PROSES PRODUKSI PT KRAKATAU STEEL (Dalam JUTA Ton)

Transcription

COMPANY PROFILE
PT KHI Pipe Industries
(KRAKATAU STEEL GROUP)
HEAD OFFICE
Krakatau Steel Building, 7th Floor, Jl. Gatot Subroto kav.54
Jakarta - Indonesia
Ph. (62-21) 5254140, 5212761, Fax. (62-21) 5204002
www.khipipe.com
FACTORY
Jl. Amerika I, Kawasan PT. Krakatau Steel, Cigading 42435
Cilegon - Banten- Indonesia
Ph. (62-254) 392438, 391020, 391971, Fax. (62-254) 392083
2
Overview
 Founded in 1972, as a part of PT. Krakatau Steel Group
 First production of spiral welded pipe since January 1973
 First Production line of High Frequency Resistance
2006.
Welding ( HFRW ) since January
 2nd Production line of large diameter High Frequency Resistance Welding (HFRW)
since 2014.
 First Production of New Coating Technology Application ( FBE, 3 Layer Polyethylene
/ Polypropylene, Internal Coating ) since January 2007.
 2nd production line for Coating application
Polypropylene) started January 2014.
of FBE, 3 Layer Polyethylene /
 Expansion of concrete weight coating and Asphalt Enamel facilities since October
2012.
 API monogrammed since 12 October 1977 with Certificate No: 5L 0203.1.
 ISO 9002 Certified since 23 November 1993 and has been upgraded to ISO 9001:
2000 Since October 2002 and ISO 9001: 2008 Since October 2010 certified by ABS .
 OHSAS 18001:2007 certified since July 2013 by SGS.
 Plant Location : Krakatau Industrial Estate Cigading – Cilegon, Banten Indonesia
3
International Quality and Safety Certifications
ISO 9001 , For Quality Management
System
API Monogram For Product
API 5L ( Specification For Line Pipe )
OHSAS 18001 Monogram For Health &
Safety Management System
TKDN Certificate (ERW)
5
TKDN Certificate (Spiral)
6
SKUP MIGAS
7
SKUP MIGAS
8
Pipe and Coating Facilities Location
Map of Indonesian
Integrated Gas Pipe Line
Project
Pipe supplied by
KHI
KHI Pipe Industries
Pipe Mill &
Coating Plant, Cilegon
Facilities
Competitive Advantages
• Long Experience as Line Pipe Manufacturer and Coating Applicator.
• Complete Production and Inspection Facilities.
• Integrated Pipe Mill ( Helical SAW line for medium up to larger
diameter and HFRW line for smaller diameter ) and Coating
Applicator such as FBE, 3LPE/PP, Coal tar Enamel, CWC, and Internal
Coating ( Flow Coat and anti corrosion ).
• As Subsidiary Company of PT.Krakatau Steel (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).
10
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
the following services:
 Oil Transmission and Distribution Pipe Line
 Gas Transmission and Distribution Pipe Line
 Steam 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 ASTM, BS EN, JIS, AS and
other customer specification.
 PT. KHI Pipe Industries already exported ± 150,000 ton of pipe to the 14
countries in the world mostly for the structural / pipe piles
 Water Pipes Industries
All of key players in Indonesia using spiral welded pipe for water transportation
refer to AWWA Standard.
11
Product and Services
Pipe Manufacturing
Corrosion Protection
External Coating
Additional Coating
Internal Coating
3LPE/3LPP
Spiral Welded Pipe
Epoxy
FBE
Asphalt/Coaltar
Concrete Weight Coating
- Impingement
- Compression
Cement Lining
ERW Pipe
Epoxy
12
Production Capacities
Plant and storage area : 46 Ha.
Spiral Welded Steel Pipe
Total Design Capacity
Diameter
Wall Thickness
Material
: 150,000 tons
: up to 80”
: 3.2 mm – 25 mm
: Up to API 5 L X-80
1st Line of High Frequency Resistance Welding ( HFRW )
Range Of Diameter
Range Of Wall Thickness
: 70.000 Ton
: 4 “ up to 12 “
: 3.2 mm up to 12.7 mm
2nd Line of High Frequency Resistance Welding ( HFRW )
Range Of Diameter
Range Of Wall Thickness
Material
: 150.000 Ton
: 10 “ up to 20 “
: 4.78 mm up to 16 mm
: Up to API 5 L X-80
Corrosion Protection
External
3 LPE/PP
FBE
: 800.000 SQM/year
: 800.000 SQM/year
Asphalt Enamel
: 800.000 SQM/year
Internal
Flow Coat Epoxy : 800.000 SQM/year
Cement Lining
: 600.000 SQM /year
Concrete Weight Coating (CWC)
Pipe Diameter
CWC Thickness
CWC Density
: 300.000 sqm/year
: up to 48 “
: up to 120 mm
: up to 190 pcf
13
14
SPIRAL WELDED SAW LINE PIPE PRODUCTION PROCESS
HRC
Outside Welding
Auxiliary-Leveling
Inside Welding
Skelp End Cutting
Forming
Skelp End Joint
Edge Preparation
Edge Prebending
Preliminary
Visual and
Dimensional
Inspection
Automatic UT for spiral weld
8 probes
Heat
Treatment as
alternative for
sour service
Oscilating UT for
Pipe body 2 probes
Radiography
Inspection if
Necessary
Manual UT
Levelling
Radiography
Inspection
Traveling cut off
Off Line UT
Hydrostatic Test
Weighing
& Measuring
End Facing & Beveling
Final Visual &
Dimensional
Inspection
Customer
Inspection
Marking
Shipping
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HFRW PRODUCTION PROCESS
Strip End
Welding
Edge
slitting
(optional)
Leveling
Uncoiling
Accumulator
Inside & Outside
Flash Trimming
Conductive & Inductive
HFRW Method
Roll Forming
Strip Auto U/T Lamination
Sizing & Straightner
Flying Cut off
Post Annealing
End
Facing
Customer
Inspection
Marking,
Weighing &
Measuring
Shipping
Visual &
Dimensional
Inspection
Automatic
Ultrasonic Offline
Hydrotest
16
Pipe Manufacture and Coating Plant Facilities
Spiral Pipe Line
ERW Line
Internal & External
Coating Line
New Line Production of Large Diameter High Frequency
Resistance (ERW) Welded Facility
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Non Destructive Examination Facilities
for HFRW
Strip Auto U/T Lamination
Hydrostatic Tester
Automatic UT off-line
UT Manual on Pipe end
19
Non Destructive Examination Facilities
Online Automatic UT
Offline Automatic UT
Hydrostatic Test
H
X
a
n
y
d
Hand Held UT
Fluoroscopy
X-Ray / Radiography
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Laboratory Test Facilities
Tensile & Bend Test
Hardness
Test
Flattening Test
Charpy Impact Test
Guided Bend Test
Chemical Composition Test
Micro Structure
Examination
Macro Section Helical SAW Pipe
Macro Section ERW Pipe
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PE/PP
Adhesive
HDPE
Grafted
adhesive
Anti-corrosion/FBE
Epoxy
22
Fusion Bonded Epoxy Coating Flow Process
External Blast Clean Blaster
In-Coming Rack
(Hold Point)
Pre-Heat
Reject / Hold
Reject (Re-blast)/
Hold
Inspection Rack
(Hold Point)
* Transfer pipe identification
* Check for surface contamination
* Check surface condition
(i.e. damage free .. etc.)
Cut-Back Tapping
Conditioned pipe
* Check
* Check
* Check
* Check
for steel defects (i.e. slivers, lamination)
for salt contamination
pipe surface temperature
pipe wall thickness (if excessive grinding)
Reject (Re-process)/
Quarantine
Inspection Rack
(Hold Point)
* Check surface cleanliness
* Check blasting profile
• Monitor elapsed time between blasting and
coating (Weather Control: %RH)
Cutback Holiday Testing
Brushing
Water Quenching
FBE Topcoat
(Rough coat)
FBE Base Coat Application
To CWC Plant
To FBE stockpile area
* Check coating thickness
* Check coating visual appearance
* Check for holiday
• Pipe marking / colour coding
• Check cut-back dimension and taper
•I nstall rope separator (3-off per joint)
In-house QC
Lab
(Hold Point)
Temperature Control
Induction Heat
3 Layer Polyethylene/Polypropylene Coating Flow Process
External Blast Clean Blaster
In-Coming Rack
(Hold Point)
Pre-Heat
Reject / Hold
Reject (Re-blast)/
Hold
Inspection Rack
(Hold Point)
* Transfer pipe identification
* Check for surface contamination
* Check surface condition
(i.e. damage free .. etc.)
Cut-Back Tapping
Conditioned pipe
* Check
* Check
* Check
* Check
for steel defects (i.e. slivers, lamination)
for salt contamination
pipe surface temperature
pipe wall thickness (if excessive grinding)
Reject (Re-process)/
Quarantine
Inspection Rack
(Hold Point)
* Check surface cleanliness
* Check blasting profile
• Monitor elapsed time between blasting and
coating (Weather Control: %RH)
Cutback
Brushing Holiday Testing
Water Quenching
Extrusion of Adhesive
and Top Coat
FBE Base Coat Application
To Concrete Coating
Plant
To FBE stockpile area
* Check coating thickness
* Check coating visual appearance
* Check for holiday
• Pipe marking / colour coding
• Check cut-back dimension and taper
In-house QC
Lab
(Hold Point)
Temperature Control
Induction Heat
Laboratory Of Coating Plant Facilities
Cathodic Disbondment Test
Tensile Test/Test
Peel Constant Rate
Bending Test
Differential Scanning Calorimeter (DSC) Analysis
Adhesion Test
Impact Test
25
Requirements of 3LPE Coating
In Service Performance : Peel Test
Peel Test Hanging Weight Method
Peel Test Constant Rate Method
Internal Flow Coating Flow Process
PE/PP Coating Line
(Endo Conveyor)
Internal Mechanical Blast Line
Inspection Rack
(Hold Point)
Inspection Rack
(Hold Point)
Paint Spray Line
PE/PP Storage Area
Internal Cut-Back Taping
Fume Extraction
(Air blower & Suction Fan)
Internal Coating Inspection
Enclosed curing area
complete with air blower
(Hold Point)
PE/PP Coated Pipe Stockpile
In-house QC
Lab
(Hold Point)
Reject (Reprocess)/
Quarantine
To Concrete Coating Plant
To PE/PP Coated Pipe Stockpile
* Check wet and dry film thickness
* Check coating visual appearanceglossiness and roughness
* Check for pinholes (glass slides)
* Check for adhesion, cureness,
flexibility and hot water immersion
(steel panel)
* Check cut-back dimension
* Re-stencil pipe marking and colour
coding
PE/PP Coated complete with Internal Flowcoat
Pipe Stockpile
Internal Coating Testing
Internal Bending Test
Pin Hole Test
Adhesion Test
Measurement of Roughness
Stripping Test
Concrete Weight Coating (CWC) Impingement Process
Incoming Feed Rack of Concrete Plants
(Hold Point)
Holiday Testing
Damage/ Hold for
Repair
* Batch Plant Calibration
• Plant parameter adjustment
• Wire mesh machine adjustment
* Rubber drum throwing unit djustment
* Check holding and feed hoppers
Concrete Mixing
(Iron ore, cement, water)
FBE Coated Pipe Stockpile
Concrete Application
(Impingement)
* Clean concrete cutback
• Check girth measurement (OD)
• Check concrete weight
* Check concrete finishing
• Calculate NB and Concrete Density
• Draw cube samples for Concrete Strength
Wire Mesh
Concrete Gap for Anode at Mid-center of Pipe
(As required)
Reject / Hold / Repair
Weighbridge
Concrete Cutback
Preparation
Concrete Weight Control
(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)
CWC Machine Facilities
Batching Plant
CWC Application
Machine Facilities
CWC Pipe
30
Laboratory Of CWC Plant Facilities
Compressive Strength
Drying Oven
Shear Strength Test
Electric Resistant Check
Sieve Analysis
Specific Gravity Analysis
31
32
Application of Spiral Welded Pipe for Piling
Structure
33
Pilling Pipe for International Cruise Terminal Project –
Singapore
34
Application Heavy Wall Spiral Welded Pipe
For Onshore Oil & Gas Transmission Pipeline
Coated Line pipe of LTRO Project, South of
Sumatera Dia. 8 inchx9.53 mm WT API 5 L X-46
(Sour Service) – Conoco Phillips (Grissik Ltd), 2010
Stringing Pipe Line activity of Gas Transmission &
Distribution for PGN, API 5L X-65, 2005
Coated Linepipe for Gas Distribution
Pipeline of Bojonegara-Serpong
Project, PT PGN, Tbk, Dia. 24”x12.7
mm WT API 5 L X-65
35
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
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
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
2006
28000
32”x14.3, 17.5, 20.6 mm WT
API 5 L X-65
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
2013
6124
24”x14.27 mm WT
API 5 L X-65
Bitung – Cimanggis Project
36
ARII Submarine Gas Pipeline
Tunu Phase 07
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
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
VICO Indonesia
37
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
PT Wijaya Karya
(Persero) Tbk
2014
17.59 KM
4.5 – 20 inch
-
31.42 KM
4.5 – 20 inch
-
Proyek Upgrading
Fasilitas Penimbunan
Gasoline di Tanjung
Uban
Tanjung Uban
Proyek Pengembangan
TBBM Pertamina Pulau
Sambu
Pulau Sambu
38
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
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
54 KM (3LPE)
12 Inch
Letang Tengah Rawa
Optimization
South Sumatera
ConocoPhillips
2012
14.4 KM (3LPP)
6 Inch
Letang Tengah Rawa
Optimization
South Sumatera
Muara Karang
Jakarta
Indonesia
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 (BitungCimanggis)
Bitung – Cimanggis
PT PGN SBU Pusat
2014
23 KM (3LPE)
12 & 16 Inch
PGN SBU I
Jabodetabek and
West Java
40
Major Experiences For Offshore Application
Client / Project
IAPCO / MAXUS
OD
(INCH)
WT (INCH)
Grade
Length (M)
20
0.375
X - 52
5500
Remarks
Line pipe included CWC
ARCO / ARII
24
0.562
X - 65
31000
TOTAL TUNU Ph. 7
20 - 36
0.5 - 0.622
X - 65
10000
TOTAL E&P INDONESIE
14
0.374
X-60
6000
KPM Oil & Gas/PHE ONWJ
36
20000
CWC
PT RPE/CNOOC
10
1104
CWC
8.5
X-52
41
Major Export Market ( Spiral SAW ) to 14 Countries
Pipe Size
No
Customer
Project / Location
1
PT. Prima Comexindo
Sudan Water Supply
2
Mitsubishi Corp.
Qardipur Gas Line
3
Mitsubishi Heavy Ind.
4
Country
Spec
Qty (Ton)
Sudan
28”
AWWA C200
2,602
Pakistan
26” & 30”
API 5L X65
3,303
Takasago Power Plant
Japan
26”
API 5L X65
2,945
Oil Serv
IOCL Project
India
24”
API 5L X52
132
5
Pipeco
United Kingdom Project
England
28” & 42”
Comm. Grade
5,225
6
Trade Arbed
Changi East Phase 2
Singapore
28” & 32”
BS 6323
3,086
7
Coutinho Caro
Iran Pipeline Project
Iran
63”
API 5L X42
137
8
Shark Bay Project
Australian Project
Australia
47”
BS 4363 Gr 55 C
2000
9
Foster Piling – USA
Panama Bridge Project
Panama
20”
Comm. Grade
160
10
Borneo Raya
Holland Project
Holland
Various
ASTM A252
1,302
11
Performance Pipe
Kuala Baram Bridge
Malaysia
60”
BS 6323
4,557
12
Mitsubishi Corp.
Kenya Steam Pipeline
Kenya
16” & 28”
API 5L Gr. B
1,576
13
McConnell Dowell
Loyang Project
Singapore
28 “& 30”
BS EN 10219
200
14
Daiho Corporation
PNG LNG Project
Papua Nuguinie
24” & 16
ASTM A252
2000
42
www.khipipe.com
Steel Pipe Manufacturer and Coating Applicator
43

PROSES PRODUKSI PT KRAKATAU STEEL (Dalam JUTA Ton)

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