Project Overview
Client: Rechmaya Hydroelectric Power Plant
Location: Rechmaya, Mount Lebanon
Project Type: Renewable Energy (Hydropower)
Capacity: 3 MW Unit Capacity
Year of Execution: 2023 – 2024
Scope: Specialized Dismantling & Precision Installation
Project Description
The Rechmaya Power Plant plays a historic and critical role in Lebanon’s renewable energy mix. ISPC was entrusted with a high-precision project involving the complete dismantling of an aging hydroelectric unit and the installation of a upgraded 3 MW Turbine. This project required exceptional mechanical expertise to handle heavy rotating equipment within the confined space of the existing powerhouse, ensuring the new unit integrated seamlessly with the existing hydraulic infrastructure.
Scope of Work
1. Dismantling Phase (Decommissioning):
Site Survey & Planning: Detailed 3D scanning of the existing turbine pit to plan the lifting procedures.
Heavy Dismantling: Systematic removal of the old generator, turbine shaft, runner, and guide vanes.
Waste Management: Safe disposal of worn-out mechanical parts and hydraulic fluids in compliance with environmental standards.
2. Mechanical Installation:
Turbine Erection: Installation of the new 3 MW turbine runner and spiral casing components.
Precision Alignment: Laser alignment of the turbine shaft with the generator rotor to ensure vibration-free operation at high RPM.
Valve Integration: Connection of the Main Inlet Valve (MIV) and hydraulic governor systems.
Bearing Installation: Fitting of new guide bearings and thrust bearings to support the rotating mass.
3. Electrical & Control Integration:
Governor System: Installation and calibration of the electronic speed governor to control water flow and turbine speed.
Generator Maintenance: Overhaul and re-connection of the generator stator and rotor windings.
Protection Systems: Upgrading vibration monitoring sensors and temperature probes.
Key Challenges & Solutions
Challenge: Working inside a historic powerhouse with limited overhead crane capacity and restricted access for heavy machinery.
Solution: ISPC engineers designed a custom rigging and lifting plan, utilizing specialized hydraulic jacks and modular gantries to maneuver the 3 MW components safely into the turbine pit without damaging the civil structure.
Results
The unit was successfully synchronized with the national grid, restoring 3 MW of clean, green energy to the network. The project demonstrated ISPC’s capability to extend the life of critical renewable energy assets through precise engineering and rehabilitation.
