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Cost Effective One-Stop-Shop CRA Solutions

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Page 1: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

Cost EffectiveOne-Stop-ShopCRA Solutions

Page 2: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

Corrosion Resistant Alloy specialist

World’s largest supplier of CRA weld overlay

Global leader in supply of CRA Mechanically Lined Pipe (MLP)

One-Stop-Shop CRA capability: Pipe, Fittings, Induction Bends, Pressure

Vessels, Spools and Valves

Manufacturing facilities in Indonesia (Batam Island), Brazil and Saudi

Arabia*

Cost effective locations with excellent global logistics

Over 800 employees

Outstanding safety performance

API5LD, API5LC, API 6A-1877, API 6D-1694, ASME U, U2 & R and

ISO9001 accreditation

ABOUT US

* From Q1 2017

Page 3: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

VISION and MISSION

Vision

Our Vision is to be the world’s leadingsupplier of Corrosion ResistantAlloy clad and lined products.

Mission

Our Mission is to understand ourcustomers needs and provide themwith cost effective and reliable CRAsolutions using innovative technologyand methods which put us at theforefront of our industry.

Page 4: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

SAFETY PERFORMANCE

0

0.5

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1.5

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3.5

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4.5

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2011 2012 2013 2014 2015 2016

Safety - Key Lag Indicators

LTIFR Industry Benchmark

TRIFR - Actual

LTIFR - Actual

Target = 0

Page 5: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

EXPERIENCE - SUMMARYTotal CRA Pipe Produced 308 km

Total Mechanically Lined Pipe 213 kmTotal WO Clad Pipe 95 kmTotal WO Clad Bends 2300+ Induction BendsTotal WO Clad Fittings 44,000+ Items Total CRA Clad Pipe Spools 5300+ Spools fabricated

Mechanically Lined 625 20 kmMechanically Lined 825 143 kmMechanically Lined 316L / Duplex 50 km

Page 6: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

GLOBAL TRACK RECORD

Page 7: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

PRODUCTS

CRA Mechanically Lined Pipes (MLP)

CRA Weld Overlay Clad Pipes, Fittings and Flanges

CRA Clad Spools & Pressure Vessels

CRA Clad Valves

Induction Bends

Seam Welded CRA Pipes

Page 8: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

MECHANICALLY LINED CRA PIPES

The Ultimate Flow-Line Solution

Low Risk – High Reliability

Passive corrosion resistance

Fast Production time

Patented process

CS carrier pipe up to X80 for strength

Rolled and longitudinally welded CRA liner of 2.5 - 11mm thickness

Various liner options available including: 316L, 317LN, 904L,6Mo, Alloy

825, Alloy 625

Pipe diameters of 4” – 26” from current facility in 6,12 or 24m lengths

Technology tested up to 42” diameter pipe size.

Qualified for HP/HT Lateral Buckling and Dynamic Service

Match bored weld overlaid ends for faster offshore installation

Page 9: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

CLADTEK MLP - ADVANTAGES

Cladtek is the only supplier offering metallurgically clad ends as standard: Hot wire GTAW/TIG overlay Improved AUT clarity during welding Weld overmatching

Cladtek guarantees superior ID and OOR tolerances through machining: +/- 0.5mm ID tolerance, rapid fit-up and superior fatigue performance 1mm maximum on OOR

Cladtek patented process uses CNC dynamic expansion control: Operates only within elastic range of CS carrier pipe and with no change

to dimensions or mechanical properties of the carrier pipe, Superior collapse resistance.

Suitable for SMLS, SAW, ERW, HFW and HFI outer pipe Only manufacturer with installed DNV F101 HFW/HFI clad pipe reference Qualified for HP/HT Lateral Buckling Service Qualified for Dynamic Service

Page 10: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

CRA WELD OVERLAY CLAD PIPES

Largest weld overlay capacity in the world

Highly reliable processes and equipment

Extensive non destructive testing regime

EC, UT, RT, DP

Innovative automatic inspection technology

Laser End Measurement System

CS carrier pipe up to X80 for strength

Wide range of overlay materials available:

3-400 Grade SS, Alloy 400, Alloy 825, Alloy 625, Stellite

6” to beyond 60” sizes in 12m lengths

Sizes < 6” can be produced, but in lengths less than 12m.

Page 11: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

CRA WELD OVERLAY CLAD FITTINGS

Vertical and Horizontal cladding equipment

Jigs to suit full range of sizes and fittings

Capability includes:

Elbows, Tees, End Caps, Flanges

Special Fittings and Valve Bodies

Barred Tee fabrication

Base material fittings can be supplied by Cladtek or Free Issue

Wide range of overlay materials available including:

3-400 Grade SS, Alloy 400, Alloy 825, Alloy 625, Stellite

Full machining capability to assure final dimensional tolerances and finish

API certified

Page 12: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

CRA CLAD PRESSURE VESSELS

Specialist in CRA Clad products

One-stop-shop CRA clad solutions including:

Pressure vessel design and fabrication

CRA cladding of nozzles and other components

Associated CRA clad piping and spools

New or replacement pressure vessels

ASME U, U2 and R stamp available

Highly reliable weld overlay production process

Wide range of cladding material options available

CS wall thickness up to 100mm

Page 13: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

INDUCTION BENDING

In-house facility in Brazil: 2” - 16” range

Batam facility in Batam: 6” - 36” range

Bend Radius: 1.5D – 10D

Wall Thickness: Up to 60mm

Material: Carbon Steel, CRA Clad, Stainless

Steel including Duplex & Super Duplex

API-6A Furnace:

Full heat treatment capability

Extensive procedures available

Capability to produce 3D and 5D bends

Experience based on supply of over 2000 bends to date

Page 14: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

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CRA CLAD VALVES

Specialist in CRA cladding technology Range of valve types and options available for surface and

subsea applications including special designs Trunnion Mounted Ball Type

Side Entry, Top Entry, Compact and Two-Block Floating Ball Type

Split Body, Top Entry, Compact and Two-Block API 6A – 1877 and API 6D – 1694 Certified Fire Safe API 6FA - API 607 – ISO 14097 Various CRA Clad material options Conform to NACE MR0175 Engineered for Sour Service, Extremely Corrosive Environment,

High Temperature, (up to 700°C) plus High-Pressure (rating up to API 15000) applications

Pipelines, Refineries, Power Plants & Desalination Plants

TWO-BLOCK BODY

TOP ENTRY BODY

Page 15: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

SEAM WELDED CRA PIPES

Rolled and longitudinal seam welded to API5LC

Wall thickness up to 15mm

Materials

300 and 400 Series Stainless Steels

Duplex (2205) & Super Duplex (2507)

904L (UNS N08904)

6 Mo (254 SMO, AL6XN)

Alloy 825 (UNS N08825)

Alloy 625 (UNS N06625)

Page 16: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

SERVICES

CRA Clad Fabrication

Testing and Simulation Services

Page 17: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

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CRA CLAD FABRICATION

Full range service for CRA clad pipe fabrication and related products

Includes pipe spool fabrication, through induction bending to complete manifolds and other subsea structures that incorporate CRA clad piping.

Highly skilled team with extensive CRA experience

For Onshore, Topsides, or Subsea applications

Scope of services covers:

CRA piping and related structural and E&I

Machining of components and products

Fitting, welding, and hydrotesting

NDE including PMI, DPT, UT, AUT, and RT

Coatings including painting and TSA

Full documentation and traceability

Page 18: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

2 point and 4 point bend test facility forLateral Buckling, Installation by reellay (including formers to suit common carousel diameters), Installation by S-lay and J-Lay and Fatigue Loading under thermal cycling

Tests can be performed at various temperatures, under pressurised conditions and when the pipeline is under tension, compression and / or lateral loads.

Suitable for uncoated pipe and pipe with corrosion protective coatings (internal and external) and concrete weight coating

Resonance Fatigue Testing Capability* High frequency / high cycle testing, particularly relevant to pipelines operatingin dynamic services such as dynamic risers for deep water applications

TESTING AND SIMULATION SERVICES

* Operational 2H 2016

Page 19: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

HYDROTEST CAPABILITY

AUTOMATIC HYDROSTATIC TEST

Pipes of size 4” to 36” and up to 12 m length

Test pressure up to 1400 Bar (20,000 psi)

MANUAL HYDROSTATIC TEST

Suitable for pipe spools and vessels

Can be used for pipe when automated test rig is unavailable, or pipe is outside test rig range.

Wide range of blind flanges, hub end caps and other containment equipment available up to 2500# class in sizes up to 48”.

Pressure pumps available to suit pressures up to 2500 Bar (36,000 psi).

Page 20: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

FACILITIES

Batam Manufacturing Facility

Brazil Manufacturing Facility

Saudi Arabia Manufacturing Facility*

* Under construction . Opening scheduled Q1 2017

Page 21: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

BATAM, INDONESIA

Page 22: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

BATAM, INDONESIA

Mechanically Lined Pipe

Weld Overlay Clad Pipes & Fittings

Testing and Simulations

Clad Pipe Spooling & Clad Pressure Vessels

Clad Valves

Induction Bending

Equipment Manufacture

Conveniently located to port

Over 20,000m2 state-of-the-art covered facility

19 twin head and 35 hex/quad head horizontal weld overlay machines

60+ vertical weld overlay machines

50,000m2 of pipe storage and laydown

Conveniently located near to major coating yard

Page 23: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

RIO De JANEIRO - BRAZIL

Over 5,000m2 state-of-the-art covered facility. Total 15,000m2

2 Quad Head and 32 Single Head Cladding Machines for Pipes & Fittings

Strategic location close to main industries and Oil & Gas operators

Weld Overlay Clad Pipes & Fittings

Induction Bending

Heat Treatment facility

Clad Pipe Spooling

Machined components

Page 24: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

DAMMAM, SAUDI ARABIA*

* Under construction . Opening scheduled Q1 2017

State-of-the-art covered facility at Dammam Industrial Area

1 Horizontal and 5 Vertical weld overlay machines, expandable to 10 horizontal and 20 vertical machines

Pipe storage and laydown

Conveniently located to port

Conveniently located near to concrete weight coating and bending facilities

Weld Overlay Clad Pipe

Weld Overlay Clad Fittings

Clad Pipe Spool Fabrication

Page 25: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

QUALITY AND RELIABILITY

Quality assurance to international standards

World class quality control systems

Cutting edge technology for inspection andverification

Automatic visual inspection

Laser scanning for discontinuities

In-house R&D team

Assured constant innovation and improvement

In-house NDE

For greater reliability and control

Cladtek: No1 in Quality and Reliability

Page 26: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

CERTIFICATION and ACCREDITATION

Cladtek are certified to:

Quality management to ISO 9001:2008

Environmental management to ISO 14001:2004

Safety management to OSHA 18001:2007

Quality management to API Q1 – since 2010

API 5LD License 0007 - since 2008

API 5LC License 0019 – since 2010

API 6A – 1877

API 6D - 1694

ASME U, U2 & R stamp

Page 27: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

LOGISTICS MADE EASY

Batam is a duty free zone

15km from Singapore

Major Global logistics hub

Easy inbound and outbound materials transport

Regular shipping and airfreight options

Flight connections to the world

Batam/Singapore ferry link

45 minutes transit time

Singapore is also a major trading hub

boasts ready availability of many services and products

Page 28: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

WHY CRA CLAD? Very high corrosion resistance

Well suited to CO2 and H2S presence where ordinary CS is readily corroded

Well suited to High Temperature / High Pressure applications (HTHP)

Eliminates the need for chemical injection for corrosion protection

Cleaner produced water for easier disposal

Cost effective when compared to solid products such as duplex

More reliable when compared to 13Cr materials

Highly reliable product: reduces project and operational risk

Lower whole of life cost

Minimal pigging requirements

High system cleanliness no scale or corrosion products to block filters

Cladtek: Your Partner for CRA

Page 29: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

WHY CLADTEK

Largest capacity for CRA weld overlay in the world

Technologically superior CRA MLP product

Cost Effective CRA manufacture

Easy Logistics

Strategically located global manufacturing capability

One-Stop-Shop CRA service

Pipe, Fittings, Bending, Pressure Vessels, Spooling and Valves

Quality and Reliability

Flexibility and friendly service

Cladtek: Your Partner for CRA

Page 30: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

Enquiries: [email protected]

THANK YOU

Page 31: Cost Effective One-Stop-Shop CRA Solutions · 14 CRA CLAD VALVES Specialist in CRA cladding technology Range of valve types and options available for surface and subsea applications

Appendices – Sample MLP Projects

CLIENT/OWNER PROJECT GRADE QTY * Tons

FLOWLINESIZE

TEMPDeg C

Lengthkm

Santos/Clough/Subsea7 Mutineer Exeter, Australia X65 - Alloy 316L2.5Mo 1410 12" 125 11

Pertamina / IKPT Sth Sumatra Gas, Indonesia (Sour Gas) X52/Alloy 825 1350 4” 6” 8” 110 49

PDO Harweel, Oman (Sour Gas + Oil) X65/ Alloy 825 3980 14” 16” 90 32

British Gas (BG) / IntecSEA

Hasdrubal, Tunisia(Sour Gas), DNV450 / Alloy 825 2200 18” 140 11

Hess Jambi Merang, Indonesia DNV360/316L 700 8” 10” 80 10

Medco Singa Lematang , Indonesia (Sour Gas) X52/825 200 6” 80 2

Tenaris Test Program X65/825, DNV450/316L 10 12” 16” N/a -

Pertamina PPGJ (Sour Gas) X60/825 1100 6” 120 29

Husky / Saipem Liwan, China DNV450 625 1000 22” 120 3

Husky / Saipem Liwan, China DNV450 316L 2500 12” 120 15

Repsol/Eni - Cardon IV Perla, Venezuela X65/316L 2200 14” 120 7

Exxon Mobil Damar, Malaysia DNV450/825 2800 16” 90 23

• Cladding only