Project Details
- Diesel Power Plant Overhaul
- 24th March 2020
- Ministry of Energy & Water Resources, Somalia
- Mechanical Overhaul, Control System Upgrade, Generator Maintenance
Lemos International successfully executed a comprehensive mechanical overhaul and control system upgrade for an 8MW diesel generator facility in Somalia. The project involved diagnostic assessments, replacement of critical components, and the installation of advanced synchronizing panels with PLC-based controls. Our team restored the plant to 100% operating capacity while achieving an 18% improvement in fuel efficiency.
Our scope of work included:
- Feasibility & Planning: Conducted diagnostic assessments, vibration analysis, and reviewed outdated control panels to identify wear and inefficiencies.
- Mechanical Overhaul: Replaced pistons, liners, and cylinder heads for six generators to restore optimal performance.
- Control System Upgrade: Installed new synchronizing panels with PLC-based controls to enhance operational reliability and automation.
- Load Testing & Alignment: Performed load testing and precision alignment of generators to ensure seamless integration and functionality.
The project was completed with meticulous attention to detail, adhering to international standards and delivering a reliable, efficient power solution for the region.
Key Features of the Project
Comprehensive Diagnostic Assessment
- Conducted detailed engine wear analysis, vibration studies, and inspections of outdated control panels to identify root causes of inefficiencies.
- Utilized advanced diagnostic tools to evaluate generator health and prioritize repairs.
Critical Component Replacement
- Replaced pistons, liners, and cylinder heads for all six generators, ensuring long-term durability and performance.
- Employed OEM-certified parts to maintain compatibility and reliability.
Advanced Control System Integration
- Installed state-of-the-art synchronizing panels with PLC-based controls, enabling precise power distribution and automated synchronization.
- Integrated real-time monitoring capabilities to enhance operational visibility and maintenance planning.
Precision Load Testing & Alignment
- Conducted rigorous load testing to verify generator performance under varying conditions.
- Performed laser alignment to minimize vibration and ensure smooth operation.
Improved Fuel Efficiency
- Optimized generator settings and replaced worn components to achieve an 18% improvement in fuel efficiency, reducing operational costs.
Challenge 1: Outdated Control Panels
The existing control panels were obsolete, posing risks to operational reliability and automation.
Solution:
We replaced the outdated panels with modern PLC-based synchronizing systems, enhancing automation and enabling seamless integration with the grid.
Challenge 2: Limited Spare Parts Availability
Sourcing spare parts for older generator models proved challenging due to limited availability.
Solution:
Our procurement team worked closely with OEMs and suppliers to secure certified components, ensuring timely delivery and compatibility.
Challenge 3: Restoring 100% Operating Capacity
Restoring full capacity required addressing multiple mechanical and electrical issues simultaneously.
Solution:
We adopted a phased approach, prioritizing critical repairs and conducting parallel testing to ensure all systems were restored efficiently.
Outcome & Client Satisfaction
The successful completion of the Diesel Power Plant Overhaul project underscores Lemos International’s ability to deliver complex mechanical upgrades under challenging conditions. Key achievements include:
- 100% Operating Capacity: The plant was restored to full functionality, ensuring uninterrupted power supply for the region.
- Fuel Efficiency Improvement: Achieved an 18% reduction in fuel consumption, lowering operational costs and environmental impact.
- Enhanced Reliability: Upgraded control systems and mechanical components ensured long-term reliability and reduced downtime.
- Client Trust: The Ministry of Energy & Water Resources expressed immense satisfaction with the outcome, praising our technical expertise and commitment to quality.
