Introduction:

The transition from coal to natural gas, and ultimately to green hydrogen, marks a significant milestone in the evolution of energy production at one massive domestic power station. The plant began producing power for entities across six states in the mid-1980s. Now faced with adoption of more modern energy demands, the plant has begun a renewal process aimed at sustainable energy production.

Challenges and Innovations:

Working hand-in-hand with key stakeholders including project engineers, contractors, and owners, ISCO supplied and fused large diameter high density polyethylene (HDPE) pipe and fittings for the project’s re-circulating cooling water loop in addition to supplying Factory Mutual firewater, potable water, and waste water HDPE pipe lines at the plant.

The transition to green hydrogen meant retiring the existing coal-fired units and the integration of natural gas-fueled electricity generating units. Additionally, a comprehensive modernization effort targeted the transmission system, vital for supplying power to a major population base. This forward-thinking approach highlights the plant’s commitment to sustainability and resilience.

Green Hydrogen Integration:

Central to the renewal project is the vision to embrace the use of “green” hydrogen, sourced from renewable energy that extracts hydrogen from water rather than fossil fuels.

After production, “green” hydrogen can be stored for months. The plant will leverage the use of nearby natural salt domes that can store thousands of tons of hydrogen. Engineers will drill over half-a-mile into the ground to access the dozens of salt caverns which are each approximately the size of the Empire State Building. Off-season production and storage of hydrogen will make it easier to keep up with peak season energy demands.

Technical Expertise and Collaboration:

The development of the HDPE re-circulating water loop posed technical challenges, demanding innovative solutions and detailed coordination. ISCO’s team navigated these complexities, offering expertise at every turn.

Notably, the fabrication of specialized HDPE fittings ranging from 24” to 63”, with the largest fittings requiring 63” DR13.5 feedstock to match the pressure rating of the 63” DR17 pipe, exemplifies ISCO’s commitment to craftsmanship and adaptability. Close collaboration with pipe manufacturers and utilization of many of ISCO’s fabrication facilities, including Corsicana, Texas and Kingman, Arizona for production of the large diameter heavy wall fabricated fittings. The project presented some tight delivery requirements, but ISCO was able to prioritize fittings and use multiple facilities to match those requirements.

Execution and Success:

All large diameter HDPE pipes and fittings were installed using ISCO large diameter fusion machines and limited access fusion machines by a team of ISCO fusion technicians. ISCO fusion technicians worked for a period of nine months installing pipes and fittings through some challenging weather conditions prior to the successful hydrotest, validating the integrity and reliability of the infrastructure.

Conclusion:

In conclusion, the transition to sustainable energy at the domestic power station represents innovation and collaboration. By embracing advanced technologies and fostering partnerships, the plant has positioned itself at the forefront of the green energy revolution.