Project Overview
Client: Sibline Cement Factory
Location: Sibline, Mount Lebanon
Project Type: Power Generation (Diesel Engines)
Capacity: 12 MW
Year of Execution: 2024 – 2025
Scope: Turnkey Mechanical & Electrical Installation
Project Description
To support the heavy energy demands of cement production and ensure operational continuity independent of grid fluctuations, Sibline Cement awarded ISPC the contract to install a complete 12 MW Diesel Power Plant. This strategic project involved the precise erection of heavy-duty diesel generators and the integration of complex auxiliary systems to guarantee a stable and reliable power supply for the factory’s kilns and mills.
Scope of Work
1. Mechanical Installation:
Heavy Lifting & Positioning: Unloading and precise positioning of the Diesel Engine Generator sets on vibration-isolating foundations.
Piping Systems: Fabrication and erection of all auxiliary piping networks, including:
Fuel Supply & Return lines.
Lubrication Oil systems.
Cooling Water circuits (HT/LT).
Compressed Air starting systems.
Exhaust System: Installation of exhaust gas silencers, ducting, and stack structures to meet environmental emission standards.
Structural Works: Erection of steel support structures for piping racks and maintenance platforms.
2. Electrical & Instrumentation:
Cabling: Laying and termination of Medium Voltage (MV) and Low Voltage (LV) power cables.
Control Systems: Installation of local control panels (LCP) and integration with the plant’s main SCADA system.
Switchgear: Erection of MV switchgear and synchronization panels to manage load sharing between generators.
Earthing: Installation of a complete grounding system for equipment safety.
3. Testing & Commissioning:
Performing hydrostatic pressure tests on all piping systems.
Conducting Megger and Hi-Pot testing for electrical cables.
Cold and Hot commissioning of the engines.
Load testing to verify performance at 100% capacity (12 MW).
Key Challenges & Solutions
Challenge: Executing works within an active cement plant environment with strict safety constraints and dust control requirements.
Solution: ISPC implemented a rigorous HSE plan, coordinating daily with factory operations to ensure zero downtime for the existing production lines during installation.
Results
The project was delivered on time and within budget, providing Sibline Cement with a robust 12 MW autonomous power source. The new plant ensures uninterrupted production capability, significantly reducing reliance on the national grid and mitigating the risk of power outages.
