Chemical Plant Piping System
Custom HDPE electrofusion fittings and corrosion-resistant piping for a chemical processing facility in Bangkok, Thailand
Project Overview
A major chemical processing facility in Bangkok’s industrial corridor required a comprehensive piping system upgrade to handle aggressive chemical solutions used in the production of specialty chemicals and intermediates. The plant’s existing carbon steel and stainless steel piping was experiencing severe corrosion within 6-12 months of installation, leading to frequent shutdowns for repairs, product contamination risks, and escalating maintenance costs that were impacting the facility’s competitiveness.
The plant management decided to replace the entire process piping network with a corrosion-resistant alternative that could provide reliable long-term service. Following a detailed technical evaluation of available materials, HDPE was selected for its proven chemical resistance, cost-effectiveness, and ease of installation.
Challenge
The piping system needed to resist attack from a wide range of chemicals including sulfuric acid, hydrochloric acid, sodium hydroxide, and various organic solvents at concentrations up to 30% and operating temperatures reaching 60°C. The system also had to maintain integrity under variable pressure conditions and withstand occasional cleaning cycles with steam and chemical sanitizers.
The installation had to be completed within a tight 4-week shutdown window, requiring efficient project planning and rapid on-site execution without compromising joint quality. The system also needed to accommodate future modifications as production processes evolved.
Solution
WorldLink engineered a custom HDPE piping system using chemically resistant PE100 material with electrofusion fittings for the majority of connections. The electrofusion jointing method was chosen for its consistency and reliability, with each joint having built-in quality indicators through the fusion bar code system. Custom flange adapters were manufactured to interface with existing equipment and valve assemblies.
For sections handling the most aggressive chemicals at elevated temperatures, a higher wall thickness was specified to provide additional corrosion allowance. The complete system was designed and prefabricated in modular sections to minimize on-site work during the shutdown period.
Specifications
| Parameter | Value |
|---|---|
| Product | HDPE Electrofusion Fittings & Pipes |
| Size Range | DN 50mm – DN 200mm |
| Grade | PE100 (chemical resistant) |
| Max Operating Temp | 60°C |
| Application | Chemical processing |
| Location | Bangkok, Thailand |
| Year | 2023 |
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