Waste-to-Energy Boiler and Grate Overhaul in Vienna
Vienna | PRO-Welding Industry Services completed a comprehensive waste-to-energy boiler and grate overhaul at a waste incineration plant in Vienna, Austria. The project was carried out simultaneously across three combustion lines by a 50-person team of welders, fitters and site supervisors.
The scope included the replacement of boiler roof tube panels, complete grate system replacement on two combustion lines, and the replacement of valves, flanged connections and selected piping sections.
INDUSTRIAL BOILER OVERHAUL IN VIENNA – SCOPE AND WORK STAGES
The project scope included:
- replacement of the boiler roof tube panels on the first combustion line,
- complete replacement of the grate systems on the second and third combustion lines,
- replacement of worn valves and piping components on all three combustion lines.
Carrying out several extensive work scopes simultaneously required precise planning, effective coordination between the teams and careful preparation for transporting large and heavy components within the confined plant environment.
1. BOILER ROOF TUBE PANEL REPLACEMENT ON THE FIRST COMBUSTION LINE
The scope included the removal and replacement of straight tube panels approximately four metres long, as well as bent tube panels connecting the boiler roof to the front wall.
Due to the size of the components and the limited space inside the plant, a dedicated method had to be developed for dismantling the existing panels and transporting the new sections.
2. REMOVAL OF THE EXISTING TUBE PANELS
The existing panels were cut into smaller sections, allowing them to be removed from the boiler through the available access routes.
The dismantling work was carried out in stages, taking into account restricted access, existing scaffolding and plant components located in the immediate vicinity of the work area.
3. TRANSPORT OF THE NEW TUBE PANELS
The new panels were considerably larger than the sections removed during dismantling and could not be transported through the standard access routes.
The components were first lifted by crane onto the roof of the building. They were then lowered through a roof opening directly into the installation area using electric lifting equipment.
The limited dimensions of the roof opening and the nearby piping runs presented additional challenges. The transport operation required precise sequencing and continuous coordination of the team.
4. RESTORATION OF THE REQUIRED BOILER GEOMETRY
The as-found condition required not only the replacement of the tube panels, but also the correction of the geometry of the upper section of the boiler.
During previous work, some of the required dimensions, diagonals and slopes had not been maintained. The PRO-Welding Industry Services team therefore had to prepare the installation so that the correct alignment of the structure could be restored in accordance with the design requirements.
The new tube panels were:
- correctly positioned and levelled,
- fitted to the existing boiler structure,
- installed without forcing the components into position,
- prepared for welding without introducing undesirable installation stresses.
Before the welded joints were made, the alignment of the individual sections was inspected and approved by the plant representatives responsible for boiler supervision.
After completion of the installation, the required dimensions, diagonals and slopes of the entire tube panel assembly were achieved.
COMPLETE REPLACEMENT OF THE GRATE SYSTEMS ON THE SECOND AND THIRD COMBUSTION LINES
The second major scope of the project involved the complete replacement of the boiler grate systems on the second and third combustion lines.
The work covered the complete grate assemblies, including:
- components forming the working surface of the grates,
- structural shafts,
- casing beams,
- drive system components,
- mechanisms responsible for the correct operation of the grates.
Selected mechanical components, including actuators, bearings and gearboxes, underwent refurbishment and modernization work.
1. REMOVAL OF WORN GRATE COMPONENTS
The work began with the dismantling of the existing, worn components. Due to their considerable weight and transport constraints, the components were divided into smaller sections and removed in stages.
Each transport operation required advance preparation, proper securing of the load, and close coordination between the fitters, equipment operators and site supervisors.
2. TRANSPORT OF NEW COMPONENTS THROUGH THE WASTE FEED SYSTEM
Moving the new components into the plant was more demanding, as some of them had to be transported in one piece.
Due to restricted access, a transport route through the waste feed system leading directly to the grate area was used.
The transport operations were carried out using:
- a telehandler,
- forklift trucks,
- hoists and lifting equipment,
- equipment available on site.
Once the components had been delivered to the designated area, they were positioned, aligned and installed.
REPLACEMENT OF VALVES AND PIPING COMPONENTS ON ALL THREE COMBUSTION LINES
The third scope of work, carried out on all three combustion lines, involved the replacement of worn valves and piping components.
The replaced components included:
- valves,
- flanged connections,
- inspection nozzles,
- selected piping components and sections,
- other components required for the correct operation of the boiler systems.
Installation and welding work on the valves and piping was carried out in parallel with the replacement of the boiler roof tube panels and the work on the grate systems.
50-PERSON PRO-WELDING INDUSTRY SERVICES TEAM
Due to the scale of the project and the simultaneous execution of work on three combustion lines, a 50-person PRO-Welding Industry Services team was assigned to the project.
The team included:
- welders,
- fitters,
- site supervisors and work coordinators.
The division of responsibilities between the individual teams enabled dismantling, transport, installation and welding work to be carried out simultaneously in several areas of the plant.
Continuous coordination of the operations and work sequence was essential, as some activities were performed in confined spaces, close to existing installations and under elevated-temperature conditions.
QUALITY CONTROL AND PROJECT COMPLETION
After completion of the welded joints, the required inspections and non-destructive testing were carried out, including:
- radiographic testing (RT),
- penetrant testing (PT).
The inspections were completed with positive results. Final acceptance of the completed work allowed the boiler to be restarted within the planned schedule.
All three work scopes were completed in accordance with the project schedule, despite the simultaneous execution of activities, restricted installation space and the need to transport heavy and oversized components through non-standard access routes.
PROJECT SUMMARY
Location: Vienna, Austria
Type of facility: waste-to-energy plant
Number of combustion lines covered by the project: 3
Team: 50 specialists, including welders, fitters and site supervisors
Scope: boiler roof tube panels, grate systems, valves and piping
NDT: RT and PT
Nature of the work: dismantling, transport, installation, welding and coordination of multiple simultaneous work scopes
LOOKING FOR A TEAM FOR AN INDUSTRIAL PLANT OVERHAUL OR MODERNIZATION?
PRO-Welding Industry Services carries out installation, welding and overhaul work on industrial boilers, piping systems, pressure parts and process equipment.
We provide experienced teams of welders, fitters and site supervisors, prepared to deliver complex industrial projects and shutdown works across Europe and worldwide.
BUSINESS ENQUIRIES AND COOPERATION
- a.cieslik@pro-welding.eu
- k.doniec@pro-welding.eu
OFFICE HOURS
- Mon–Fri: 8:00–16:00
- office@pro-welding.eu
URGENT TEAM MOBILIZATION
For urgent requirements involving a welding and installation team, please contact:
+48 666 664 469
+48 666 663 916