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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
3
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
CTR : Accepted CLR : Accepted
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
CTR : Accepted CLR : Accepted
CSR : Accepted
No crack
72%
SMYS
12
• 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
Research & Development
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
Research & Development
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
21
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/reprocess (quarantine)
Reject/Hold
Concrete coating process
In house QC Lab
CD Test, Adhesion, Bending, Tensile, elongation, impact
40-60 oC
3 oC above dew point
Check wall thickness after grinding
-Monitor elapsed time between blasting-coating
-Check RH
-Check for steel defect (i.e. sliver,)
-Check for salt contamination
-Check blasting profile
-Check surface cleanliness
- 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)
Concrete coating process
Reject/reprocess (quarantine)
80-120 micron
SA 2.5
-Check for steel defect (i.e. sliver, lamination..etc)
-Check blasting profile
-Check surface cleanliness
-Check wall thickness after grinding
-Monitor elapsed time between blasting-coating
-Check RH
40-60 oC
3 oC above dew point
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
24
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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
26
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
32
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)
Customer Year Length Size Project Location
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
Customer Year Length Size Project Location
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
36
Customer Year Length Size Project Location
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
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