In the pipeline

A round-up of major suppliers and players in the waste water sector

ANALYSIS, MEP

From water to wastewater and district cooling, piping plays a major role. We look at some of the major players in this vital infrastructure sector.

Abu Dhabi Pipe Factory

The Abu Dhabi Pipe Factory LLC (ADPF) was established in 1981 in technical collaboration with Cord International of France. It is a leading manufacturer of glass-reinforced plastic (GRP) pipes and fittings in the Gulf. It uses dual helical filament winding for core pipes from 25 mm to 2 000 mm, and continuous filament winding for jacket pipes from 250 mm to 3 200 mm.

The factory has a total area of 150 000 m², of which the production area is 40 000 m² (Abu Dhabi and Dubai combined). The production capacity is 50 000 tons of pipes and fittings a year. It has a combined total of nine production lines for dual helical winding and four for continuous winding.

ADPF pre-insulated GRP pipes are used widely in piping networks for district cooling systems. A pre-insulated GRP pipe consists of a core pipe, also called a carrier pipe, and a jacket pipe, also called a casing pipe, with polyurethane foam in the annular space between the pipes. Insulation provides the primary thermal resistance against heat gain in chilled water systems. Normally two pipes are laid in parallel in the same trench to serve as a separate supply and return.

Borouge

Borouge is a leading provider of innovative plastics solutions. Established in 1998 as a joint venture between the Abu Dhabi National Oil Company (ADNOC) and Borealis, a leading European plastics provider, Borouge employs Borstar technology for end-use plastics applications throughout the Middle East, the Asia-Pacific and Africa.

Its petchem complex is located at Ruwais in Abu Dhabi, with a multi-billion dollar expansion due to commence production this year. This will effectively triple existing production capacity to two million tons a year, including – for the first time – polypropylene. Borouge provides a range of differentiated products for high-value infrastructure applications, including water, gas and industrial pipe systems and power and communications cables.

Corys-Hepworth PME LLC

Hepworth PME LLC is the Middle East’s premier manufacturer and supplier of a range of high-quality plastic pipes, fittings and accessories used for the distribution and transmission of water, wastewater and gas. Corys is the holding company. Distributed in Dubai for over 35 years, all products are represented by a chain of offices throughout the area. Hepworth products conform to the highest of international standards used in the region. Its substantial stockholding ensures it is able to consistently satisfy the requirements of the industry.

Hepworth PME offers a range of PVC-U pressure pipes and non-pressure pipes and fittings, PVC and ABS fittings and PP, PP-R, ABS and PE pipes in imperial and metric sizes. Its engineered fittings have been installed on sewerage, water supply, irrigation, fire mains, soil and waste contracts throughout the Middle East. Grease traps, end caps, land drain slotted pipes, long radius bends for street lighting bends, road gulleys, catch basins and sealed dry manholes are just some of the fabricated products from Hepworth PME.

In March 2009, Hepworth PME entered into a joint venture with George Fischer, a global corporation across 130 companies worldwide with 50 production sites (80 companies are based in Europe, 35 in Asia and the Middle East, 12 in America and two in Australia.) The company’s core competency is piping systems, plastic and metal fittings, valves and shut-offs for water, gas and other liquids.

Another recent joint venture is with MDS Meyer GmbH, a German specialist in the production of rubber seals and gaskets. The new company formed under this agreement, Corys MDS LLC, will produce a range of MDS branded rubber gaskets in Dubai. This latest step in the group’s growth will help reduce the high costs of importation and the attendant delays in transportation. It will also help expand its customer base worldwide.

Corys has manufacturing units in Rashidiya in Dubai, Dubai Investment Park and Qatar, as well as fabrication workshops in Sharjah and Abu Dhabi. A new unit is due to open in 2010 that will double the production capacity to accommodate expansion within the UAE and other export markets. Corys employs over 800 staff across all its sites, and offers its customers a range of more than 25 000 products. A fleet of over 50 vehicles permits site delivery within an efficient timeframe.

Production is achieved with the use of European equipment of the highest quality from suppliers such as KraussMeffai, Battenfeld, Weber and Engel, and raw material from suppliers such as Borouge and Sabic. Hepworth PME is an industry leader in installing and integrating the Oracle ERP (Enterprise Resource Planning) system. This automated system allows supply chain excellence, real-time management and communication, and gives Corys a major administrative advantage.

Recently recertified for ISO 9000, Hepworth PME has worked on iconic projects such as The Palm Jumeirah, Burj Khalifa, Burj Al Arab and Atlantis, and is one of only three approved suppliers to Dubai Municipality. It is aiming for ISO 14000 in environment management.

Dubai Pipe Factory

Established in 2001, the Dubai Pipe Factory Company LLC (DPF) is located on a 150 000 m² facility in the Jebel Ali Industrial Area, of which 5 000 m² comprise manufacturing and testing facilities, in addition to storage areas for glass and resin and other consumables. It employs the continuous filament winding process to manufacture a range of GRP pipes, tanks, manholes, fittings and accessories.

DPF is part of the Amiantit group, a leading manufacturer of pipe systems. The group’s pipe systems division comprises almost 30 wholly-owned, majority-owned or joint-venture manufacturing facilities in 18 countries. Using the latest technologies, pipes are produced in a wide variety of materials such as glass reinforced plastic (GRP), glass reinforced epoxy (GRE), thermoplastic (HDPE, PVC and PP), concrete, polymer concrete and ductile iron.

International brands include AmPlas, Amipol, Amipox, Flowtite, Meyer Polycrete, Speedmark, C-Tech, AmiGrip and Vectus. The comprehensive range of Amiantit products includes pipes and accessories for water, sewage, hydro-power, gas, oil services, construction, engineering, municipal, industrial, agricultural and marine applications.

ELIPS

The UAE’s largest pre-insulated pipe manufacturing facility, Empower-Logstor Insulated Pipes Systems (ELIPS), was launched officially in Jebel Ali recently by HRH the Crown Prince of Denmark Frederik Andre Henrik Christian and HH Sheikh Mansoor Bin Mohammed Bin Rashid Al Maktoum.

ELIPS is a joint venture (JV) between Emirates Central Cooling Systems Corporation (Empower), a leading district cooling company in the UAE, and Logstor, the world’s largest manufacturer of pre-insulated pipes. The US$25 million facility will cater to the requirements of the district cooling and oil and gas sectors across the Middle East.

ELIPS will ensure high quality of insulation and casing of pipes, enhancing efficiency and maintenance costs of district cooling services. It will also ensure price control by improving supply chain and eliminating artificial price fluctuations created by various players due to the demand-supply gap, added Bin Shafar.

Logstor has been serving the Gulf region since 1992, and is now marking its commitment to serve the region by establishing an anchored presence with the ELIPS factory. Depending on dimensions and output from 100 to 300 pipe joints a day, the factory will offer job opportunities for a wide range of competences, from operators to highly-skilled engineers.

ELIPS will use spray technology for manufacturing large-diameter pre-insulated pipes, which will ensure high-quality products and also result in savings in raw material costs as compared to traditional injection technology. This technology also enables the JV to enter the oil and gas industry, which is not possible with traditional injections. Currently, only one out of five existing pre-insulated pipe manufacturers are using spray technology.

Future Pipe Industries

The Future Pipe Industries group (FPI) is a global leader in large-diameter fibreglass pipes, developing, manufacturing and supplying systems in over 50 countries. Headquartered in Dubai, it comprises ten factories and a global network of sales offices across four continents, serving customers and end users in a variety of sectors, including, oil and gas, infrastructure and municipal, water distribution, desalination and power, petchem and industrial.

FPI was established in 1984 when Fouad Makhzoumi acquired a stake in Gulf Eternit Industries, the first company in the group. As a manufacturer of a comprehensive portfolio of fibreglass pipe systems, FPI has successfully promoted fibreglass as a substitute for pipe systems based on traditional materials.

Polyester and vinylester based fibreglass reinforced composites (GRP/GRV) offer excellent performance in terms of corrosion resistance and resistance to loads (buried installations) in high pressure and high temperature applications. GRP pips have been used extensively in the desalination and power industries (salt water systems, intake and discharge/outfall, cooling water systems, flue gas desulphurization and utility piping), water distribution and municipal/infrastructure applications (storm and surface drainage, sewer and district cooling and heating.)

Saudi Pipe Systems

Saudi Pipe Systems Company is based in Jeddah in Saudi Arabia, and manufactures valves, cast iron and ductile iron fittings, GRP and HDPE pipes and pre-insulated pipes and fittings. PE100, considered the most heavy-duty among polyethylene pipes, is ideal for water and gas mains due to its maximum working pressure. It has enhanced toughness, higher permissible design strength and improved resistance to crack propagation. High-density polyethylene pipes (HDPE) offer the water engineer substantial benefits in performance. PE100 pipes are used in various applications, including sewage pumping mains, fire mains and chilled water. Pipes are manufactured in diameters from 25 mm to 3 000 mm.

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