Corrosion proof Fiberpipe pipe systems: solution examples for power plant operators

Fibreglass is on the rise in pipe construction – including in the power supply industry.
Because the material is resistant to smoke gases, heat, chemical and mechanical stress,
lightweight
and advantageous processing characteristics enable fast mounting processes
which also entail price benefits.

The pipes from the fibreglass pipe specialists Fiberpipe from Stolberg (Germany) are manufactured together with worldwide partners and are fully compatible with existing systems due to their ISO dimensions. Customisations are also part of our core business.

The following examples show how fibreglass pipe systems and parts have established themselves in the power supply industry:

The company: gas preheaters were needed for the flue gas desulphurisation plant of the RWE Power hard-coal fired power plant in Ibbenbüren which had existed since 1985. Fiberpipe's customer was Alstom Power Recovery. The hard-coal block uses anthracite coal in the largest molten ash chamber boiler of this construction type in the world.

The task and its solution: from a procedural perspective, it is sensible to heat up the pure gas - thus the smoke gas after cleaning. A gas preheater was constructed for this purpose, which leads the gas flows against one another, whereby the smoke gas cools off and the pure gas heats up. The combustion air from the boiler should flow through pipes which must be resistant up to 160º. The pre-planned detailed engineering was carried out within six weeks.

Together with Alstom and the plant operator, Fiberpipe defined the job specification and the pipe routing. All aspects of the pipe construction were included in a quality assurance concept with subsequent acceptance procedures. The detailed engineering was assumed by Fiberpipe – including the stress analysis, 3D pipe routing, acquisition of the components and turnkey installation of the GRP connection pipes.

The expertise concerning which resins are resistant to high temperatures was brought into the construction proposals by the company. These also considered the structural specifications, pressure, isolation, heat loss, resistance and surface temperature. The glassfibre components, for example, were given a 2.5 mm thick chemical protective layer which ensures an optimum resistance.
All components were prefabricated as much as possible by Fiberpipe. The complex reconstruction was thus reduced to a planned plant downtime of only 48 hours.

The company: Enertec Hameln is a power plant site offering waste incineration, biomass generation and district heating supply. Every year, the plant makes use of 240,000 tonnes of waste, 120,000 tonnes of biomass and creates 110 million kWh of power and 240 million kWh of district heat from this.

The task and its solution: as part of a capacity expansion, the cooling water circuit within the power plant had to be replaced within six weeks. Enertec wanted to use the latest technology for GRP pipes. An external service provider was commissioned with the planning of the capacity expansion and on the basis of its existing cooperation with Enertec, Fiberpipe was the first contact partner for the pipe construction. A detailed test and acceptance procedure was developed with everyone involved. The specifications resulted in a demanding pressure resistance of 4 bars with a simultaneous ring stiffness of a nominal size of SN 10.000. Fiberpipe GmbH fulfilled these requirements with a sand filled, cross-wound pipe. A short reconstruction period of a few days was also specified. In order to avoid laborious laminate connections, Fiberpipe constructed a pipe system that accommodates the longitudinal forces with a locking device.. At the same time, this made the ring stiffness independent from the pressure range. With this innovation, Fiberpipe reduced the assembly time and costs by 80%. Through precise planning, the assembly time and thus the duration of the plant downtime were able to be kept to an absolute minimum. The reconstruction was carried out according to plan within five days in October 2007. Very convenient for the customer: the preparation, delivery and assembly were carried out by a single source as a complete service by Fiberpipe.

The company: at the Voerde site, Evonik Steag operates both of the "West" and "Voerde" anthracite coal power plants. RWE Power AG has a 25% holding in the operating company. The plant's useable current flow is 10,328 gigawatt hours per year. The plant components included two pulverised coal Benson boilers with fluid ash removal (980 t/h each), two pulverised coal Benson boilers with dry ash removal (2160 t/h) and two turbo generators with 350 and 761 megawatts.

The task and its solution: repair materials and replacement pipes are needed at irregular intervals at the power plant site. To avoid having to maintain an individual reserve of particular articles, the operating company entrusted Fiberpipe with providing a 24 hour service. The pipe company was happy to act as an extended warehouse for the operating company. An extensive storage area and fast response times were crucial for this contract – Fiberpipe ensures that all desired products are always available at short notice.

The company: the Ingolstadt power plant of the E.ON-Kraftwerke GmbH is operated with heavy fuel oil. The blocks offer a capacity of 386 megawatts each and are above all used to cover the peak and average loads.

The task and its solution: short notice works are from time to time necessary in the power blocks. Flexibility, the ability to carry out the assembly works in compliance with the highest safety requirements and speed were crucial in the selection of the commissioned service provider. If unforeseen repairs are to be carried out in the flue gas desulphurisation, these must usually be carried out immediately, by ongoing operation and if required with protective equipment. Here Fiberpipe provides a repair service with contractually agreed lead times of up to 24 hours. The standard pipe system from Fiberpipe is designed according to ISO dimensions. In addition to the full compatibility of the various pipe systems, the advantage is the applicability of standard components as supports. The fact that the lightweight GRP pipes also allow a faster assembly and processing than standard pipe systems also saves on time and therefore costs in all works. Fiberpipe also performs a similar service for the Großkraftwerk Mannheim AG.

The company: the Hamon group specialises in heat exchange systems. Hundreds of natural draught cooling towers have been planned and implemented, every year well over hundred forced-air cooled cooling towers and numerous other projects are added. Hamon is a market leader in the area of wet cooling. In addition to the planning and implementation, the company also assumes downstream services.

The task and its solution: during along-term collaboration, Fiberpipe has improved the construction and ease of assembly of the pipes used in the cooling towers for Hamon Thermal Germany, for example, winter closed circular pipelines, which serve the preheating and thus ensure freeze protection, are prefabricated by Fiberpipe by up to 80 %. The custom fit GRP pipe systems were able to reduce assembly times here by 50% . The companies work closely together for the entire piping construction, which ensures short delivery times and a high efficiency.