PROJECT FACTS: HOLCIM LEBANON Plant Details: 5 X MAN B&W 9L52/55 (32.5MW)

PROJECT FACTS: HOLCIM LEBANON
Plant Details: 5 X MAN B&W 9L52/55 (32.5MW)
2 X MAN B&W 9L52/55B (15 MW)
1 X MAN B&W 18V 48/60 (18.5MW)
Total Plant Capacity: 66 MWe
Total Plant Consumption: 31 MWe Max

RESTORING POWER PLANT
CAPACITY & LOAD RESERVE
BY 7.5 MW
FULL ENGINE REHABILITATION,
CRANKSHAFT RENEWAL & CONCRETE
FOUNDATION MODIFICATION
Holcim Lebanon awarded Goltens a contract in March 2011
to perform a full overhaul and engine rehabilitation project on
diesel generator #8, a 7.5MW MAN B&W 9L52/55B. The
engine had been inoperative for more than 5 years and
required significant repairs and modifications before returning
it to service.
Holcim viewed the restoration of the engine as essential to
boost the plant total power capacity back to 66 MW,
providing operational flexibility and increase back-up power
required on an average plant load demand of 31 MW.
The scope of the project was significant as the foundation for
the engine required renewal and the entire engine needed to
be removed as part of the project.
Goltens deployed a team of one Senior Supervisor, one
Foreman and an average of 8 technicians to complete the
mechanical work. Additionally, a team of Electrical
Specialists was deployed to complete engine monitoring
system upgrades which increased safety features by adding
wireless crankpin bearing sensor monitoring.
REPAIRS CONSISTED OF:
• Disassembly and removal of complete engine from
foundation
• Modification of concrete generator foundation using
Chock fast Red.
• Overhaul of all engine components on site
• Laser cheek of main bearing pockets
• Removal & installation of new crankshaft
• Installation & Commissioning of wireless crankpin
bearing sensors
• Commissioning and 2 week reliability test of Engine

RESULTS:
During operational testing the generator reached 7.0 MW
load with further capacity to increase to 7.5 MW as all
operating parameters were demonstrated to be within maker
specifications.
The entire project was executed in accordance with the
work plan and the Holcim plant was restored to full capacity
with less vibration and increased engine safety features,
optimizing equipment efficiency.
Goltens full spectrum capability related to expertise in major
engine repair, industrial Chock fast application and
specialized electro/automation work enabled Holcim to
engage Goltens for the end-to-end completion of this
complex job.