Project Overview
Client: Hrayche Power Station
Location: Hrayche, North Lebanon
Project Type: Thermal Power Plant Maintenance
Equipment: Industrial Water-Tube Boiler
Year of Execution: 2019
Scope: Phase III – Pressure Parts Replacement & Refractory Works
Project Description
Industrial boilers are the heart of thermal power generation. Over years of operation under high pressure and temperature, components degrade, leading to efficiency losses and safety risks. ISPC was commissioned to execute Phase III of the boiler rehabilitation program at the Hrayche facility. This critical phase focused on replacing worn-out pressure parts and restoring the thermal insulation integrity to ensure the boiler operates at peak efficiency and complies with safety regulations.
Scope of Work
1. Pressure Parts Replacement:
Tubing Works: Cutting and removing damaged sections of the boiler water walls and superheater tubes.
Welding: Precision TIG/ARC welding of new alloy steel tubes, ensuring zero-defect joints to withstand high steam pressure.
Headers: Inspection and repair of steam headers and distribution manifolds.
2. Refractory & Insulation:
Refractory Repair: Replacing damaged refractory bricks and castables inside the combustion chamber to prevent heat loss and protect the outer casing.
Cladding: Repairing the external insulation cladding to ensure personnel safety and improve thermal efficiency.
3. Valves & Auxiliaries:
Safety Valves: Overhauling and calibration of main safety relief valves.
Soot Blowers: Maintenance of soot blowing systems used to keep the tubes clean from ash deposits.
4. Testing & Quality Control:
NDT Testing: Performing Radiographic Testing (RT) on all new tube welds.
Hydrostatic Test: Pressurizing the boiler system to 1.5x operating pressure to certify leak-proof integrity before restart.
Key Challenges & Solutions
Challenge: Executing welding works in confined spaces inside the boiler drum and furnace with restricted access.
Solution: ISPC deployed certified welders specialized in “Mirror Welding” and confined space operations, ensuring high-quality workmanship even in the most difficult sections of the boiler.
Results
The rehabilitation successfully extended the operational lifespan of the boiler and improved its heat transfer efficiency. The unit was brought back online safely, contributing to the stability of the power supply.
