Project Overview
Client: Electricité Du Liban (EDL)
Location: Hrayche Power Station, North Lebanon
Project Type: Boiler Revamping Phase I (Thermal Power Maintenance)
Year of Execution: 2016
Scope: Pressure Parts Replacement, Burner Maintenance & Ductwork
Project Description
In 2016, ISPC was commissioned to execute Boiler Revamping Phase I at the Hrayche Power Station. As one of the critical power generation nodes in North Lebanon, the station required urgent rehabilitation to address aging pressure parts and improve thermal efficiency. This initial phase focused on stabilizing the boiler’s operation and extending the lifespan of critical components before further modernization could take place.
Scope of Boiler Revamping Phase I
1. Pressure Parts & Tubing:
Tube Replacement: Cutting and replacing corroded water wall tubes and superheater coils to prevent steam leaks and maintain pressure integrity.
Welding: High-precision certified welding of alloy steel tubes, followed by rigorous quality control and radiographic testing.
2. Burner & Combustion Systems:
Burner Maintenance: Overhaul of the main fuel oil burners, including cleaning of atomizer nozzles and calibration of air registers to ensure optimal combustion.
Ignition Systems: Checking and repairing pilot igniters to guarantee reliable startup sequences during the Boiler Revamping Phase I operations.
3. Air & Flue Gas Systems:
Ductwork Repair: Repairing corroded sections of the air and flue gas ducts to prevent air ingress and improve draft efficiency.
Expansion Joints: Replacement of damaged expansion joints to accommodate thermal expansion during boiler operation.
Key Challenges & Solutions
Challenge: The boiler had to be rehabilitated within a very short shutdown window to minimize power outages in the North.
Solution: ISPC deployed multiple shift teams working 24/7, utilizing pre-fabricated tube panels to accelerate the on-site installation process.
Results
Phase I was completed successfully, restoring the boiler to safe operational parameters. This project laid the groundwork for subsequent rehabilitation phases (Phase III), proving ISPC’s reliability in handling critical Power Plant Rehabilitation projects.
