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BorPipe. 40th Indian Water Works Association Convention in Indore. Borouge Launches Water for the World initiative in the Middle East

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A Borouge newsletter for the pipe industry BorPipe Issue 8, March 2008 Borouge Launches Water for the World initiative in the Middle East 40th Indian Water Works Association Convention
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A Borouge newsletter for the pipe industry BorPipe Issue 8, March 2008 Borouge Launches Water for the World initiative in the Middle East 40th Indian Water Works Association Convention in Indore It s a record pull for PE in New Zealand! Beta PP Industrial Piping Systems Solve Corrosion Problem MEMBER OF BorPipe Editor's Note Welcome to the first issue of BorPipe in I trust you have all had a good start to the year and have identified many new polyethylene pipe projects for Here in Borouge, we have finalized our organizational development in the Marketing organisation. Besides the existing Marketing positions in North East Asia, Indian Sub Continent and Middle East Africa, we welcome Robin Bresser, Marketing Manager Pipe, located in Singapore for South East Asia and Australia/New Zealand, and Peter Hayes as Value Chain Manager, located in Abu Dhabi Early in January, the Water for the World programme was formally launched in the Middle East at the 11th GCC Industrialists Conference by the new CEO of Abu Dhabi Polymers, Mr Abdulaziz Al Hajri. The GCC Industrialists Conference is a high level conference which is organised in one of the GCC countries every two years. Representatives of the Ministries of Industries of all of the GCC states participated in the event. One of the important partnerships in the Water for the World programme is our involvement in Water and Sanitation to the Urban Poor (WSUP), which is an organisation dedicated to the provision of water, sanitation and hygiene services to the urban poor around some of the major cities in the world. Recently the organisation received a major boost in the form of a US$11.3 million grant from the Bill & Melinda Gates Foundation. This funding from this grant will be used to assist local water and sanitation providers in Mozambique and Madagascar to provide services to a total of 340,000 people. Sometimes living here in Singapore, it is difficult to grasp the full significance of the world water crisis, as good quality water is available from the tap But this was not always the case, as in the 1960 s, water was so scarce that it was rationed. This transformation has been due to the good water management by the Public Utilities Board (PUB) which has been so effective that in 2007, they were awarded the Stockholm Water Prize for adopting innovative ways to solve the crisis. At the recent Indian Water Works Association Convention, Mr. Moh Wung Hee, one of the directors of PUB, stated that most countries don t take water demand and supply seriously. In Singapore, PUB have taken it seriously and they now harvest 50% of the rainwater and have a large wastewater recycling facility using state of the art technology for more information see There is also some good news on the global front, as recent data shows that from 1990 to 2004, the proportion of people who have access to improved water supply has risen from 78% to 83%. This means that the lives of an additional 1,228 million people around the world are benefiting from the considerable efforts that have been made but so much more still needs to done. It is worth remembering that the water industry is worth US$ 260 billion globally. It provides the world s greatest business opportunities and is the 21st century s equivalent to the oil industry. Countries and cities across the globe are actively seeking solutions for their water and environmental water management needs and many of these solutions involve plastic products (pipes, films and mouldings). André van Uffelt Vice President Business Unit Pipe Contents 3 Borouge Launches Water for the World initiative in the Middle East 4 It s a record pull for PE in New Zealand! 5 New PE pipeline replaces leaking iron pipe in Yemen 6 WSUP projects receive a major boost from the Bill & Melinda Gates Foundation 7 WBCSD highlight the water crisis 8 Water Conference highlights the need for innovation to solve the deficiencies in Indian water supplies 9 Plastics Pipes XIV on course to be the most successful yet! 10 Beta PP Industrial Piping Systems Solve Corrosion Problem 11 New International Standard for PE Water Pipes Calendar of Pipe Events Borouge Launches Water for the World initiative in the Middle East Borouge publicly launched its Water for the World in the Middle East at the GCC 11th Industrialists Conference in Abu Dhabi, UAE in January. During the opening session, Mr. Abdulaziz Al Hajri, CEO of Abu Dhabi Polymers, which is the Borouge polyolefin production company based in Abu Dhabi, stated The challenge is not about finding more water; it is about using and preserving it. We are proud to launch this pioneering effort in our industry to make a difference in the Middle East. Water for the World leverages the expertise that both Borouge and Borealis have strongly built in the Middle East, Asia and in Europe. Together with our partners from around the world we will foster local knowledge and partnerships throughout the value chain to provide sustainable solutions for the availability of safe water and sanitation. During the accompanying press conference Mr Harald Hammer, CEO of Borouge Pte stated: Addressing the global water challenges is a strategic commitment for Borouge and requires new longlasting and sustainable solutions, such as our BorSafe grade for pipe systems. The GCC Industrialists Conference is a high level conference which is organised in one of the GCC countries every two years. Representatives of the Ministries of Industries of all of the GCC states participated in the event. The theme of this year was the Petrochemical Sector - A Vision for As the representative of the local polyolefin business Borouge also outlined their expansion plans in Abu Dhabi including the development of a Polyolefin Innovation Centre and the Gulf Plastics Pipes Academy. Borouge, who was a diamond sponsor of the conference, also had an exhibition stand where they displayed many innovative products produced from polyolefin materials including a short length of the 1600mm polyethylene cooling water supply pipe for the new Borouge plant at Ruwais, Abu Dhabi. 3 BorPipe It s a record pull for PE in New Zealand! The 1000mm polyethylene pipe in position under the Whanganui River By relining an existing 1200mm concrete pipe under the Whanganui River with PE, $2.5 million is saved and the river water quality improved. The Whanganui is New Zealand s third longest river and originates high on the volcanic plateau of the North Island and drains into the Tasman Sea adjacent to the city of Wanganui, some 290km downstream. Like many cities the sewage system of Wanganui developed in a piecemeal fashion as the settlement grew. There was no separation of the storm water from the sewage and there was little regard to the effects of untreated outflows discharging directly into the river. Therefore by the end of the 1990 s it was clear that a major upgrade was necessary to reduce leakage and infiltration of the sewers and improve the quality of river water. In 2002 Wanganui City Council developed a scheme to separate storm water from sewage and to eliminate the outfalls into the river in favour of a 18km sea outfall off nearby South Beach. This outfall would be served by a pumping station on the city side of the river. Allied to this plan was 4 the design and construction of an interceptor main to convey screened sewage and tradewaste to a new treatment plant prior to discharge into the sea. One of the major problems was that the new treatment plant was on the other side of the river from the existing pumping station. Although there was a 1200mm diameter concrete pipe under the river this could not take the design pressure and therefore they were faced with three options; build an additional pumping station, upgrade the current submarine pipe or build a new one. After a feasibility study it was decided that the most cost effective solution was to insert a 600m long 1,000mm diameter polyethylene pipe inside the concrete pipe. Undoubtedly there would be some challenges as the total weight of the pipe would be 116 tonnes which could result in a high pulling force and the insertion was complicated by the presence of four bends in the host pipe. However if these problems could be overcome it would save the city $2.5 million. The 1000x58mm pipe was manufactured by Tyco Flow Control using BorSafe HE3490-LS from Borouge. The low sag properties of the material meant that the wall thickness distribution of the pipe could be easily controlled whilst maintaining a good output rate from the extruder. In addition the high resistance to slow crack growth means that any damage during installation will not lead to a propagating crack. The insertion of the pipe took place in April 2007 and went without a hitch. Because the PE pipe floated in the flooded host pipe the pulling forces were significantly lower than expected. The complete network including the new treatment plant was commissioned in July and today it transports 32,000m3 of wastewater every day which has lead to a great improvement in the water quality of the mighty Whanganui River. Borouge would like to acknowledge the cooperation and support from Darryl Mason of Tyco Flow Control, Neil Vanner of Smythe Contractors and Colin Anderson of Inframax. Additional information about the project can be found on the Wanganui District Council website New PE pipeline replaces leaking iron pipe in Yemen Like many coastal regions around the world the soil around the city of Aden in the Republic of Yemen is very corrosive and aggressive to iron pipes, which ultimately leads to their failure and the loss of valuable water. To overcome the water leakage problems the 25km iron water main linking the villages of Khor-Maksar to Beer-Ahmed was recently replaced by a new polyethylene main made from Borsafe HE3490-LS material. This 630mm diameter SDR 17, 10 bar pipeline was produced by the Munir Munif Group for Pipes and Fittings based in Saudi Arabia and shipped to the worksite in Yemen. The corrosion resistant properties and reliability of Borsafe HE3490-LS will provide a long and leak free service for the system operators, the Ministry of Water and Environment in Aden, and the 800,000 inhabitants of the region. 5 BorPipe WSUP projects receive a major boost from the Bill & Melinda Gates Foundation One important part of the Borouge and Borealis Water for the World programme will be our involvement in Water and Sanitation to the Urban Poor (WSUP) who are a group of companies and charities who have joined together to provide water, sanitation and hygiene services to the urban poor around some of the major cities in the world. In the developing world many cities are now termed mega-cities with populations of over 10 million and still more people continue to flow into these cities. In fact every day, over 100,000 people move into cities somewhere in the world, many of them into low income, peri-urban settlements or urban slums. These communities often lack safe and affordable water supply and basic sanitation services. At the same time, local service providers lack the capacity to reach these communities due to the technical, financial and institutional challenges involved. The members of the WSUP pool their expertise relevant to water, sanitation and hygiene and work directly with local service providers and with communities to design, develop and implement effective solutions. The WSUP selects projects based on a clear request for assistance from local authorities and service providers who are motivated and willing to invest in improved services to the urban poor. The organisation was founded in 2005 and has a target to reach 3.5 million 6 people by 2015 with improved water, sanitation and hygiene. A number of projects are now reaching the implementation phase. The Naivasha (Kenya) project is assisting in the provision of improved water, sanitation and hygiene in Mirera- Karagita, an urban community on the outskirts of Naivasha. The Antananarivo (Madagascar) project is working with local government and the water utility to extend service provision to the peri-urban areas of the city. In Bangalore (India), work is underway in three slums in the city to test community managed models of water and sanitation service provision together with hygiene promotion, The Maputo (Mozambique) project aims to assist the local service provider and the municipality to improve services in low income wards of the city. Recently the programme has received a major boost thanks to an US$11.3 million grant awarded to Water and Sanitation for the Urban Poor (WSUP) by the Bill & Melinda Gates Foundation. This funding from this grant will be used to assist local water and sanitation providers in Mozambique and Madagascar to provide services to a total of 340,000 people. The local service providers will build capacity to serve the poor and to sustain and expand these services by strengthening links with poor communities, regulators and other key stakeholders. The grant will also support early stage project development in two other countries, together with an environmental management component. The grant is being made by the Global Development Program of the Bill & Melinda Gates Foundation. The Global Development Program works with motivated partners to create opportunities for people to lift themselves out of poverty and hunger. WBCSD highlight the water crisis The World Business Council for Sustainable Development (WBCSD) have devoted the whole of the latest issue of their Sustain magazine to the water crisis. In the opening article entitled No water no business they trace the WBCSD s involvement in water over the last 10 years. Many of the earlier publications were around fact finding and awareness but in more recent years this has developed into spreading best practice and the development of practical tools like the Global Water Tool. Also in this addition are a number of examples of what member companies are doing in the water area including an article of Borealis and Borouge s Water for the World programme. For your copy of the WBCSD s Sustain Magazine go to 7 BorPipe Water Conference highlights the need for innovation to solve the deficiencies in Indian water supplies At the opening of the 40th Indian Water Works Association Convention in Indore, Dr. Sam Godfrey of UNICEF set the scene by stating You need fresh thinking to get fresh water. The current boom in Indian industry means that the natural resources are being depleted at a fast pace. Water being the most important renewable resource for industry as well as domestic and agricultural use is on high demand. This will inevitably lead to conflict unless industries understand their water footprint and consider water recycling and reuse as part of their social responsibility for sustainable growth. One of the major issues at the conference concerned the contamination of the existing water reserves in many parts of India. In Rajasthan for example where the population largely depend upon groundwater supplies many of the sources are severely contaminated with fluoride and nitrates. This has lead to serious health problems in a number of villages in the region and in order to reduce this health hazard more rainwater harvesting schemes were recommended together with a change in the local agricultural practices. At the same conference Chanchal Dasgupta of Borouge India presented a paper on the whole life costing of large diameter PE water projects to 8 Plastics Pipes XIV on course to be the most successful yet! Following the very successful Plastics Pipes XIII Conference in Washington in 2006 attended by 450 delegates from 35 countries the organisers of the XIV Pipes Conference are confident this year s event to be the largest ever. The conference brings together the global plastic pipe community and will be held from September 2008 at the Marriott Hotel in Budapest. Plastic pipe systems are making important inroads in Central Eastern Europe. Frank Jones, director of the BPF Plastic Pipes Group in the UK explains: This year s premier conference takes place at a turning point for the industry and especially for the region. The pace of plastics conversion is now accelerating in every application and on every continent. The reasons are clear: the poor legacy of competitive pipe materials, concern for climate change and attendant water shortage and surfeit coupled with a wider appreciation for the benefits of plastic pipe systems. The three-day schedule will comprise the presentation of about ninety papers, a trade exhibition and a social programme. There will be many papers from other parts of the world including a number of presentations from the Borouge team and their customers. In all as many as 600 participants are expected. clearly demonstrate that plastics provide best solutions for today s and tomorrows water networks. Water engineers in Europe have found from practical experience that the practical benefits offered by PE pipes out way those of other materials. For example the cost advantage of new innovative installation techniques. Technical information will not be the only resource on offer: communication will also be a valuable medium. Zoran Davidovski, Vice President Marketing of Pipelife and Chairman of the Organising Committee comments: The conference is always an ideal meeting place for delegates and the latest ideas from utility companies, technical and certification institutes, plastic pipe companies, equipment manufacturers, compound makers and other suppliers. So make sure that that you put the dates in your diary now. For more information and registration: Plastic Pipes XIV is organised by TEPPFA, PE Association, PVC4Pipes and the Plastics Pipe Institute. 9 BorPipe Beta PP Industrial Piping Systems Solve Corrosion Problem Acid circulation pump assembly Inlet and outlet pipes from the electrolysis cells Hindustan Zinc Ltd is the leading producer of zinc in India and the third largest in the world. They were established in 1966 and more recently became part of the Vedanta Group of companies, a group with an annual turnover of $7 billion. As a company they are dedicated to growth through constant innovation, meticulous attention to detail and they continue to make extensive investments in R&D and new technology. In their plant they handle many nasty substances including abrasive slurries and acids at high temperatures (50 C to 90 C) in their process pipelines. Since these conditions would quickly destroy steel pipes they had tried a number of other non metallic alternatives before finally selecting polypropylene. For many years they had used glass fibre reinforced pipes (GRP) but the inner surfaces of the pipes rapidly deteriorated under the abrasive action of the slurries which encouraged deposits to build up until they blocked the pipe work. Clearing the blockages with crow bars tended to crack the pipes which meant they then had to be replaced. They tried HDPE pipes which had a very good resistance to corrosion but were not suitable for operation above 60 C and so could only be used in certain parts of the system. Some chlorinated PVC pipes were also tried but these were expensive and only available in small sizes. The low impact resistance of the CPVC pipe also made them vulnerable to impact damage when clearing blockages. In the end pipes produced from Borealis beta nucleated polypropylene PP (grade BE ) proved to be the best solution. The beta nucleation increases the materials performance at high temperatures and its resistance to a wide range of acids and other chemicals and is therefore ideal foe harsh industrial environments. In addition to the better performance the total installed cost of the PP system was 18% lower that the GRP system and a staggering 40% less than the CPVC system. The material supplied by Borouge India was converted into pipes by Sangir Plastics Pte Ltd. In the first phase in 2003 over 2000 metres of pipe were
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