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BrederoShaw Pertamina Balongan Presentation 2015-04-09
BrederoShaw Pertamina Balongan Presentation 2015-04-09
FUNDAMENTALS
FUNDAMENTAL
STRENGTHS
2
Update on ShawCor - Bredero Shaw
Company and Bredero Shaw Indonesia Kabil
Capability
ShawCor – A Global Energy
Services Company
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Delivering Leading Solutions to Our
Customers Around the World
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Active in All High Growth Segments
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Unmatched Scale, Diversity and Global
Reach
Western Hemisphere Eastern Hemisphere
ShawCor Pipeline Performance
Group
• ShawCor Pipeline Performance Group consists of the best
of the best of the 4 global leaders in the pipeline coating
market:
– Bredero Shaw (line pipe coatings and field joint/custom coatings)
– Socotherm (Line pipe coatings)
– CANUSA - CPS (Field joint coatings)
– Dhatec (Pipe preservation)
• The largest team of experienced & dedicated
professionals
• Over 700,000 km of pipelines coated worldwide
• ShawCor Pipeline Performance will be divided in Eastern
hemisphere (EH) organization and Western Hemisphere
(WH) organization
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Asia Pacific Pipe Coating Facilities
Kabil, Indonesia
– Anti-corrosion coatings
– Concrete weight coatings
– Internal coatings
– Flow assurance coatings
– Rock Jacket
– Custom coatings
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Kabil, Batam Island, Indonesia
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Kabil Port Load In / Out Overview
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Kabil 2015
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Kabil - Overview
Eight coating plants capable of applying over 15 different types of
coating.
All plants capable of handling 18 metre pipes (MLPP 24 M).
Main site built with a 1% slope across the site for drainage.
Main site is 21.5 Hectares with 11.5 Hectare of production facilities
and 10 Hectares of pipe storage area.
Four additional pipe storage sites with a total of 54 hectares.
Automatic pipe handling and advanced safety features built into the
design of all plants.
Logistics handled by company owned fleet of cranes, trucks,
Reachstackers and fork lifts.
Full city power plus back up generators.
Load out Washing, Tally and Inspection station.
Load out pre staging area at the Port for accelerated load out rates.
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Kabil Coating Capabilities
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Kabil Coating Capabilities
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The State-of-the-Art Customer
Coating Facility in Kabil
FBE/DLFBE PE Custom Coating PP Custom Coating
Maximum 120oC 85oC 110oC (Onshore)
Recommended 140oC (Offshore)
Operating Temperature
Maximum Coating 1.0 mm 3.5 mm 3.5 mm
Thickness
OD Pipe Size 4.5”-40” 4.5”-40” 4.5”-40”
Pipe Wall Thickness 9.5 mm -28mm 9.5 mm -28mm 9.5 mm -28mm
Range
Maximum Pipe Length <12 m (straight pipe) <12 m (straight pipe) <12 m (straight pipe)
Standard Maximum 5DR 5DR 5DR
Bend Radius†
Standard Bend Degrees 45°/90° 45°/90° 45°/90°
Application Method Hand-Flocking Spray Hand-Flocking Spray Hand-Flocking Spray
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New Pipe Handling Technology
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In House Testing Facilities
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Bredero Shaw’s experiences and solutions
on line pipe coatings and FJC related to
Balongan project
Scope of Work of Balongan Project
• Anti-corrosion (3LPE):
– Minimum 300 microns of Fusion Bonded Epoxy Powder Primer
– Minimum 250 microns of Polyethylene Adhesive
– Polyethylene to minimum 3.50 mm finished coating system thickness
• 5LPP Coating:
– Nominal 300 microns of Fusion Bonded Epoxy Powder Primer
– Minimum 300 microns of Copolymer Adhesive
– Nominal 5.40 mm protective Polypropylene Topcoat
– 12.7mm of Polypropylene foam layer
– Polypropylene protective shield of nominal 3.00mm.
A total insulation thickness of 0.3+0.3+5.4+12.7+3.0=21.7mm
• Concrete with Anode Installation:
– 55mm thickness of 3040 kg/m3 saturated density concrete reinforced with continuous
rebar cage for buried section, 55mm-135mm for un-buried sections
• Field Joint Coatings: HSS+IMPU (+Pre-made PU Foam for
offshore FJ)
– Specification requirement: 2.5 mm adhesive with PE backing
– We recommend: GTS-PE/PP (2.5 mm minimum total thickness)
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Bredero Shaw APAC Experience
List – ACC+MLPP+CWC
Year Customer Project Name Pipe Size Length Type of Coating Concrete Location of
(inch) (kms) Thks. (inch) Pipeline
2014 Mubadala Nong Yao Field Development 6", 8", 10", 12" 19.4 FBE, Prilo-K, 5Lyr PP, Thailand
Petroleum Project FBE
2013 McDermott Inpex Ichthys URF 6", 8", 12", 20" 118.3 3Lyr PP, 7Lyr PP Australia
Australia Pty Ltd
2013 PT. KPM Oil & Gas Petronas Carigali Bukit Tua - 8.625", 12.75" 49.2 FBE, 3Lyr PP, 7Lyr PP, 1.96" Indonesia
Ketapang Development & 16" AE, CWC
2013 Apache Australia Julimar 4", 18" 73.2 3Lyr PP, Multi Lyr 2.95", 4.13" Australia
PP, Conc
2012 Chevron Australia Chevron Wheatstone 14", 24" 76.0 3Lyr PP, Multi Lyr 1.5", 2.4" Australia
Flowlines PP, Conc
2011 Marubeni Itochu ExxonMobil Sakhalin I 20" 27.3 FBE, Multi Lyr PP, 2.0" Russia
Tubulars Asia Arkutun-Dagi Conc
2009 J. Ray McDermott CuuLong Su Tu Den North 10", 16", 24" 80.0 FBE, Multi-Lyr PP, 1.5" - 2.4" Vietnam
East Conc, SPU
2008 Woodside Pluto LNG 20", 36" 237.0 Int, AE, 3Lyr PP, 1.57" - 4.72 Australia
Multi-Lyr PP, Conc
2007 J. Ray McDermott Cuu Long Su Tu Vang Blk 15-1 4", 10", 12", 33.2 FBE, Multi-Lyr PP, 1.18", 1.89", Vietnam
16", 24" Conc 2.36"
2007 Intraline Talisman Northern Field 4" - 26" 86.0 AE, 3Lyr PP, Multi- 1.77" - 4.13" Malaysia
Resources Bunga Orkid Lyr PP, Conc
2007 Petronas Carigali Puteri to Penara 8", 12" 28.2 AE, Multi-Lyr PP, 2.17" Malaysia
Conc
2007 Petronas Carigali Angsi-D 6", 10", 12" 33.1 AE, 3Lyr PP, Multi- 1", 1.18" Malaysia
Lyr PP, Conc
2006 J. Ray McDermott Talisman Bunga Tulip 4", 6", 14" 23.0 AE, 3Lyr PP, Multi- 1.61" - 2.95" Malaysia
Lyr PP, Conc
2006 Delcom / SBM Murphy Kikeh Gap System 10" 5.4 3Lyr PP, Multi-Lyr PP Malaysia
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Bredero Shaw References (GTS-PE)
Year Country Project Name No. of Client OD Operating
joints temp (°C)
2014 Norway Martin Linge Project TOTAL 6,000 2" 65
2014 Thailand Bundled Project - B3M PTTEP 766 24"
2014 Thailand Bundled Project - A2C PTTEP 7,000 18" 80
Devon,
2007- Canada Various Projects Imperial Oil, 1,500 24 and 48” 100
2009 Pennwest
2013 China Bo Xi CNOOC 1,125 6"to10" 70
Gulf of
Tubular Bells Project HESS 4,500 12" to 16" 80
2013 Mexico
2012 China Liwan Deepwater Husky 26,075 6" 70
6.625",
China Liwan Shallow Water ProjectCNOOC 13, 620 80
2012 12.75", 22"
2012 China Liwan Deep Water Project CNOOC 26,083 3" to 22" 80
2012 Thailand Bundled Project -Phase I- PTTEP 1,000 3" to 22" 80
2012 China Liwan Shallow Water Husky 21,000 16" 70
2012 Vietnam HST/D Riser Thang Long 50 3"
6.625" &
Vietnam Bien Dong 1 PetroVietnam 40 80
2012 8.625"
CACT Huizhou Pipelines
China CNOOC 3,900 10" and 12" 100
2011 Replacement Project
Indonesia Ruby Project TOTAL 1,000 10" and 12" 80
2011
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Bredero Shaw References (GTS-PP)
Year Country Project Name No. of Client OD Operating
joints temp (°C)
2015 Indonesia Total Bekapai (Ongoing) TOTAL 12” 115
2015 Indonesia MILA–A and ASTI–A CNOOC 10.75” 115
platforms and pipelines
(Ongoing)
2014 Bulgaria South Stream Line # 1 - 2050 ENI / 6", 16", 32" 55
Offshore Gazprom & 32.5"
2014 Bulgaria South Stream Line # 1 - 56550 ENI / 32” 55
Onshore Prefabrication Gazprom
2014 Thailand Bundled Project - B3M 1919 PTTEP 14" & 18" 120
2014 Thailand Bundled Project - A2C 1006 PTTEP 12" & 24" 120
2013 Indonesia Sisi Nubi Project 1653 TOTAL 20" & 28" 100
2013 Indonesia Panyu PY35-1/2 Project 1724 COOEC 6"to10" 70
2013 Australia Ichthys Flowlines 4275 Inpex 6.625" and 90
Project 8.625"
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Bredero Shaw References (IMPU)
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Bredero Shaw Concrete Coating
Technologies
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Steel Cage vs. Wire Mesh
Reinforcement
• Reinforcing steel shall be steel cage. Steel bars shall conform to
ASTM A185 with a minimum bar diameter of 5.0mm. The
material used shall conform to the tensile property
requirements in Table 1 of ASTM A82. For welded cages, the
spacing between circumferential bars should be maximum 120
mm. Galvanised welded wire mesh shall only be used for
surface reinforcement for concrete thickness > 100 mm where
the first layer of reinforcement shall be steel welded cage. If
wire mesh is used it shall be Bekaert "Armapipe" or Company-
approved equivalent conforming to ASTM A82.
• The number of layers of reinforcement shall be determined by
the required concrete coating thickness as follows:
– Up to 100 mm 1 layer (Cage reinforcement)
– over 100 mm 2 layers (First layer shall be cage reinforcement)
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Thick CWC Coating
It has been the BrederoShaw manufacturing standards using a fabricated
reinforcement cage made from cold drawn steel bars, >3mm dia. complying with
ISO 21809-5 and DNV OS F101 for offshore impinged concrete application since
1980s.
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Bredero Shaw’s Thermal Design
Process
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Wet Insulation Technology for Flow
Assurance
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MLPP (5,7,9 layers)
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U=7.44 W/m2K of 21.7mm 5LPP
(incl. 12.5 mm PPF) + 55mm CWC
Customer Pertamina Design Shiwei
Project Approved
Recipient Balongan Revision 0 Date Apr 10 2015
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Material T hickness (mm) T hickness (in) k (W/mK) k (BT U/ft.h.F) Density kg/m Density lb/cu.ft
Cp (J/kg.K) Cp (BT U/lb.F)
FBE 0.3 0.01 0.300 0.173 1450 90.53 1500 0.359
Adhesive 0.30 0.01 0.220 0.127 900 56.20 3407 0.814
Solid PP 5.4 0.21 0.220 0.127 900 56.20 3267 0.781
PP Foam 12.4 0.49 0.178 0.103 754 47.07 2798 0.669
Solid PP 3.0 0.12 0.221 0.128 900 56.20 2420 0.578
Concrete 55.0 2.17 2.000 1.156 3040 189.78 880 0.210
Start of Life
Sub Mass Empty 101.28 (kg/m) 67.93 lb/ft
Sub Mass Full 577.63 (kg/m) 387.44 lb/ft
End of Life
Sub Mass Empty 101.45 (kg/m) 68.05 lb/ft
Sub Mass Full 577.94 (kg/m) 387.64 lb/ft
S.G. Empty 1.135 1.14
S.G: Full 1.770 1.77
T otal compression (%) 0.09 0.09
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The Industry’s Largest Simulated Service Vessel
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Combining the Best into One in APAC
- Bredero Shaw’s Field Applied Coatings Services
• To deliver increased value to clients, Bredero Shaw Field Joint and
Custom Coating and Canusa-CPS businesses are transitioning into one
business
• Both businesses will maintain their discrete brands and support all
existing customers for their current products with fair market pricing,
while the new entity will offer:
– Field application of Canusa-CPS products
– Provision and field application polyurethane infill
– Bundled offers including field joint products, application of those products in
the field, main line factory-applied coating from regional coating facilities in
Kuantan and Kabil, and custom coating
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Bringing Value to the Customers
- Field Applied Coatings Services
• Guaranteed compatibility of factory and field applied coating
• Optimization of factory and field applied coatings with coordinated spec review
• Factory – chamfer angles, cutback widths, toe configurations
• Field – Field joint type, width, heating characteristics
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Complete Field Joint Solution
Provider
Insulation
System
Concrete Infill
HDPUF System
Field Joints for Anticorrosion Coatings
Field Joints for Anticorrosion Coatings
• Factory Grade FJC –
compatible with factory
applied 3LPO coatings (to ISO
21809-1).
Backing (PE
or PP)
Adhesive
Liquid Epoxy
Not specified
Not specified
Minimum level of performance for any true 3LPP coating, factory or field-applied
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Injection Moulding FJC Process
3LPE Coating
3LPPE Coating
Anode Location
Approx.1.0 m (Approx. 1.0 m from End of Concrete Coating)
Thermit Weld
225 – 255 mm
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Goose Neck Coating
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Bredero Shaw’s recommendations for critical
technical items in Balongan project
specifications
Suggestions to Specification
Proposed Changes Rational of Change
Pipeline Corrosion Coating
1. To include the requirement that PQT and Production An ISO 17025 accredited laboratory ensures competency of
testing shall be performed by an ISO 17025 accredited testing and calibration of site laboratories.
laboratory
2. To include the requirement for minimum NACE Level 3 Applicator to provide qualified and experienced NACE Level 3
Coating Inspector to supervise QC testing and approval. certified inspectors to supervise QC testing and ensuring
compliance to approved ITP.
3. To include the requirement for a preservation plan that End Seal Tape is an effective moisture barrier and provide
includes End Seal Tape as a measure to protect pipe durable end protection compared to varnish/paint or other
ends for extended storage purposes. material. For long term storage > 3 months, End Seal Tape is
proven to effectively minimise end disbondment and mitigate
rust formation/deterioration at pipe ends.
Suggestions to Specification
Proposed Changes Rational of Change
Pipeline Concrete Weight Coating
1. To specify that reinforcing steel shall be steel cage and Cage reinforcement for concrete weight coatings is required
applied on coating thickness up to 100mm. Wire mesh as a minimum. Mesh is typically used on larger concrete
shall only be used for concrete thickness > 100 mm thickness if more than one layer of reinforcement is used.
where the first layer of reinforcement shall be steel
welded cage.
2. To include the requirement to provide track records of Proven track records to demonstrate capability to apply up to
applying minimum 135mm concrete thickness. 135mm coating thickness and meeting specification
requirements.
Macedon: 508 mm OD, 15.9mmWT –
40mm, 70mm, 100mm, 120mm, 140mm,
3400 kg/m3 CWC
3. To include the requirement for minimum NACE Level 3 Applicator to provide qualified and experienced NACE Level 3
Coating Inspector to supervise QC testing and approval. certified inspectors to supervise QC testing and ensuring
compliance to approved ITP.
3. To include the requirement of smoothed surface finish To reduce airborne dust during the pipelay which reduces
for impingement concrete weight coating. HSE concern and offers an environmental benefit due to
reduced dust disposal requirements offshore.
Suggestions to Specification
Proposed Changes Rational of Change
Pipeline Thermal Insulation
1. To include the requirement of submitting historical data
of Simulated Service Testing (SST) and project track
records for the thermal insulation coating system. To qualify that the applicator has proven capability in thermal
insulation coating.
2. To replace the requirement of thermochromatic Thermochromic materials may give off vapors if not
indicators and specify that the application of sleeves handled with care. Similar indicators are localised
shall follow manufacturer’s recommendations. modifications to the backing and does not indicate the
full condition of the sleeve. The Contractor has to ensure
the field joint coating application temperature is within
the temperature range specified by the manufacturer
and that the heating is uniform on the entire sleeve.
3. To amend the requirements for HSS to align with ISO To ensure compatibility and performance of the field
21809-1 on peel strength, hardness, indentation and joint coating to the factory-applied line pipe coating.
cathodic disbondment test criteria.
4. To include the requirement for minimum NACE Level 3 Applicator to provide qualified and experienced NACE Level 3
Coating Inspector to supervise QC testing and approval. certified inspectors to supervise QC testing and ensuring
compliance to approved ITP.
STRONG
FUNDAMENTALS
FUNDAMENTAL
STRENGTHS