Innovative technology for low-impact penstocks: safety, efficiency, and cost savings
The development of hydroelectric projects in areas with high tourism and environmental value now requires solutions that combine energy efficiency with minimal landscape impact. Idroweld, a company specialized in the design and installation of penstocks, has transformed the industry with its FSSL (Free Standing Steel Lining) system—an innovative technology for installing steel penstocks inside vertical or inclined shafts.
A sustainable solution for local needs
Modernizing existing hydroelectric plants must balance energy upgrades with landscape preservation. The FSSL system eliminates unsightly external penstocks on mountain slopes by integrating them into rock-drilled shafts. This approach significantly reduces visual and environmental impact, increasing project acceptance among local communities.
Efficiency and safety with the FSSL system
While traditional methods require complex welding operations inside shafts, Idroweld’s patented system moves all work above ground. The penstock is assembled and welded on the surface, then lowered into the shaft in a controlled manner using a system of joints and hydraulic cylinders that guide its descent—even in non-perfectly straight shafts.
Key benefits include:
- Enhanced safety (no confined-space work for operators)
- Faster installation
- Adaptability to various geological conditions
- Significant cost optimization
Real-World success: the S. Antonio power plant
The S. Antonio hydroelectric plant upgrade demonstrated the system’s effectiveness. A 520-meter vertical shaft received an 800-ton penstock made of high-strength steel (DN2200, up to 30 mm thick). All MIG/MAG welds underwent 100% ultrasonic testing, ensuring maximum reliability.
Idroweld: expertise for clean energy
Founded in 2005, Idroweld combines engineering expertise with technological innovation, delivering turnkey solutions for hydroelectric projects. From design to maintenance, the company stands out for developing cutting-edge systems like FSSL—one of the most advanced responses to industry challenges today.
