ArchivesProcess Engineering & Simulation

Umm Qasr 29 MW Power Plant

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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.

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Ladol 24 MW Dual Fuel Power Plant

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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.

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Malicounda 130 MW HFO Power Plant

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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.

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Nocibe 16 MW Power Plant

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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.

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Kotu 11MW Power Plant

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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.

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