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
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.