Gulf Eternit Industries (GEI), a member of the Future Pipe Group (FPG), was a key contributor to the successful implementation of Dubai Aluminium's (Dubal) Condor project.
The $736 million Condor project entailed the construction of Dubal's sixth potline and the installation of an additional 440 MW of power generation capacity.
The Dubai-based GEI was involved in the supply of glass reinforced polyester (GRP) pipes for the onshore, offshore and jacking pipe sections of the expansion project. Also included in GEI's scope of work was the supply of the chlorination injection line and the stormwater drainage pipe system, as well as the piping system for the cooling lines of the steam turbine condensers.
Engineering design - particularly focusing on the jacking pipe - was provided by Dynaflow International, part of the Future Pipe Group since 1989 as a consultant for pipe system design. Dynaflow International has bases in the Netherlands, Dubai and Abu Dhabi. Contractors and consultants involved in the expansion project at Jebel Ali included Mott MacDonald of the UK, Al Futtaim Tarmac and Alstom of France.
Stephen Lewis Jones, area sales manager - industrial of GEI, is enthusiastic about the project, highlighting that the company beat the installation schedule, with the jacking pipe work started in March 1999 and completed in April 1999. Installation of the jacking pipe was completed with the help of Iseki microtunnelling system.
"In fact, the jacking pipe sections of the project are one of the most interesting aspects of the project - they were 2,000 mm in diameter and were designed to withstand an incredible axial thrust load of 730 tonnes - a never-before-accomplished task in the world," according to Jones.
This was made possible by the combination of the expertise of GEI and Iseki. Each of the three lines jacked was 90 m long.
"Both consultants and the contractor relied exclusively on our company," he comments.
Jones is also proud that Gulf Eternit beat off stiff competition for the project from European competitors. "There was stiff competition on pricing and on design criteria and the delivery schedule was of the utmost importance. Our location was clearly an advantage," he says.
"The concern of the end-user (Dubal) was that none of the competition had any experience with this kind of jacking work.
"Phase II of the Condor Project related to the supply and installation of a combined cycle (four gas turbines Frame 9E, 100 MW each) with the necessary auxiliary systems such as the seawater intake, seawater pumping house and the cooling system of the steam turbine condensers.
"GEI supplied 6.5 km of GRP pipes for the onshore and offshore pipes, 2,000 mm in diameter and stiffness classes ranging from 2500 kN/sq m to 10,000 kN/sq m. Also, 12 km of glass reinforced vinylester pipes, for the seawater cooling system, ranging from 150 mm up to 2,000 mm with six bar pressure class and stiffness classes from 2,500 kN/sq m to 10,000 kN/sq m. Double bell couplers and rubber seal lock joints were some of the jointing systems used," he says.
The Future Pipe Group is a leading manufacturer of high-performance anti-corrosive pipe systems for the municipal, petrochemical and industrial markets. The group began production and trading in 1973 and over the course of 27 years, has evolved into a leading provider of fibreglass and thermoplastic pipe systems and technologies.
"The group is dedicated to supporting its clients throughout the Middle East, North Africa, Europe and the Far East. That commitment has produced a comprehensive support system that includes engineering and installation capabilities, and that is supported by a global network of manufacturing plants, sales offices, engineering consultants and representative agents.
"Through its experience, the group and its members have built a reputation for reliability and integrity, two qualities that embody FPG's commitment to excellence," says Jones.
Future Pipe Group has manufacturing plants in Abu Dhabi, Dubai, Egypt, France, Holland, Lebanon, Oman and Qatar; engineering offices in Abu Dhabi, Dubai and Holland, and agents and sales and support offices throughout the Middle East, Europe, the Far East and the US. Plants are under consideration in the US, Malaysia, Saudi Arabia and Kuwait.
