Working on Turkey’s energy supply

Located in the densely populated Bosporus area and only about 300 kilometers away from the country’s largest city Istanbul, the station is a strategic pillar in the energy supply of the country. The coal plant complex in the city of Zonguldak consists of 3 coal-fired stations with a total output of 16 TWh annually. Coal is imported via the close port of Eren. Completed in 2016, the complex forms the largest coal-powered power station in Turkey and is licensed to run until 2053.

Working in a tight spot
For its maintenance, the boilers of a coal plant rely on regular and diligent inspection. Each of the four boilers need to be inspected once a year; keeping this downtime as short as possible is of course essence. In order to allow service personnel to inspect the inlaying pipes that carry the water which in the end heats up and moves the generator, a scaffold needs to be erected. Using three units of the GEDA 300 Z Boiler Hoist to transport all the scaffolding parts, company Mod Industrial Services installed a LAYHER Allround modular scaffold. On the whole, they managed to impress everyone on site: what was projected to take 9 days could be finished in less than 4 days – with 60 people working in 2 shifts. A central aspect of this enormous raise in efficiency was the use of the Boiler Hoist.

Statement from Mr. Cagdas Kayahan – General Manager of Mod Industrial Services
The successful use of the GEDA 300 Z Boiler Hoist in this project was maximized thanks to the exceptional field execution by Mod Industrial Services. From the outset, the team demonstrated precise planning, fast decision-making, and a clear understanding of the challenges posed by confined space work in industrial shutdowns. Working inside a boiler structure measuring 18m x 18m x 65m, the team completed scaffolding operations in a total of 128 hours — 56 hours in the combustion chamber and 72 hours in the SH-RH zones. All scaffolding was installed with great care, supported by detailed static calculations tailored to the confined and vertical geometry of the boiler. In total, 180 tons of Layher Allround material were used. The company’s deep knowledge of modular systems, combined with agile site management, ensured that the advantages of the GEDA hoists were fully leveraged. In high-stakes maintenance projects where every hour counts, such operational excellence sets the benchmark.

GEDA Boiler Hoist – specialised equipment for specialised works
When repairing and maintaining silos, blast furnaces, co-generation plants, boilers, etc., every minute and especially every centimetre of space count, since access is only possible through the small manhole (45 cm diameter). This is precisely where the GEDA 300 Z Boiler Hoist scores: the platform of the material hoist can be completely dismantled. The individual parts fit easily through the manhole provided, allowing the hoist to be brought into the boiler, assembled, and removed after its disassembly in no time. All connection cables are fitted with plug-and-socket elements to ensure easy and fast assembly of the rack and pinion hoist. For added safety, devices such as the safety gear, safety stop with acoustic warning and overload protection are included as a standard. At a load capacity of 300kg and a running speed of 25 m/min, the hoist can be installed up to a height of 100m.