MW energy asset that guarantees absolute power autonomy, protects vital data integrity, and secures uninterrupted central banking infrastructure operations.
All Projects

Umm Qasr 29 MW Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Umm Qasr 29 MW Power Plant2019Umm Qasr, IraqButecPower PlantGreenfield natural gas power plant based on Wartsila reciprocating engines in port areasFull detailed engineering of the plant and a 33KV substation (mechanical, electrical, I&C)

Project Background & Objectives

The Umm Qasr 29 MW Power Plant project was initiated to build a high-capacity, heavy-duty captive generation solution to support expanding maritime and industrial logistics at Iraq’s premier deep-water shipping hub in Umm Qasr, Iraq. Commissioned by Butec, this critical utility infrastructure asset focused on the development of a greenfield natural gas power plant based on Wartsila reciprocating engines in port areas. Within this high-demand coastal operational framework, PDP Energy was selected to command the complete multidisciplinary engineering phase. The primary company-specific objectives centered on executing the full detailed engineering of the plant and a 33KV substation (mechanical, electrical, I&C), establishing an optimized, utility-grade blueprint to insulate the strategic port district from localized grid deficits.

Project Challenges

Designing a centralized 29 MW greenfield gas power facility and an integrated distribution substation within a highly active, harsh marine port environment introduces extreme civil, thermodynamic, and automation complexities. Reciprocating Wartsila gas engines demand highly meticulous mechanical engineering to optimize high-pressure fuel gas supply loops, exhaust systems, and high-volume cooling infrastructure under tight spatial constraints and corrosive coastal air conditions. On the electrical and automation side, PDP Energy had to resolve intense hurdles regarding synchronized load-sharing across multiple engine units, transient grid stability, and harmonic distortions. Furthermore, engineering the unified 33KV substation and the overarching instrumentation and control (I&C) systems demanded crafting complex, redundant automation loops capable of monitoring thousands of real-time variables to guarantee immediate fault isolation and prevent catastrophic blackouts across vital port operations.

Project Outcomes

Operating as the primary detailed engineering partner, PDP Energy successfully formulated and delivered the complete mechanical, electrical, instrumentation, control, and substation engineering packages for the power generation facility. The project effectively established an unshakeable, utility-grade energy foundation tailored for mission-critical marine energy and logistics hubs. By providing highly synchronized civil-mechanical layouts, precise process schematics, and robust electrical network blueprints, PDP Energy cleared the path for Butec to securely deploy the 29 MW natural gas asset and 33KV substation, ensuring an uninterrupted, highly stable, and energy-efficient electricity supply to sustain heavy container terminals, port cargo machinery, and regional infrastructure.

Project Gallery

All Projects

Ladol 24 MW Dual Fuel Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Ladol 24 MW Dual Fuel Power Plant2023Ladol Island, Lagos, NigeriaLadol free zonePower PlantCentralized power plant based on dual-fuel reciprocating engines burning natural gas and dieselFull detailed engineering covering mechanical, electrical, instrumentation, control, fire detection, and fighting system

Project Background & Objectives

The Ladol 24 MW Dual Fuel Power Plant project was initiated to build a cutting-edge, high-availability captive generation facility to sustain critical economic operations within the Ladol free zone on Ladol Island, Lagos, Nigeria. Commissioned directly by the free zone authorities, this utility-grade infrastructure project focuses on establishing a centralized power plant based on dual-fuel reciprocating engines burning natural gas and diesel. Within this high-demand, autonomous industrial zone framework, PDP Energy was selected to lead the complete technical realization phase. The primary company-specific objectives centered on executing the full detailed engineering covering mechanical, electrical, instrumentation, control, fire detection, and fighting system, setting up a highly resilient, fully integrated multi-engine generation hub.

Project Challenges

Designing a centralized 24 MW dual-fuel facility on an isolated industrial island introduces extreme engineering, thermodynamic, and logistical complexities. Managing reciprocating engines that must seamlessly transition between natural gas and diesel fuel requires highly meticulous process engineering to optimize dual-supply lines, exhaust systems, and high-volume cooling arrays within strict spatial boundaries. On the electrical and automation side, PDP Energy had to resolve intense hurdles regarding synchronized load-sharing across multiple massive engine units and transient stability control under heavy industrial load fluctuations. Furthermore, engineering the integrated safety systems demanded crafting highly complex, redundant instrumentation, control, fire detection, and fighting systems capable of monitoring thousands of real-time process loops to guarantee immediate hazard isolation and prevent catastrophic blackouts across the free zone.

Project Outcomes

Operating as the primary multi-disciplinary engineering partner, PDP Energy successfully formulated and delivered the complete mechanical, electrical, control, and fire protection detailed engineering packages for the power generation facility. The project effectively established an unshakeable, industrial-grade energy foundation tailored for one of West Africa’s premier free trade zones. By providing highly synchronized and robust multi-trade technical blueprints, PDP Energy cleared the path for the secure deployment of the 24 MW dual-fuel plant, ensuring an uninterrupted, highly flexible, and cost-efficient electricity supply to sustain massive logistics, manufacturing, and maritime operations across Ladol Island.

All Projects

Malicounda 130 MW HFO Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Malicounda 130 MW HFO Power Plant2018Malicounda, SenegalMatelec engineering & contracting divisionPower PlantSeven Wärtsilä 18V50 engines running on heavy fuel oil (HFO) with Flexicycle™ heat recoveryDetailed engineering of all systems/areas outside DG/SG halls, 220KV substation, and building MEP

Project Background & Objectives

The Malicounda 130 MW HFO Power Plant project was initiated as a massive, utility-scale infrastructure development to drastically expand power generation capacity and stabilize the national electricity grid in Malicounda, Senegal. Commissioned by the Matelec engineering & contracting division, this flagship energy facility was built around seven Wärtsilä 18V50 engines running on heavy fuel oil (HFO) with Flexicycle™ heat recovery technology to maximize thermodynamic efficiency. Within this highly sophisticated industrial development framework, PDP Energy was selected to lead the extensive engineering balance-of-plant phase. The primary company-specific objectives centered on executing the comprehensive detailed engineering of all systems and areas outside the DG/SG halls, the 220KV substation, and building MEP, establishing a robust and highly integrated foundation for the entire utility complex.

Project Challenges

Designing the balance-of-plant infrastructure for a large 130 MW multi-engine facility equipped with complex combined-cycle heat recovery systems introduces extreme mechanical, thermal, and electrical integration hurdles. PDP Energy had to navigate massive process constraints across extensive outdoor areas, including optimizing dense heavy fuel oil handling, storage, and pre-heating networks, alongside complex water treatment and cooling utility loops. Coordinating the fluid dynamics and pipe stress analysis for large-bore piping networks across multiple facility zones required absolute precision to withstand extreme thermal expansion and mechanical loads. Furthermore, interfacing these distributed auxiliary systems seamlessly with the core generation halls and a high-voltage 220KV substation demanded flawless multi-trade coordination to prevent system imbalances or catastrophic operational disruptions.

Project Outcomes

Operating as the primary detailed engineering partner, PDP Energy successfully formulated and delivered the complete multi-disciplinary engineering packages for the comprehensive balance-of-plant systems. The project effectively established an elite technical reference for high-efficiency, combined-cycle power infrastructure in West Africa. By providing highly synchronized mechanical layouts, precise process schematics, and robust utility integration designs, PDP Energy cleared the path for Matelec to securely deploy the 130 MW energy asset, dramatically minimizing regional power deficits, lowering fuel consumption per megawatt-hour through heat recovery, and ensuring a stable, high-performance electricity supply for the national grid.

Project Gallery

All Projects

Nocibe 16 MW Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Nocibe 16 MW Power Plant2015Adja, Ouèrè, BeninNouvelle Cimenterie du Benin (Nocibe)Power PlantHFO power plant based on four-stroke Hyundai engines for a cement factoryExecuted full detailed engineering covering mechanical, electrical, instrumentation, and control

Project Background & Objectives

The Nocibe 16 MW Power Plant project was initiated to construct a dedicated, heavy-duty captive power generation facility to support large-scale industrial operations in Adja, Ouèrè, Benin. Commissioned by the Nouvelle Cimenterie du Benin (Nocibe), this high-reliability project focused on establishing an independent energy source to run a massive industrial cement production site. Within this critical manufacturing framework, PDP Energy was selected to handle the complete multidisciplinary technical realization phase. The primary company-specific objectives centered on the execution of the full detailed engineering covering mechanical, electrical, instrumentation, and control systems, setting up a robust HFO power plant based on four-stroke Hyundai engines to protect raw material production lines from localized grid instability.

Project Challenges

Designing and integrating a heavy fuel oil (HFO) captive power plant for an active cement factory introduces severe process, mechanical, and power quality hurdles. Cement production requires absolute electrical continuity, as sudden voltage drops or power failures can freeze high-temperature kilns, resulting in catastrophic equipment damage and massive financial losses. PDP Energy had to resolve intense technical challenges, including balancing the structural layout requirements for massive four-stroke Hyundai engine blocks, optimizing complex heavy fuel handling and pre-heating subsystems, and designing robust fault-ride-through capabilities to handle abrupt industrial motor load variations. Furthermore, engineering the unified instrumentation and control (I&C) network demanded crafting complex automation loops capable of monitoring thousands of real-time variables to prevent cascading blackouts across the factory floor.

Project Outcomes

Operating as the primary detailed engineering partner, PDP Energy successfully formulated and delivered the complete mechanical, electrical, instrumentation, and control engineering packages for the heavy industrial power asset. The project effectively established an optimized, highly resilient technical framework tailored for high-demand captive industrial operations in West Africa. By providing synchronized civil-mechanical layouts and advanced automation schematics, PDP Energy cleared the path for the secure deployment of the 16 MW power plant, ensuring the cement factory gains complete energy self-sufficiency, maintains uninterrupted production cycles, and isolates its core machinery from external grid disruptions.

All Projects

Kotu 11MW Power Plant

on Share

Project Details

NameYearLocationClientTypeDescriptionScope
Kotu 11MW Power Plant2015Kotu, The GambiaNAWECPower PlantHFO power plant based on two-stroke Doosan engines.Executed the full detailed engineering of the extension, including civil, mechanical, electrical, instrumentation, and control.

Project Background & Objectives

The Kotu 11MW Power Plant project was initiated as a critical utility infrastructure expansion to enhance grid capacity and support rising energy demands in Kotu, The Gambia. Commissioned by the National Water & Electricity Company (NAWEC), this essential project focused on an extension utilizing an HFO power plant based on two-stroke Doosan engines. Within this strategic brownfield utility framework, PDP Energy was selected to command the full design phase. The primary company-specific objectives centered on executing the full detailed engineering of the extension, including civil, mechanical, electrical, instrumentation, and control, ensuring complete system integration into the active facility.

Project Challenges

Engineering an 11MW heavy fuel oil (HFO) extension utilizing massive two-stroke Doosan engines inside an operational brownfield complex presents severe technical and structural hurdles. PDP Energy had to navigate the mechanical and civil complexities of designing robust structural foundations capable of dampening the immense low-frequency vibrations generated by two-stroke machinery. On the electrical and automation side, integrating the new block required meticulous planning to sync fuel handling, cooling loops, and high-voltage connections into NAWEC’s existing grid interface without causing operational downtime. Furthermore, coordinating thousands of real-time automation loops under a unified instrumentation and control (I&C) system demanded extreme precision to eliminate the risk of cascading grid failures.

Project Outcomes

Operating as the multi-disciplinary engineering partner, PDP Energy successfully formulated and delivered the complete civil, mechanical, electrical, and control detailed engineering packages for the extension. The project successfully established a resilient technical blueprint for increasing national generation capacity under tight operational constraints. By delivering highly synchronized and detailed technical blueprints, PDP Energy cleared the path for NAWEC to safely commission the 11MW energy asset, significantly stabilizing the Gambian national electrical grid and delivering a dependable power supply to local communities and commercial sectors.

All Projects