Project Overview
Client: BUROTEC / Electricité Du Liban (EDL)
Location: Zouk Mikael Power Plant, Lebanon
Project Type: Boiler Rehabilitation Phase I (Unit II Maintenance)
Year of Execution: 2016
Scope: Economizer Repair, Refractory & Safety Valves
Project Description
In 2016, ISPC partnered with BUROTEC to execute the critical Boiler Rehabilitation Phase I for Unit II at the Zouk Power Plant. This unit is a cornerstone of the Lebanese grid, and its boiler required urgent mechanical intervention to address efficiency losses caused by long-term thermal stress. The project focused on restoring the integrity of the steam generation circuit and ensuring the safety of the pressure vessel.
Scope of Boiler Rehabilitation Phase I
1. Economizer & Pressure Parts:
Tube Replacement: Identification and replacement of eroded tubes in the Economizer banks to improve heat transfer efficiency from flue gases to feed water.
Leak Repair: Welding repairs on steam drum connections and downcomers to eliminate steam losses.
2. Refractory & Insulation Works:
- Heat Retention: Repairing damaged refractory lining inside the furnace to protect the boiler casing from high temperatures and improve thermal efficiency.
- Cladding: Replacement of damaged outer insulation and aluminum cladding to ensure personnel safety and reduce heat radiation.
3. Valves & Mountings:
Safety Valves: Overhaul and calibration of the boiler safety relief valves (PSV) to ensure they open at the correct set pressure.
Soot Blowers: Maintenance of the soot blowing system to ensure effective cleaning of ash deposits on the boiler tubes.
Key Challenges & Solutions
Challenge: Working inside the confined space of a boiler drum and furnace presents significant safety hazards (Confined Space Entry).
Solution: ISPC implemented strict safety protocols, including continuous ventilation, gas monitoring, and the use of dedicated safety watchmen for all personnel working inside Unit II.
Results
The rehabilitation of Unit II was completed within the scheduled outage period. The Boiler Rehabilitation Phase I successfully restored the unit’s steam generation capacity, allowing for a smooth synchronization with the national grid.
