Development of metal-free Polyethylene (PE) piping solution for sea water cooling
Client Requirement
EDF sought a pioneering solution to replace its Reactor Sea Water (RSW) cooling pipeline system at Heysham 2 Nuclear Power Station. The new design needed to address safety concerns, particularly the risk of cooling loss that could lead to a reactor trip.
Compliance with nuclear standards, the ability to withstand dynamic effects such as seismic activity, and durability over an extended lifespan were critical. EDF also required the project to be completed within the statutory outage period and deliver significant long-term cost savings.
Our Solution
We worked closely with EDF to develop an innovative solution using polyethylene (PE) piping. Advanced modelling tools were employed to create a 3D walkthrough of the installation, alongside detailed stress analysis using the Caesar II stress analysis package. Potential stresses, displacements, and forces on pipeline supports and tie-ins were carefully evaluated, ensuring the design met all safety and operational requirements.
Strategically placed neoprene bellows were introduced to facilitate the removal of in-line equipment and accommodate thermal growth. These, combined with innovative anchor designs, effectively managed static thrusts while maintaining pipeline pressure. All PE piping supports were designed to meet specific stress and force parameters, ensuring resilience and longevity.
In accordance with recognised codes and standards, we produced detailed construction drawings for EDF’s approval. Procurement, fabrication, and installation were completed within the statutory outage period, meeting all client deadlines. EDF highlighted the system’s unique design, calling it the first of its kind globally.
