Durability and efficiency were the determining factors behind the choice of PE100 BorSafe™ HE3490-LS from Borealis, a leading provider of chemical and innovative plastics solutions, for renovation of a crucial cooling water circulation system at the world’s two biggest oil shale-fired thermal power plants.
Estonian Energy, referred to locally as “Eesti Energia,” owns and operates the large production facilities at Narva, close to Estonia’s northeast border with Russia. The Narva thermal power plants have a power generating capacity in excess of 2,300MW. Estonia Energy is the leading electrical energy producer in Estonia, one of the largest providers in the Baltic region and an exporter of electricity to the Nordic power market.
Upon discovering extensive pipe corrosion in the system as part of an ongoing improvement programme at Narva, Estonia Energy turned to independent Estonia-based specialist plastic pipe producer Krah Pipes OU to upgrade the approximately 40-year-old steel cooling water pipes. The old pipes did not have a Borealis coating and were not made of Borealis material. Key requirements for the new network, involving two parallel pipelines running from a pumping station to the plants’ turbine room, were safety and the reduced maintenance of leak-free pipes with a minimum 30-year service life. Speed and flexibility of installation were particularly important to avoid significant power generating downtime and major cost penalties.
Borealis’ bimodal HDPE BorSafe HE3490-LS was identified as the pipe material offering the optimum balance of properties to meet the project’s criteria. The high performance PE100 material, classified MRS 10 and on the positive list of the PE100+ Association, exceeds the reference standard for the production of these pipes. It has become the reference material for many industrial pipe and pipe relining projects globally.
BorSafe HE3490-LS offers a wide range of advanced properties including low notch sensitivity. Three installation techniques - open trench, relining, and prefabricated segments for horizontal and vertical bends - were required at Narva because of the complexity of the system, which includes a 30m section beneath a concrete platform supporting 120 tonne transformers. Here electro-fusion welded pipes were pulled through and positioned in the pre-existing metal pipeline.
The consistent quality of BorSafe HE3490-LS allows for easy processing of both straight pipe sections and bends. The PE100 material creates smooth inner pipe surfaces and therefore a lower roughness coefficient than metal. As a result, Krah Pipes was able to produce spiral wound pipes with a reduced inside diameter of 1400mm, compared to the 1580mm of the previous steel pipes whilst maintaining the same flow. A wall thickness of 20mm was used to deliver the necessary ring stiffness to ensure pipe integrity at the weld lines.
The Estonian Energy Narva plant pipe system renovation project commenced in September 2010 and was completed, system-tested and reactivated in November 2010.
“Choosing a material such as BorSafe HE3490-LS with a long track record was essential for the success of the project,” comments Peeter Kirtsi, CEO of Krah Pipes OÜ. “Also, the very good processability of the product contributed to the trouble-free production of the pipes.”
“This successful application of BorSafe HE3490-LS clearly demonstrates how Borealis’ innovation is able to bring value-added benefits to the entire chain: trouble-free production for Krah Pipes OU and excellent end-user performance for Estonian Energy,” adds Jane Toogood, Borealis Vice President Business Unit Pipe. “Such an example is built on our long-standing leadership and dedication to the industry.”
Borealis Business Unit Pipe
Borealis is the leading supplier of advanced polypropylene and polyethylene pipe system solutions. Through the close dialogue with our customers and stakeholders, we have developed a broad and innovative product and service portfolio over the last 50 years. Our applications cover water and gas distribution, waste water and sewage disposal, chemical and industrial pipelines, in-house plumbing and heating as well as pipe systems for oil and gas exploration and transportation. Through our close relationships with our customers and partners we strive to deliver a steady stream of innovative pipe and fittings solutions that add real value for all members in the value chain.
Borealis and Borouge
Borealis is a leading provider of chemical and innovative plastics solutions that create value for society. With sales of EUR 6.3 billion in 2010, customers in over 120 countries, and around 5,100 employees worldwide, Borealis is owned 64% by the International Petroleum Investment Company (IPIC) of Abu Dhabi and 36% by OMV, the leading energy group in the European growth belt. Borealis is headquartered in Vienna, Austria, and has production locations, innovation centres and customer service centres across Europe and the Americas.
Through Borouge, a joint -venture between Borealis and the Abu Dhabi National Oil Company (ADNOC), one of the world’s major oil and gas companies, the company’s footprint reaches out to the Middle East, Asia Pacific, the Indian sub-continent and Africa. Established in 1998, Borouge employs approximately 1,600 people, has customers in more than 50 countries and its headquarters are in Abu Dhabi in the UAE and Singapore.
Building on Borealis’ unique Borstar® technology and their more than 50 years experience in polyolefins, Borealis and Borouge provide innovative, value creating plastics solutions for the infrastructure (pipe systems and power and communication cables), automotive and advanced packaging markets. In addition, Borealis offers a wide range of base chemicals from melamine and fertilizer to phenol and acetone.
Today, Borealis and Borouge have a manufacturing capacity of over 5.4 million tonnes of polyolefins (polyethylene and polypropylene) per year having recently completed a 1.5 million tonne capacity expansion in Abu Dhabi. The Borouge 3 plant expansion will be completed at the end of 2013 with a further capacity of 2.5 million tonnes per year (t/y) being fully operational in mid-2014. The companies continue to invest to ensure that their customers throughout the value chain and across the globe, can always rely on product quality, consistency and security of supply.
Borouge (borouge.com) and Borealis (borealisgroup.com) are committed to the principles of Responsible Care® and proactively contribute to addressing the world’s water and sanitation challenges through their Water for the World™ (waterfortheworld.net) initiative.
BorSafe and Water for the World are trademarks of the Borealis group.
Borstar is a registered trademark of the Borealis group.