Highly corrosion resistant piping systems
Precision piping solution for the world’s largest diesel-electric icebreaker: Oden
To the customized solutions To our references The advantages of PETechnical implementation, ecological & economical aspects
As part of this project, a complete replacement of the existing corrosion-prone steel pipe system on board the icebreaker Oden was commissioned. The customer placed high demands on both the technical implementation and the ecological and economic aspects of the solution.
Project scope
- 2000 h
- Offer: January 2023
- Order: March 2023
- Installation: April to June 2024
The icebreaker Oden in the port of Landskrona, Sweden (STAR Piping Systems GmbH, 2024)
Technical requirements
The main technical challenge was to replace the old piping system under confined structural conditions and within the existing ship design. Due to the high system complexity and the requirements for pressure resistance and flow rate, precise planning and execution were essential. A customized piping system made of highpressure polyethylene (HDPE) was used, which ensures both mechanical strength and permanent tightness. This material enabled a corrosion-free, durable and reliable solution - especially in view of maritime operating conditions.
Ecological and economic objectives
One of the customer‘s main concerns was to implement a future-proof, low-maintenance system. The decision to use a corrosionfree HDPE system helps to minimize future maintenance costs and contributes to sustainable use over an extended service life of up to 100 years. In addition, the smooth inner surfaces of the plastic pipes improve the energy efficiency of the overall system, as they reduce pressure losses and thus lower the energy required to transport media. Compared to a costly repair or complete replacement with a new metal system, the chosen solution also proved to be much more economical.
Custom piping solutions under pressure, space & time limits
During the course of the project, a variety of challenges arose that required close coordination between all parties involved as well as a high degree of technical flexibility.
Narrow interior of the ship with specially designed parts (STAR Piping Systems GmbH, 2024)
Planning and construction challenges
The switch from a metal system to a plastic pipe system entailed complex planning tasks. In particular, extensive feasibility studies and hydraulic calculations were required to ensure technical feasibility. The limited space on board restricted the use of standardized planning specifications and made customized solutions necessary. In addition, several adjustments had to be made during the course of the project and coordinated with the relevant authorities, which made it necessary to involve all approval bodies at an early stage.
The structural implementation posed a logistical challenge, particularly due to the limited space on board. The transport and installation of pipes with a diameter of up to d 1000 mm required specialized processes and detailed preliminary planning. In general, particular attention was given to the conversion and the installation of the fittings, as the jet thruster system plays a critical role in the vessel’s maneuverability during operations and must perform flawlessly at all times.
Organizational aspects
On an organizational level, the project was characterized by high time pressure, as the ship could only be taken out of active operation for a very limited period of time. This made precise coordination of all trades as well as close and transparent communication between suppliers, technical teams and the operator essential.
The smooth cooperation of project participants was crucial in order to meet the tight schedule and ensure the quality of the implementation.
A resilient piping solution
Custom PE parts & expert support for maritime performance
To successfully implement the project, we developed and supplied technically sophisticated and individually produced PE fittings. The piping system was specially constructed for high pressures and flow rates in maritime applications and meets the highest requirements in terms of mechanical strength and operational safety. In addition, the prefabrication of the piping systems has led to a considerable reduction in installation time on site.
- 4th segment with reduced Tee d 1,000/110 mm
- Pressure class conform
- With special valve flange DN 1.000/d 1.000 mm short spigot
- With EPDM-O-ring gasket and backing ring steel plastic coated
- Sealing surface side machined on the inside
- Pressure class conform
- Passage extended on both sides for
electrofusion coupler - Outlet with short spigot and backed loose flange PP/steel - PN 10 drilled
- Short spigot
- With EPDM-O-ring gasket and backing ring steel plastic coated
- Sealing surface side machined inside to
di = 991 mm
Customized branch ready for transportation (STAR Piping Systems GmbH, 2024)
Customized branch ready to be installed (STAR Piping Systems GmbH, 2024)
PE: a future-proof alternative to materials such as steel or cast iron
No corrosion
and low maintenance
Ideal for maritime and saltwater use.
Durability
up to 100 years
Thermoplastic materials such as PE100 and PE100-RC have a significantly longer service life (up to 100 years) than piping systems made of metal or other materials.
Higher
efficiency
Smooth inner surfaces improve flow
& permanently lower energy use.
Significantly
lower weight
Compared to steel, plastic piping systems are significantly lighter, this makes transportation and installation easier and helps to reduce fuel consumption.
Flexibility
during implementation
Customized prefabricated systems enable precise integration - even in tight, complex installation spaces.
In-house
engineering expertise
With our own engineering team, we support projects with technical drawings, 3D models and individual planning – for precise and efficient implementation right from the start.
Comprehensive
project support
For new builds or retrofits, we offer high-performance products and expert advice on the optimal solution.
