Presentation Pipeline Coating

Manufacture of Welded Steel Pipe and Application of Coating

Cilegon-Banten, INDONESIA
 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

Map of Indonesian
Integrated Gas Pipe Line
Project

KHI Pipe Industries

Pipe Mill &
Coating Plant, Cilegon
Facilities

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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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International Quality Certification

ISO 9001:2008 API Monogram For Product

For Quality Management System API Spec 5L
( Specification For Line Pipe )

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International Quality Certification

OHSAS 18001 : 2007

ISO 14001 : 2004 / SNI 19 – 14001 : 2005
Occupational healt and safety Management system
For Environmental Management System
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Production Capacities
For Bare Pipe
Spiral Welded Steel Pipe
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

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

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

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Pipe Manufacture and Coating Plant Facilities
Spiral Pipe Line
ERW Line

Internal & External

Coating Line

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Production Capacities For Coating Facility
Corrosion Protection For Plant II
External
3 LPE/5LPP : 800.000 SQM/year Internal
FBE : 800.000 SQM/year 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 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
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
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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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• List of line pipe project for sour service requirements supplied by KHI.

Size of Pipe Mediu Test HIC SSCC

Year Pipes Grade
( OD x WT x L) m Solution pH Test Test
HIC : 3 CTR : Accepted No crack
30 “ x 9.53mm x X-60
1995 SAWH Gas SSCC : 3 CLR : Accepted 72%
30km (103 Heat) CSR : Accepted SMYS
Full Ring : 3
CTR : Accepted No crack
20 “ x 9.53mm x X-60 Crude HIC : 5
2009 SAWH CLR : Accepted 80%
72km (121 Heat) Oil SSCC : 3 CSR : Accepted SMYS
12.75" x
CTR : Accepted No crack
6.35mm & HFW/ X-52MS HIC : 3
2011 Gas CLR : Accepted 72%
8.74mm ERW (49 Heat) SSCC : 3 CSR : Accepted SMYS
56km

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Research & Development
Test For Sour Service Application

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Research & Development
Bursting Test

Opening rupture area

Longitudinal Welded SAW Helical / Spiral Welded

Longitudinal Welded ERW

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

After 3 years exposure

Installation on PT. CPI Field

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Corrosion Coating

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Multi Layers Coating System

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Schematic of 3 Layer Pipe Coating

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Pipeline Coating Performance Comparison

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 Fusion Bonded Epoxy (FBE) Process
-Check for steel defect (i.e. sliver,)
-Check for salt contamination Check wall thickness after grinding
Reject/Hold -Check blasting profile -Monitor elapsed time between
40-60 oC blasting-coating
3 oC above dew point -Check surface cleanliness -Check RH

SA 2.5
-Transfer pipe Identification
-Check for surface contaminant
-Check surface condition (i.e.
damage free…etc)
Temperature control
350-500 micron 180-230 oC
(single/dual)

In house QC Lab
CD Test, Adhesion, Bending, Internal coating process
Tensile, elongation, impact

<60 oC Reject/reprocess
-Check coating thickness (quarantine)
-Check visual coating appearance
- Check cutback dimension / taper -Pipe Marking / colour coding Concrete coating process
-Install rope separator
Adhesive & PE/PP Extruder

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 3 LPE External Coating Process
-Check for steel defect (i.e. sliver,)
Check wall thickness after grinding
Reject/Hold -Check for salt contamination
-Monitor elapsed time between
40-60 oC -Check blasting profile blasting-coating
3 oC above dew point -Check surface cleanliness -Check RH

-Transfer pipe Identification SA 2.5

-Check for surface contaminant
Temperature control
-Check surface condition (i.e.
damage free…etc) 180-230 oC
1.8-3.5 mm 100-150 120-200
micron micron

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

In house QC Lab
CD Test, Adhesion, Internal coating process
Bending, Tensile,
elongation, impact

<60 oC
- Check cutback dimension / taper
-Install rope separator
Reject/reprocess
-Check coating thickness (quarantine)
-Check visual coating appearance
-Pipe Marking / colour coding Concrete coating process
 Internal Coating Process -Check for steel defect (i.e. sliver,
lamination..etc)
-Check blasting profile
-Check surface cleanliness
40-60 oC
SA 2.5 -Check wall thickness after grinding
3 oC above dew point
-Monitor elapsed time between
blasting-coating
-Check RH

PE/PP Coating Internal Cutback

taping

80-120 micron
Reject/reprocess
(quarantine)

Enclosed curing
room complete with
air blower
In house QC-Lab
-Check for pinholes (glass sides)
-Check for adhesion,
cure/stripping, flexibility, hot
water immersion (steel panel)
Concrete coating process
-Check wet & dry film thickness
-Check coating visual appearance-
glossiness and roughness
-Check cut back dimensions
-Re-stencil pipe marking / colour
coding
 Flow Process Multilayer Coating

In-Coming Rack
External Blast Clean Blaster Pre-Heat (Hold Point)

Reject / Hold

* Transfer pipe identification

Inspection Rack * Check for surface contamination
(Hold Point) Cut-Back Tapping * Check surface condition
Reject (Re-blast)/ (i.e. damage free .. etc.)
Hold
Conditioned pipe

* Check for steel defects (i.e. slivers, lamination) * Check surface cleanliness
* Check for salt contamination * Check blasting profile
* Check pipe surface temperature • Monitor elapsed time between blasting and
* Check pipe wall thickness (if excessive grinding) coating (Weather Control: %RH)
Extrusion of Adhesive
Inspection Rack Cutback and Top Coat PE plus
(Hold Point) Brushing Holiday Testing Water Quenching sinter coat FBE Base Coat Application Induction Heat
Reject (Re-process)/
Quarantine

To Concrete Coating
Plant
To FBE stockpile area

* Check coating thickness

* Check coating visual appearance
* Check for holiday In-house QC
• Pipe marking / colour coding Lab Temperature Control
• Check cut-back dimension and taper
(Hold Point) 24
Laboratory Of Coating Plant Facilities

Cathodic Disbondment Test Peel Constant Rate Bending Test Adhesion Test

Tensile Test/Test Differential Scanning Calorimeter (DSC) Analysis Impact Test

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

Peel Test Hanging Weight Method

Peel Test Constant Rate Method

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Concrete Weight Coating

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Concrete Weight Coating (CWC) Impingement Process

Incoming Rack Pipe

and Preparing Cut back for Concrete
Holiday Testing
Damage/ Hold for
• Batch Plant Calibration Repair
• Weighing Scale Calibration
• Plant parameter adjustment
• Wire mesh machine adjustment
• Rubber drum throwing unit adjustment
Coated Pipe Stockpile
• Check holding and feed hoppers

Concrete Mixing * Clean concrete cutback

(Iron ore, cement, water)
Concrete Application
Wire Mesh (Impingement)
• Check girth measurement (OD)
Curing Agent • Check concrete weight
* Check concrete finishing Concrete Gap for Anode at Mid-center of Pipe
• Calculate NB and Concrete Density (As required)
• Draw samples for Concrete Strength Reject / Hold / Repair

Weighbridge

Concrete Cutback Concrete Weight Control

Preparation (Hold Point)

Pipe transfer to curing bay

DELIVERY

Concrete Coated Pipe Curing Bay / Storage

* Concrete repairs (if any Spalling)

In-house QC
Lab
(Hold Point)
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CWC Machine Facilities

Batching Plant
Machine Facilities

CWC Application CWC Pipe

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Laboratory Of CWC Plant Facilities

Shear Strength Test Sieve Analysis

Compressive Strength

Drying Oven Electric Resistant Check Specific Gravity Analysis

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

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 1997 11591 42”x14.27 mm WT API 5 L X-65
Kalimantan Indonesia
TOTAL Elf 1998 12075 20”, 36”x12.7 mm &15.88mm API 5 L X-65 Tunu Phase 07
WT
Pertamina Proyek 2005 32254 28”, 32” & 11.9 mm & 14.27mm API 5 L X-52
Pengembangan Gas Sumatera & 15.88 mm, 19.05 mm &
Selatan 20.06mm WT
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 2007-2009 60 KM 4 – 12.75 Inch Gas Distribution For East Java,
Negara ( PGN ) Banten Area , Batam Riau, & East
and Surabaya Java
Indonesia
Chevron Pacific 2007-2009 260 KM 4 – 12,75 Inch North Duri Development Riau
Indonesia Project Indonesia
2007- 2009 42 KM 6 Inch East Kalimantan Gas Balikpapan
VICO Indonesia Distribution System East Kalimantan
Indonesia
Medco Indonesia 2008 30 KM 6 – 8 Inch Crude Oil Pipeline South Sumatera
System 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 2014 28.67 KM 10,752 Inch Proyek FPRO – ECOM North West Java
Energi ONWJ Offshore

PT Wijaya Karya 2014 17.59 KM 4.5 – 20 inch - Proyek Upgrading Tanjung Uban
(Persero) Tbk Fasilitas Penimbunan
Gasoline di Tanjung
Uban

31.42 KM 4.5 – 20 inch - Proyek Pengembangan Pulau Sambu

TBBM Pertamina Pulau
Sambu

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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 East Java
Pipeline Project Indonesia

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

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

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

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

Perusahaan Gas 2009 74 KM (3LPE) 24 Inch Bojonegara – Serpong Gas Banten

Negara Pipeline System 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 South Sumatera
Optimization

Pertamina / Pertagas 2015 300 KM ( 3LPE ) 28 Inch Semarang - Gersik Central to East Java
Major Experiences of FBE and 3LPE/PP Coating

Customer Year Length Size Project Location

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

Cimanggis)

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

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Major Experiences For Offshore Line Pipe and CWC

OD
Client / Project WT (INCH) Grade Length (M) Remarks
(INCH)
IAPCO / MAXUS 20 0.375 X - 52 5500 Line pipe included CWC
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

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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 Thank you very much
www.khipipe.com