Specialist EPC and O&M

Power Systems Service is a trusted partner for the design, supply and construction (EPC) and operation and maintenance (O&M) of turnkey hybrid power systems and medium voltage and low voltage distribution systems for the mining sector in Southern and West Africa. We work collaboratively with our clients to ensure their specific needs are identified, addressed and met with the singular purpose of ensuring they get the highest reliability and performance out of their hybrid power plant.

For the past 25 years, the core staff of Power Systems Service have been 100% focused on the design, supply, construction, commissioning, operation, servicing and maintenance of “off grid” power plants for remote operations in the mining industry.

Our first experience was for Anglo Gold in an EPCM role on the Sadiola Gold Mine project in Mali in 1996 and since then we have devoted all our intellectual, financial and physical effort into developing our capabilities in this specific market sector.

To ensure we offer the best possible service we have focused specifically on the mining sector - which we understand intimately, and geographically to operations that are in Southern and West Africa where we have a good understanding of the logistical and geopolitical challenges and have daily direct access.

We have delivered more than 400MW of projects over the past 25 years.

In this specific niche, we offer industry leading construction and engineering knowledge with proven experience of providing solutions to our customers’ design, project and service requirements. Our engineers focus on combining the client’s specific needs, their own deep experience, best practice, modern technology and a solid understanding of the economics and management of hybrid power plant infrastructure to ensure that we make the client's electrical power systems efficient, reliable, cost effective and safe.

EPC Services

There is no such thing as a typical client and each client's need is individual. Our service is specifically tailored to suit your unique requirements and we will start with a full project analysis and consultation with the client from which the project's key objectives and targets are set and the key performance targets agreed. We anticipate that typically a turnkey project will proceed in the following way

Our CAD team will construct a virtual model of the proposed hybrid power plant which will be used to produce detailed drawings which the client will check and approve for construction. Our input on design will be focused on areas where we believe that practical improvements can be made rather than the principles of the design and the verification of quantities and sizing which are part of the system engineering.

Newly incorporated into our offering is PV Solar design, installation, commissioning and integration with the rest of the power system to offer a hybrid power solution. We draw from the best OEMs to ensure that high quality and reliable outcomes are achieved and utilize their support to ensure our designs are optimized to the site conditions and matched to the equipment characteristics. The necessary geotechnical, earthworks, groundworks and civils will be completed to the agreed designs and signed off with a detailed survey prior to structural construction.

The shipping and delivery of the main components will be carried out by a specialist heavy lift transport contractor, and PSS will manage receipt, storage and positioning of equipment through the construction period. Our procurement and shipping team will also be engaged in the sourcing and shipping of piping, steelwork, PV modules, tracking support systems, inverters, batteries and cable with all the ancillary items necessary to provide a fully integrated Hybrid Power solution.

A dedicated fabrication shop will be established on site to prepare the supports and platforms for all piping. All piping will be sandblasted and primed prior to installation and teams of pipe fitters and coded welders will prepare piping according to the drawings provided. 100% of the welds will be inspected by separate QA team and prior to putting into service all pipe work will be cleaned and flushed in accordance with the procedures specified.

As soon as there is clear access around each generator package, the installation and termination of MV, LV, control and instrument cables will commence. We anticipate installation of cables in both pre-formed ducts and on elevated vertical cable trays. We expect to use cable winches and pulling socks to install the cables in pre-formed ducts we witnessed being cast on site. There are separate staff for the installation termination and connection of cables and we have allowed for 100% QA check of all electrical and instrumentation work and this will include separate verification of all cable testing prior to connection.

Prior to hand over to the clients taking over team, each structural, mechanical, piping, electrical and instrumentation component will be checked and tested. This includes all mechanical alignment, engine deflections, electrical primary and secondary injection testing and instrument calibrations. All the testing is done with our own certified and calibrated test equipment with fully traceable documentation.

After completion of the construction work and prior to hand over to the client taking over team, the internal finishing of the powerhouse and solar installation will be completed to the highest standard to ensure that the plant is safe for operation.

We will normally have a small team remain on site for 2 months after completion to deal with any snagging, client training and hand over.

Operation and Maintenance

Following completion of the construction, installation and commissioning of your Hybrid Power Plant PSS offers an on-going operation and maintenance of the complete integrated power plant.

We are able to offer the full spectrum of the engineering life cycle as our engineers are able to continuously analyze your operations and establish if your needs are still being met months and years after the initial installation.

We additionally provide on line asset management record service allowing you to have a greater understanding of your system and easy access to design, documentation and maintenance records.

Optimized and Integrated Power

Selecting the optimal mix of Energy Technologies and then ensuring they are seamlessly integrated into a single system is essential to achieving an optimized power solution.

Various metrics such as upfront capital costs, ongoing fuel costs, operating and maintenance costs, security of supply, system response capacity and stability, total cost of ownership, levelized cost of electricity, carbon footprint and ESG metrics all need to be considered when designing a Hybrid Power Plant.

Once the optimal design is achieved it is essential that the various components are all carefully integrated together. A key risk to Hybrid Power plants is the failure to fully integrate the system. This is a key risk to having components of the hybrid plant supplied by disparate suppliers.

Furthermore ensuring the supplier has long-term responsibility for the Hybrid Plants performance ensures that initial as well as long-term considerations are addressed in the design and construction of the plant.

PSS takes a completely holistic approach to Hybrid Power, from cradle to grave and encompassing all the various energy technologies available. This ensures the client receives a fully-integrated system that is optimized across all metrics.

Local Resources

Essential to ensuring that your Hybrid Power plant is developed and operates in a efficient and reliable manners is by ensuring that resources are available locally.

PSS has over 200 employees located across four regional offices and various sites to ensure that projects are executed efficiently, operation and maintenance activities are continuous and that our clients experience uninterrupted power supplies.

When situations arise and quick and effective responses are required the PSS pool of resources are deployed to overcome issues promptly with minimal interruption to our clients.

PSS has invested heavily in Training, Equipment, Plant, Test Equipment and Tools to ensure every challenge is overcome in the quickest and most effective manner possible.