Specialist Economizer Replacement in Austria (ECO)

Project Information:

Scope: Full ECO replacement – 4 packages with 147 coil assemblies each

Project location: Austria

Contractor: PRO-WELDING Industry Services – team of 27 certified specialists

Project duration: 17 days

Welding technology: TIG

Productivity: over 2,000 high-pressure welds

Quality: 0 RT defects, pressure test successfully completed

Project Scope

The replacement covered the entire ECO K7 economizer, consisting of four coil packages. Each package contained 147 coil assemblies, which required precise planning of logistics, prefabrication, installation, and the welding process.

PRO-WELDING INDUSTRY SERVICES

Stages and Challenges

A key challenge was the need to carry out unforeseen additional works while maintaining a strict pressure test deadline. Direct communication between the execution office and the on-site teams enabled immediate technical decisions and the elimination of downtime.

1. Dismantling and Preparation of the Installation

The first stage of the works included dismantling of the old coil assemblies, repair of the entire economizer casing, and preparation of the structure for installation of new components.

The works were carried out in stages, in compliance with strict HSE procedures and technical documentation requirements.

2. Prefabrication and Vertical Logistics

All installation components underwent a professional pre-assembly stage in the prefabrication workshop, which significantly reduced the duration of on-site installation works.

3. Vertical Transport – Just-in-Time System

The coil assemblies were delivered individually through the open boiler casing using a Just-in-Time system, requiring millimeter-level precision in crane coordination.

4. Quality Under Control – Zero Defects

Radiographic testing (RT) was planned in cycles, allowing welding continuity to be maintained. A result of 0% repairs was achieved on more than 2,000 high-pressure welds. The pressure test was successfully completed on the first attempt.

Final Project Outcome

The project was completed on schedule and in full compliance with technical requirements.

Full coordination between fitters, welders, and inspection personnel resulted in a successful hydrostatic test on the first attempt and timely closure of the boiler casing.

high-pressure welds

repairs