Project Overview
Client: Electricité Du Liban (EDL)
Location: Zouk Mikael & Jieh Power Plants, Lebanon
Project Type: Fuel Pipe System Modification (Industrial Piping)
Year of Execution: 2020
Scope: Piping Fabrication, Valve Replacement & System Upgrade
Project Description
In 2020, ISPC was tasked with a critical upgrade project at Lebanon’s two major thermal power plants: Zouk and Jieh. The scope involved the comprehensive Fuel Pipe System Modification to improve the efficiency and safety of fuel transfer operations. The objective was to replace aging infrastructure and re-route specific fuel lines to accommodate new operational requirements, ensuring a leak-free and reliable fuel supply to the boilers and turbines.
Scope of Fuel Pipe System Modification
1. Piping Fabrication & Welding:
Line Modification: Cutting and removing corroded or obsolete fuel lines and replacing them with high-schedule Carbon Steel pipes capable of withstanding high pressure and temperature.
Certified Welding: Execution of high-precision TIG and Arc welding by certified welders, followed by 100% NDT (Non-Destructive Testing) including X-Ray and Ultrasonic testing to guarantee weld integrity.
2. Valve & Instrumentation Upgrade:
Valve Integration: Installation of new industrial gate, globe, and check valves to improve flow control and isolation capabilities during maintenance.
Instrumentation: Upgrading pressure gauges and flow meters along the modified lines to provide accurate real-time data to the control room.
3. System Tie-in & Testing:
Hot & Cold Tie-ins: Seamlessly connecting the new modified lines to the existing live fuel network with minimal downtime.
Pressure Testing: Conducting rigorous hydrostatic pressure tests on the entire Fuel Pipe System Modification to ensure safety before commissioning.
Key Challenges & Solutions
Challenge: Working on live fuel lines in a high-risk explosive environment required extreme safety precautions.
Solution: ISPC implemented strict “Hot Work” permits and utilized spark-free tools and continuous gas monitoring during cutting and welding operations to ensure zero accidents.
Results
The project was completed with zero safety incidents. The modified fuel system improved the flow efficiency to the burners and significantly reduced maintenance downtime associated with leaks and valve failures.
