Project Overview
Client: BUROTEC / Electricité Du Liban (EDL)
Location: Zouk Mikael Power Plant, Lebanon
Project Type: Desalination Unit Erection (Water Treatment)
Year of Execution: 2017
Scope: Mechanical Erection, Piping & Commissioning
Project Description
Water quality is the lifeline of any thermal power plant. In 2017, ISPC partnered with BUROTEC to execute the complete Desalination Unit Erection at the Zouk Power Plant. The project involved the installation of new, high-efficiency desalination trains designed to provide ultra-pure boiler feed water, ensuring the longevity of the plant’s steam turbines and preventing scaling or corrosion.
Scope of Work
1. Mechanical Assembly & Positioning:
Heavy Lifting: Precision lifting and positioning of massive evaporator vessels and heat exchangers using mobile cranes within the confined spaces of the active plant.
Structural Alignment: Erection of steel support structures and skid alignment to ensure stability under operating vibrations.
2. Process Piping & Integration:
Seawater Intake: Fabrication and installation of large-diameter piping for seawater intake and brine discharge.
High-Pressure Lines: Welding of stainless steel (Duplex/Super Duplex) piping for high-pressure reverse osmosis (SWRO) or thermal vapor lines.
Pump Stations: Installation and alignment of high-pressure feed pumps and energy recovery devices.
3. Commissioning & Testing:
Hydrostatic Testing: Conducting rigorous pressure tests on all piping and vessels to ensure zero leakage.
Performance Testing: Calibrating flow rates and monitoring water conductivity to meet EDL’s strict purity standards.
Key Challenges & Solutions
Challenge: Executing heavy erection works inside an operational power plant without disrupting existing power generation.
Solution: ISPC implemented a strict SIMOPS (Simultaneous Operations) safety protocol, scheduling heavy lifts during low-load periods and using modular assembly techniques to speed up on-site installation.
Results
The new units were successfully commissioned on time, significantly boosting the plant’s water production capacity. The Desalination Unit Erection project demonstrated ISPC’s ability to handle complex mechanical integrations for critical utility infrastructure.
