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Installation of the HDPE pipeline with concrete sinker-blocks to sink and secure the pipeline in the sea

By Borouge

  • Material selection is critical when project pipelines are situated in challenging aquatic environments.
  • BorSafe™ polyethylene is lighter and has high resistance to corrosion and abrasion versus traditional materials, offering the lowest life-cycle cost.
  • BorSafe™ polyethylene’s leak-proof welded joints can withstand pipeline movements due to tidal waves without snapping.

India is one of the world’s global manufacturing hubs for the chemicals and petrochemicals sector. The industrial clusters in this sector generate chemical sewage streams that must be adequately treated before discharge into the sea or river. While the proper treatment of chemical sewage streams is important, the pipelines used for transporting sewage are also crucial and should be robust, leak-free, and with a long lifespan to minimize any environmental risks from potential leakage of hazardous effluents.

In April 2019, India’s National Green Tribunal set out strict requirements for plant discharges, which the Supreme Court of India subsequently endorsed in June 2021. These discharge standards are on par or even more stringent than that of many developed nations, sending a clear message that the country is serious about improving the quality of its water bodies.

More than half of India’s chemical industry is currently located in its western state of Gujarat. Borouge, a leading petrochemicals company that provides innovative, value-creating plastic solutions, recently collaborated with Sangir Plastics Pvt Ltd and successfully completed a marine outfall project to install a 12-kilometer long polyethylene effluent pipeline for Gujarat Fluorochemicals Limited (GFL) in Dahej, Gujarat.

Gujarat Fluorochemicals Limited (GFL), an Indian chemicals company producing fluoropolymers, fluoro-specialities, refrigerants, and chemicals, commissioned a project that involved the manufacturing, supplying, and laying of marine outfall polyethylene (PE) pipelines to transport treated industrial effluent from the GFL plant in Dahejinto the sea, which is about 12 kilometers away. The project also involved a polyethylene diffuser at the end of the outfall discharge pipeline, complete with duckbill valves – a check valve or component used to prevent backflow.

Sangir Plastics Pvt Ltd, a leading manufacturer of piping solutions in India, was selected to deliver this project with a marine installation contractor. As a trusted partner, Sangir Plastics chose Borouge’sBorSafe™ HE3490-LS PE100 material for its reliability to accomplish this task, having used the same PE100 pre-compounded raw material successfully in numerous intake and outfall lines projects for the past 17 years.

Borouge is a leading manufacturer of black pre-compounded PE100 raw materials for large diameter High-Density PE (HDPE) pressure pipes and assures its materials can be used for 50 to 100 years of service life. The same materials have been used in many critical marine intake and outfall lines projects for over 20 years in the past, and they continue to operate efficiently.

HDPE pipeline weighed down by concrete sinker blocks in the inter-tidal zone

HDPE pipeline weighed down by concrete sinker blocks in the inter-tidal zone

To meet the challenges of installing and operating in aquatic environments, HDPE is an environmentally sustainable and cost-effective choice for outfall pipelines because of its advantages such as:

  • Lightweight (floats in water) and flexible for ease of installation
  • High resistance to corrosion and abrasion for long-term protection of the environment

Sangir Plastics produced the HDPE pipeline required for this project, which included a nine-kilometer pipeline of 315 millimeters (mm) in diameter, and another three-kilometer pipeline of 280mm in diameter. The last three-kilometer pipeline was installed in the inter-tidal zone – an area where the ocean meets the land between high and low tides.

Due to the extreme tidal situations, the installation of the last three kilometers of pipeline was a major challenge with various hurdles but was eventually successfully completed by Sangir Plastics using a thick pipeline with a Standard Dimension Ratio (SDR) of 9 which is an indication of the high amount of pressure the pipe can handle.

The superior product performance of BorSafe™ HE3490-LS PE100 as well as the expertise and quality assurance offered by Borouge are the reasons Sangir Plastics counts on Borouge as a long-time, trusted partner to succeed in such demanding projects.

Borouge will continue to support the infrastructure industry in India to deliver safe, durable, and reliable piping solutions that create value for the businesses and communities in the country.

About the Contributor

Borouge (a joint venture between ADNOC and Borealis) is a leading petrochemicals company that provides innovative plastics solutions for the energy, infrastructure, mobility, packaging, healthcare, and agriculture industries. Following the fourth world-scale expansion of our integrated polyolefins complex in Ruwais, UAE, Borouge will become the world’s largest single-site polyolefin complex by 2025, with an overall production capacity of 6.4 million tonnes annually.

This case study was published in the annual “Finest-50 Global Case Studies” Special Digital Edition, March-April 2022. Click here to read the complete e-Magazine issue.

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