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1. Introduction
Most power plants require a circulating water system to transfer the waste heat
generated by steam cycle into the ambient environment. Recently three kinds of pipe
materials have been used widely; these are steel, GRE (Glass Reinforced Epoxy),
and HDPE materials.
HDPE pipe is selected for the Ras Djinet Combined Cycle Power Plant Project to
intake sea water from the intake head located 1 km away shoreline. Ultra large size
of 2500 mm diameter of HDPE pipeline was successfully installed by Daewoo
Engineering & Construction Co., Ltd. through rigorous analysis with respect to design
and installation. A bird's-eye view of the project is shown in Figure 1. This paper
covers the design of HDPE pipeline and the procedures of its installation.
Figure 1. A Birds-Eye View of the project
Intake Pipeline
A Intake Pipeline B
Type
SDR30
SDR26
Material
HDPE
HDPE
Material Grade
PE100
PE100
mm
2500
2500
Service
Pressure Regime
LP
LP
mm
83.3
96.2
bar(g)
5.5
6.4
Design Temperature
40
40
Operating Temperature
24
24
MPa
10
10
Wall Thickness
Design Pressure
Value
Unit
Density
960
kg/m
23
MPa
Elongation at Yield
37
MPa
-4
2.4x10
m/m /C
Poissons Ratio
0.4
10.0
MPa
7.7
MPa
Anchor bolt
Lower concrete collar
15
15
Specific
Gravity
Lateral
Stability
(Vertical)
7.272
14.247
1.251
1.251
Lateral
Stability
(Lateral)
2.485
4.528
Collar
Volume (m3)
6.7
6.7
Unit
m
m
m
m
m
Design Condition
Installation
Hydrotest
10.42
10.42
33.72
34.74
34.66
35.68
10.42
10.42
6
6
Figure 6. Maximum/Mean/Minimum von Mises Stress along Offshore Intake Pipeline Length
When long module HDPE pipes approach to the port, the harbor authority grants
permission to proceed. The harbor tug holds the pipes and the assisting vessels
position and secure them.
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4. Conclusion
There are many advantages to use HDPE pipeline for seawater intake and outfall in
power plant projects. Continuous manufacture of long module has the pipeline more
integrity by reducing the welding joint in the site and contributes saving time requiring
installation.
The engineers should make a careful assessment in design and installation for
HDPE to be installed with no harm and keep safe during its operation. In terms of
design large diameter HDPE pipeline might adopt traditional offshore pipeline
engineering procedures. But on-bottom stability analysis is to be performed most
critically when assessing the pipeline movement underwater. For rigorous approach
the projected area of submerged concrete collar should be considered in calculating
the force caused by currents and waves. These forces are not much small to be
neglected. The connection between lower and upper part of concrete collar is also be
stringently checked because of possibility to breaking and loosening of bolts in the
harsh condition. Daewoo Engineering & Construction Ltd., have been conducting
research about optimizing concrete collar and miscellaneous parts.
In addition to design, the installation of HDPE pipeline should be analyzed and
investigated previously before start up the sinking so that it could be controlled
delicately. The results of simulation could provide information such as what tension
would be required to hold the pipeline to keep the S-shape and to avoid buckling.
These meticulous engineering analyses and controlling performed in the site lead the
pipeline to be finally said installed successfully.
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