Providing Power Station with a Unique PLASSON Solution

In 2018, a malfunction occurred in the underground pipeline of a power station cooling system located in the southern region of Israel. The pipe was an 800mm PE100 SDR11 pipe.

The repair was carried out by removing a section of the pipeline several meters long and replacing it with a new section which was welded to the system using two 800mm electrofusion couplers. The job was executed around the clock using heavy-duty tools, and the cooling system resumed operation in less than 36 hours from the moment of malfunction detection.

The failed section of pipe was sent for testing at a US located laboratory. Test findings suggested that the reason for failure was related to the structural material of the pipe.

Due to concern for additional failures and the possible consequences of future shutdowns, it was decided to replace the existing buried line with two 560mm Polyethylene above ground lines.

Transition to two lines will enable partial operation of the production site even during specific failure or during maintenance. In addition, design emphasis was given to minimize the damage caused by stopping the cooling system during the transition between the old and new lines.

The pipes chosen to build the system were PE100-RC PN16 SDR11, whereas the fabricated connection accessories to the feeding points will be manufactured from PE100-RC SDR 7.4 pipes, this in order to preserve the system’s ability to withstand a maximum pressure of 16 bar (at 20°C) after fabrication (and factor lowering). Selecting the above material for an above ground line exposed to UV radiation, required placing a shading net 1 meter above the construction.

Upon finalization of the preliminary design, data was delivered to PLASSON’s fabrication department, to examine the feasibility of execution considering PLASSON’s manufacturing capabilities. The detailed design process required full collaboration between PLASSON and the customer. After many hours of sketching and endless changes, the final drawing was submitted for customer approval.

As part of the final design, it was decided to incorporate REINERT-RITZ SF transitional flange adaptors in diameters of 560/20”.