Project Overview
Client: BUROTEC / Electricité Du Liban (EDL)
Location: Zouk Mikael Power Plant, Lebanon
Project Type: Rehabilitation of Boiler Zouk Unit 1 (Thermal Power Maintenance)
Year of Execution: 2018
Scope: Superheater Replacement, Refractory & Soot Blower Overhaul
Project Description
Following the successful rehabilitation of Unit 2, ISPC was entrusted in 2018 with the Rehabilitation of Boiler Zouk Unit 1. As one of the foundational units of the Zouk Power Plant, Unit 1 required a comprehensive life-extension program. The project focused on replacing critical pressure parts that had suffered from long-term thermal fatigue, ensuring the unit could continue to operate safely and efficiently at full load.
Scope of Rehabilitation of Boiler Zouk Unit 1
1. Superheater & Reheater Works:
Coil Replacement: Extensive replacement of damaged high-temperature superheater and reheater coils to restore steam temperature control.
Support Alignment: Realignment of tube supports and hangers to prevent vibration and stress fractures during operation.
2. Furnace & Refractory:
Skin Casing Repair: Repairing the boiler skin casing and refractory insulation to minimize air ingress, which is critical for maintaining combustion efficiency.
Burner Throat Repair: Re-casting the refractory throats of the fuel oil burners to ensure a stable flame shape and optimal heat distribution.
3. Auxiliaries Maintenance:
Soot Blowers: Complete overhaul of the rotary soot blowers to ensure effective removal of slag deposits from heat transfer surfaces.
Valve Maintenance: Lapping and seating of high-pressure steam valves and safety relief valves.
Key Challenges & Solutions
Challenge: Unit 1 had severe accessibility issues due to older structural designs.
Solution: ISPC engineering team designed custom scaffolding and lifting plans to safely access and replace heavy superheater bundles within the boiler penthouse.
Results
The Rehabilitation of Boiler Zouk Unit 1 significantly improved the unit’s availability factor. The boiler was returned to service with reduced tube leak frequency and improved thermal performance.
