presentation pipeline coating

Manufacture of Welded Steel Pipe and Application of Coating

Cilegon-Banten, INDONESIA

Presentation Pipeline Coating

PT. KHI PIPE INDUSTRIES (Krakatau Steel Group)

• Merupakan anak perusahaan dari PT. Krakatau Steel Group dan sebagai perusahaaan terbesar di Indonesia dalam bidang manufaktur pipa untuk pancang konstruksi, pipa air, serta minyak & gas

bumi. • Memiliki sertifikat API Monogram, ISO 9001-2008,

ISO 14001:2004, OHSAS 18001:2007 . • Komitmen kami dalam memberikan kepuasan

pelanggan adalah dengan mensuplai pipa yang berkualitas tinggi secara konsisten sesuai dengan

persyaratan pelanggan, “Ontime Delivery” dan “Competitive Price” .

Pipe and Coating Facilities Location

KHI Pipe Industries

Pipe Mill &

Coating Plant, Cilegon

Facilities

Map of Indonesian Integrated Gas Pipe Line Project

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Competitive Advantages

• Long Experience as Line Pipe Manufacturer and Coating Applicator.

• Complete Production and Inspection Facilities.

• Integrated Pipe Mill ( Helical SAW and HFERW line pipe) and Coating Applicator such as FBE, 3LPE/5 LPP, Concrete Weight Coating (CWC), Asphalt Enamel, Coal tar Enamel, and Internal Coating ( Flow Coat and anti corrosion ).

• As Subsidiary Company of PT.Krakatau Steel (Persero) Tbk. (the biggest steel manufacturer at South East Asia Countries ) .

• The position of Mill integrated with Steel producer ( KS ) , private and Public Port Facilities (PT.KBS and Cigading Port).

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API Monogram For Product

API Spec 5L

( Specification For Line Pipe )

ISO 9001:2008

For Quality Management System

International Quality Certification

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International Quality Certification

OHSAS 18001 : 2007

Occupational healt and safety Management system ISO 14001 : 2004 / SNI 19 – 14001 : 2005

For Environmental Management System

Total Design Capacity : 150,000 tons Diameter : up to 80” Wall Thickness : 3.2 mm – 25 mm Material : Up to API 5 L X-80

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1st Line of High Frequency Resistance Welding ( HFRW )

Total Design Capacity : 70.000 Ton

Range Of Diameter : 4 “ up to 12 “

Range Of Wall Thickness : 3.2 mm up to 12.7 mm

Spiral Welded Steel Pipe

Production Capacities For Bare Pipe

2nd Line of High Frequency Resistance Welding ( HFRW )

Total Design Capacity : 150.000 Ton

Range Of Diameter : 10 “ up to 20 “

Range Of Wall Thickness : 4.78 mm up to 16 mm

Material : Up to API 5 L X-80

Pipe Manufacture and Coating Plant Facilities

ERW Line Spiral Pipe Line

Internal & External

Coating Line

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Production Capacities For Coating Facility

Concrete Weight Coating (CWC) for Plant I

Total Design Capacity : 300,000 SQM/year

Pipe Diameter : up to 48 “

CWC Thickness : up to 120 mm

CWC Density : up to 190 pcf

Corrosion Protection For Plant II External

3 LPE/5LPP : 800.000 SQM/year

FBE : 800.000 SQM/year

Internal

Flow Coat Epoxy : 800.000 SQM/year

Cement Lining : 2000 SQM / day

Corrosion Protection For Plant III External

3 LPE/5LPP : 800.000 SQM/year

FBE : 800.000 SQM/year

Asphalt Enamel Coating : 800.000 SQM/year

Concrete Weight Coating (CWC) for Plant III

Total Design Capacity : 800,000 SQM/year

Pipe Diameter : up to 48”

CWC Thickness : 30 up to 120 mm

CWC Density : up to 190 pcf

Market Segment of Products

Oil and Gas Industries Key players of oil and gas operators in Indonesia such as Exxon Mobil, Total E&P,

Pertamina, BP, State Gas Company (PGN), ConocoPhillips and Chevron Pacific Indonesia already used spiral and/or ERW welded steel line pipe since many years mostly using API 5L specification, DNV, BS, AS and other customer specification for Oil / Gas Transmission and Distribution Pipe Line.

Construction and Structural Industries

All of key players (Domestic & International) in this sector used of spiral welded for structural pipe and pilling pipe refer to SNI, ASTM, BS EN, JIS, AS and other customer specification.

Water Pipes Industries All of key players in Indonesia using spiral welded pipe for water transportation

refer to SNI, AWWA Standard and other customer specification. Application of Coating All of key players in Indonesia using anti corrosion protection and anti mechanical

damage for onshore (above/underground) and offshore service.

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Year Size of Pipe

( OD x WT x L) Pipes Grade

Mediu

m

Test

Solution pH

HIC

Test

SSCC

Test

1995 30 “ x 9.53mm x

30km SAWH

X-60

(103 Heat) Gas

HIC : 3

SSCC : 3

Full Ring : 3

CTR : Accepted CLR : Accepted

CSR : Accepted

No crack

72%

SMYS

2009 20 “ x 9.53mm x

72km SAWH

X-60

(121 Heat)

Crude

Oil

HIC : 5

SSCC : 3


CSR : Accepted

No crack

80%

SMYS

2011

12.75" x

6.35mm &

8.74mm

56km

HFW/

ERW

X-52MS

(49 Heat) Gas

HIC : 3

SSCC : 3


CSR : Accepted

No crack

72%

SMYS

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• List of line pipe project for sour service requirements supplied by KHI.

Research & Development

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Test For Sour Service Application

Longitudinal Welded SAW Helical / Spiral Welded

Longitudinal Welded ERW

Opening rupture area

Bursting Test


Application Of Spiral Welded For Steam Pipe Line at Chevron Texaco Field (Caltex)

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After 3 years exposure Installation on PT. CPI Field


Corrosion Coating

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Multi Layers Coating System

Schematic of 3 Layer Pipe Coating

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Pipeline Coating Performance Comparison

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-Transfer pipe Identification

-Check for surface contaminant

-Check surface condition (i.e. damage free…etc)

40-60 oC

3 oC above dew point

-Check for steel defect (i.e. sliver,)

-Check for salt contamination

-Check blasting profile

-Check surface cleanliness

SA 2.5

Temperature control

180-230 oC 350-500 micron

(single/dual)

-Check coating thickness

-Check visual coating appearance

-Pipe Marking / colour coding

<60 oC

In house QC Lab

CD Test, Adhesion, Bending, Tensile, elongation, impact

Reject/Hold

Concrete coating process

Reject/reprocess (quarantine)

Internal coating process

Check wall thickness after grinding

-Monitor elapsed time between blasting-coating

-Check RH

- Check cutback dimension / taper

-Install rope separator

Fusion Bonded Epoxy (FBE) Process

Adhesive & PE/PP Extruder

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3 LPE External Coating Process

-Transfer pipe Identification

-Check for surface contaminant

-Check surface condition (i.e. damage free…etc)

SA 2.5

Temperature control

180-230 oC 120-200 micron

100-150 micron

1.8-3.5 mm

220-250 oC 200-230 oC 180-230 oC

<60 oC

Internal coating process


Reject/Hold


In house QC Lab

CD Test, Adhesion, Bending, Tensile, elongation, impact

40-60 oC


Check wall thickness after grinding


-Check RH

-Check for steel defect (i.e. sliver,)

-Check for salt contamination



- Check cutback dimension / taper

-Install rope separator

-Check coating thickness

-Check visual coating appearance

-Pipe Marking / colour coding

Internal Coating Process

PE/PP Coating Internal Cutback taping

Enclosed curing room complete with air blower -Check wet & dry film thickness

-Check coating visual appearance- glossiness and roughness

-Check cut back dimensions

-Re-stencil pipe marking / colour coding

In house QC-Lab

-Check for pinholes (glass sides)

-Check for adhesion, cure/stripping, flexibility, hot water immersion (steel panel)



80-120 micron

SA 2.5

-Check for steel defect (i.e. sliver, lamination..etc)



-Check wall thickness after grinding


-Check RH

40-60 oC


In-Coming Rack

(Hold Point) Pre-Heat

Inspection Rack

(Hold Point)

Reject / Hold

Reject (Re-blast)/

Hold

Cut-Back Tapping

* Transfer pipe identification

* Check for surface contamination

* Check surface condition

(i.e. damage free .. etc.)

* Check surface cleanliness

* Check blasting profile

• Monitor elapsed time between blasting and

coating (Weather Control: %RH)

* Check for steel defects (i.e. slivers, lamination)

* Check for salt contamination

* Check pipe surface temperature

* Check pipe wall thickness (if excessive grinding)

* Check coating thickness

* Check coating visual appearance

* Check for holiday

• Pipe marking / colour coding

• Check cut-back dimension and taper

Induction Heat FBE Base Coat Application Water Quenching Inspection Rack

(Hold Point) Reject (Re-process)/

Quarantine

External Blast Clean Blaster

Cutback

Brushing

Conditioned pipe

Holiday Testing

Temperature Control In-house QC

Lab

(Hold Point)

To Concrete Coating

Plant

To FBE stockpile area

Extrusion of Adhesive

and Top Coat PE plus

sinter coat

Flow Process Multilayer Coating

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Laboratory Of Coating Plant Facilities

Cathodic Disbondment Test

Tensile Test/Test Impact Test

Bending Test Adhesion Test

Differential Scanning Calorimeter (DSC) Analysis

Peel Constant Rate

Requirements of 3LPE/5LPP Coating In Service Performance : Peel Test

Peel Test Constant Rate Method Peel Test Hanging Weight Method

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Concrete Weight Coating

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Incoming Rack Pipe

and Preparing Cut back for Concrete

Damage/ Hold for

Repair

Concrete Weight Control

(Hold Point)

Reject / Hold / Repair

DELIVERY

Concrete Weight Coating (CWC) Impingement Process

• Batch Plant Calibration

• Weighing Scale Calibration

• Plant parameter adjustment

• Wire mesh machine adjustment

• Rubber drum throwing unit adjustment

• Check holding and feed hoppers

* Concrete repairs (if any Spalling)

Holiday Testing

Concrete Coated Pipe Curing Bay / Storage

* Clean concrete cutback

• Check girth measurement (OD)

• Check concrete weight

* Check concrete finishing

• Calculate NB and Concrete Density

• Draw samples for Concrete Strength

Concrete Cutback

Preparation

Concrete Gap for Anode at Mid-center of Pipe

(As required)

Weighbridge

In-house QC

Lab

(Hold Point)

Concrete Application

(Impingement)

Coated Pipe Stockpile

Pipe transfer to curing bay

Concrete Mixing

(Iron ore, cement, water)

Wire Mesh

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Curing Agent

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Batching Plant Machine Facilities

CWC Application CWC Pipe

CWC Machine Facilities

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Laboratory Of CWC Plant Facilities

Compressive Strength

Drying Oven Specific Gravity Analysis

Shear Strength Test Sieve Analysis

Electric Resistant Check

Major Experience of PT. KHI Pipe Industries, Line Pipe in Oil & Gas Industries

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Customer Year Ton Size Spec Project

ARCO 1994 7000 24” x14.27 mm WT API 5 L X-65 ARII Submarine Gas Pipeline

Qadipur Gas Pipeline Pakistan 1994 3300 26”, 30”x8.74 mm WT API 5 L X-65

Exxon Mobil Indonesia 1995 8000 30”x9.52mmWT API 5 L X-60 Sour Gas Pipeline

Total Fina Elf 1995 14288 12”, 14”,32” API 5 L X-65 Tunu North -114

State Gas Company (PGN) 1997 85600 28”x8.74 ,10.31, 12.7 mm WT API 5 L X-65

Bontang Train H, East Kalimantan Indonesia

1997 11591 42”x14.27 mm WT API 5 L X-65

TOTAL Elf 1998 12075 20”, 36”x12.7 mm &15.88mm WT

API 5 L X-65 Tunu Phase 07

Pertamina Proyek Pengembangan Gas Sumatera Selatan

2005 32254 28”, 32” & 11.9 mm & 14.27mm & 15.88 mm, 19.05 mm & 20.06mm WT

API 5 L X-52

State Gas Company (PGN) 2006 28000 32”x14.3, 17.5, 20.6 mm WT API 5 L X-65

State Gas Company (PGN) 2009 12000 24”x12.7mm WT API 5 L X-65

Exxon Mobil (MCL 2009 10000 20”x9.52mm WT

Total E&P Indonesie 2012 500 14”x9.52 mm WT API 5 L X-60 M

PT pertagas 2013 3602 24”x12.7 mm WT API 5 L X-52 Arun Belawan Project

State Gas Company (PGN) 2013 6124 24”x14.27 mm WT API 5 L X-65 Bitung – Cimanggis Project

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PT. KHI Pipe Industries Experiences for Supplying HFRW Pipe

Customer Year Length Size Project Location

Perusahaan Gas Negara ( PGN )

2007-2009 60 KM 4 – 12.75 Inch Gas Distribution For Banten Area , Batam

and Surabaya

East Java, Riau, & East

Java Indonesia

Chevron Pacific Indonesia

2007-2009 260 KM 4 – 12,75 Inch North Duri Development Project

Riau Indonesia

VICO Indonesia

2007- 2009 42 KM 6 Inch East Kalimantan Gas Distribution System

Balikpapan East Kalimantan

Indonesia

Medco Indonesia 2008 30 KM 6 – 8 Inch Crude Oil Pipeline System

South Sumatera Indonesia

EMP kangean 2008 12 KM 6 Inch East Java Gas Pipeline East Java Indonesia

PERTAMINA 2007- 2009 60 KM 4 – 12 Inch Crude Oil Pipeline System Sumatera and Java

Indonesia

Pertamina 2010 75 Km 10 Inch Oil Transmission West Java Indonesia

ConocoPhillips 2012 54 Km 12.75 Inch Gas Distribution South Sumatera

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PT. KHI Pipe Industries Experiences for Supplying HFRW Pipe (Continued)


PT Pertamina Hulu Energi ONWJ

2014 28.67 KM 10,752 Inch Proyek FPRO – ECOM North West Java Offshore

PT Wijaya Karya (Persero) Tbk

2014 17.59 KM

31.42 KM

4.5 – 20 inch

4.5 – 20 inch

- Proyek Upgrading Fasilitas Penimbunan Gasoline di Tanjung Uban

- Proyek Pengembangan TBBM Pertamina Pulau Sambu

Tanjung Uban

Pulau Sambu

Major Experiences of FBE and 3LPE/PP Coating


Pertamina 2007 6 KM (3lPE) 32 Inch Relocation of East Java Gas Pipeline Project

East Java Indonesia

Pertamina 2008 120 KM (3LPE) 16 Inch Cikampek Balongan Oil Pipeline Project

West Java Indonesia

Perusahaan Gas Negara ( PGN )

2008 40 KM (3LPE) 6 – 12 Inch West Java Gas Distribution System

West Java Indonesia

PLN – Power Plant 2008 24 KM (3LPE) 24 Inch Gas Pipeline System For Power

Plant

Muara Karang Jakarta Indonesia

EMP kangean 2008 12 KM (3LPE) 6 Inch East Java Gas Pipeline East Java Indonesia

Perusahaan Gas Negara

2009 74 KM (3LPE) 24 Inch Bojonegara – Serpong Gas Pipeline System

Banten Indonesia

Pertamina 2010 75 KM (3LPE) 10 Inch Ujung Berung - Tasikmalaya West Java Indonesia

ConocoPhillips 2012 70 KM (3LPE PP) 6-12 Inch Letang Tengah Rawa Optimization

South Sumatera

Pertamina / Pertagas 2015 300 KM ( 3LPE ) 28 Inch Semarang - Gersik Central to East Java

Major Experiences of FBE and 3LPE/PP Coating

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PT PGN, Tbk 2013 57 KM (3lPE) 32 Inch PGN CP 10 (Bitung-Cimanggis)

Bitung – Cimanggis

PT PGN SBU Pusat 2014 23 KM (3LPE) 12 & 16 Inch PGN SBU I Jabodetabek and West Java

Client / Project OD

(INCH) WT (INCH) Grade Length (M) Remarks

IAPCO / MAXUS 20 0.375 X - 52 5500 Line pipe included CWC

ARCO / ARII 24 0.562 X - 65 31000 Line pipe included CWC

TOTAL TUNU Ph. 7 20 - 36 0.5 - 0.622 X - 65 10000 Line pipe included CWC

TOTAL E&P INDONESIE 14 0.374 X-60 6000 Line pipe included CWC

PHE ONWJ 8 - 20 60.000 CWC

PT RPE/CNOOC 10 8.5 X-52 1104 CWC

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Major Experiences For Offshore Line Pipe and CWC

Thank you very much

www.khipipe.com

presentation pipeline coating

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