Case Studies: Operations and Maintenance
Mining Power Station Refurbishment in Mali
104 MW Power Station Refurbishment and Expansion
THE CHALLENGE
The mining power station refurbishment project at the Loulo-Gounkoto complex in western Mali comprises two mining permits, Loulo and Gounkoto, adjacent to the Senegal border and the Falémé River. Operating at this scale in a remote region introduced challenges including geopolitical risks, environmental compliance, community relations, safety standards, logistical hurdles, production efficiency, financial risks, and coordination between separate mining permits.
The project required a complete rebuild of over 80 MW of Caterpillar engines, plus the installation of 24 MW of new generation capacity to meet the power demands of large-scale mining operations.
The Solution
USP&E was selected to deliver the full scope of engineering, refurbishment, installation, and commissioning. Our solution comprised refurbishment of 80 MW of existing Caterpillar CM32 engines to restore performance and extend asset life, supply and installation of three new zero-hour Cat 12CM32 engines adding 24 MW of generation capacity, and full project execution including engineering, procurement, construction oversight, and commissioning.
USP&E acted as the single point of technical accountability throughout the project lifecycle, delivering engineering precision under frontier conditions.
The Outcome
USP&E delivered 104 MW of reliable power generation capacity. The refurbished and newly installed power station achieved 300% greater reliability and availability than ever previously recorded at site. The project demonstrated USP&E’s ability to execute complex, large-scale power infrastructure in demanding mining environments.
Client Reference
“All the work performed by USP&E was extremely diligent and to a high standard of detail and thoroughness. Reporting and feedback and a willingness to exchange ideas and share suggestions with our project team and consultants demonstrated the professional and international capabilities of USP&E in performing such work and as such we would recommend them for other similar work.” – Barrick Gold Client
Built for the Frontier
This project demonstrates Ownership and Together in action: USP&E delivered a 104 MW power station refurbishment and expansion, achieving a 300% reliability improvement in one of the most demanding mining environments in West Africa. Entrepreneurial speed. Engineering credibility. That is what Powering Precision means.
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