See Our Product Catalogue
July 2022

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.

icon Design and Production Phase

Design of the new pipeline started beginning of 2020.

Challenges which had to be handled during the design phase where the following:

  • The above ground route included a connection to the original 800mm feeding point and 5 existing connection points along the line. These connections alone seriously questioned the project feasibility due to highly complex design, requiring maximum precision of a specification system, including bow segments with unconventional structure, manifolds, transitional manifolds, sleeves, flanges, valves and air release points.
  • Crossing the existing systems and 3 roads.
  • The seawater flowing in the system was at approx. 40°C and 8.2 bar pressure.
  • The system is above ground, hence exposed to environmental conditions which may affect its functionality.
  • Minimize downtime of the cooling system following replacement of the line.

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”.

Further challenges were encountered during production phase, as PE100-RC SDR 7.4 pipes in a diameter 560mm could not be found. “PALAD” (Israeli pipe producer) agreed to manufacture such pipe specifically for this project, enabling the continuation of the manufacturing process.

icon Site Installation Phase

In February 2021, installation begun. The system’s head was delivered and stored in the power station. Installation was carried out at short notice, by several crews working simultaneously for around 48 hours (due to another failure in the underground pipeline which required a rapid change in the project’s schedule and resources).

Installation included dismantling of the existing systems and installing the new system head in 6 different sections.

The system was installed over concrete supports along the entire route, while adapting the execution to the existing situation on site.

Following completion of the assembly the system was activated, at which time temporary shading was performed.

Installation over concrete supports
Installation process

The full operational activity resumed upon activation of the new system, and without any malfunctions.

In accordance with the design, one of the connections performed in the system’s head enables feeding the now repaired old system, to enable its use in case of future needs.


The entire planning process was done
in collaboration between PLASSON, the contractor company and the customer.
There is no doubt that the professionalism and capabilities of PLASSON led to the success of this project.
Project Engineer,