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PT INDAL STEEL PIPE

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INTERNALCEMENTLININGFORWATER
PIPELINE

Welcome to Indal Steel Pipe

WrittenbyIndalSteelPipe

PTINDALSTEELPIPE(ISP)isamembercompanyofMaspionGroup.
MaspionGroupisoneoftheconglomerateinAsianCountriesandleadingof
severalindustries,fromhomeappliances,electronics,steelindustry,aluminum
industry,constructionmaterialsandindustrialestate(visitwww.maspion.com).
LocatedstrategicallyatMaspionIndustrialEstate,Manyar,Gresik,EastJava,
itisonly30minutesawayfromJuandaInternationalAirportofSurabaya,andaccessableeasilythroughexpresswayto
theplant.Therearethreeportsnearby,namely:SiamMaspionTerminalwhich(visitwww.siammaspionjetty.com,
PublicPortofGresik(visitwww.pelindo.co.id),andPublicPortofTanjungPerakSurabaya(visitwww.pelindo.co.id.
TheaccesstoSiamMaspionTerminaliswithintheindustrialestateandsothatthetruckingfromISPPlanttotheport
andviceversacanbecarriedouteasily.
ISP is the most integrated steel pipe manufacturer and anti-corrosion coating applicator in the region. All requirements
for steel pipe and coating may be fulfilled in one location to minimize handling, transportation and any potential
damages which provides many added values to customers and users.
ISPhassixmodernlinesofspiralpipeformingmachineandonecompletelineofHighFrequencyElectricResistance
Weldingpipeformingmachine.Thetotalinstalledcapacityis325,000metrictonsperyear.Themachinariesare
designedformanufacturingofAPIlinepipesintendedforoilandgastransmission.WiththosemachineriesISPis
capabletomanufacturelinepipecomplytothelatestrequirementsoftheAPI5LPSL1andPSL2forpipeline
transportationsystemofgasorpetroleumofsweetservice,sourservice(H),onshoreandoffshore(J).ISPcanalso
supplywaterpipeandstructuralpipeforpipepile,sheetpipepile,andotherconstructionneeds.
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supplywaterpipeandstructuralpipeforpipepile,sheetpipepile,andotherconstructionneeds.
ISPalsohasacompletelineofmodernexternalandinternalpipecoatingfacilities.Theexternalcoatingincludethree
layerpolyethylene(3LPE),threelayerpolyprophylene(3LPP),MultiLayerPolyProprophylene(MLPP),PolyUrethane
Foam(PUF)andHDPEjacket,FusionBondedEpoxy(FBE),multilayerpaintepoxycoating,asphaltenamel(AEC),
neoprene/EPDM,andconcreteweightcoating(CWC).Theinternalcoatingincludescementmortarlining,liquidepoxy
paint,andFusionBondedEpoxy(FBE).Forspecificpurpose,e.g.bends,tee,reducer,flange,etc.,acustomized
coatingprocessmaybeofferedbyISP.ISPfulfillsallapplicableinternationalstandards,industrialstandards,and
specificcustomerrequirements.
Thosemodernandcompletefacilitiescombinedwithamodernmanagementorganizationmanagedbyprofessionalsand
supportedbymanytechnicalexpertises,ISPmayfulfillallapplicablestandardsacceptablebyworldclassindustries.

PLANTFACILITIES

PIPE MAKING
ISPhassixcompletelinesofSAWHpipemillstoproducesteelpipefrom4inchesupto80inches,onecomplete
lineofHFWpipemilltoproducecarbonsteelpipefrom6upto16nominalpipesizesandtwoslittinglines.

COATING FACILITIES
ISPhasthemostcompletecoatingfacilitiesintheregion.Fromistfunctionsthecoatingfacilitiesmaycatagorized
into4groups:
ExternalAnticorrosioncoating:
a.SinglelayerLiquidepoxycoating(Simpleliq)
b.MultilayerLiquidepoxycoating(DuroCoat)
c.Highbuildepoxycoating(HBE)(Hibox)
d.SinglelayerFusionBondedEpoxycoating(SFBE)
e.DuallayerFusionBondedEpoxycoating(DFBE)
f.Asphaltenamelcoating(Greencoat)
g.Threelayerpolyethylenecoating(3LPE)
h.Threelayerpolyprophylenecoating(3LPP)
i.NeopreneCoating(Neorub)
j.EPDMcoating(Highrub)

Internalcoating/lining
a.Cementmortarlining(SELFCURE)
b.Singlelayerepoxypaintcoating(Flowsure)
c.Rubberlining(Rubline)

Heatinsulation:
a.MultiLayerPolyprophyleneCoating(Thermoright)
b.PolyurethaneFoam(Thermosafe)

Heavyweightcoating
a.Withsteelcage(Rhinocage)
b. Wiremesh(Rigidmax)
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b.Wiremesh(Rigidmax)
Customcoating
a.Twolayerpolyethylene(RondoV)
b.SinglelayerFBE(GoundheZ)
c.3LPP(MahareT)

SPACIOUSSTORAGEYARD

LABORATORY

SPECIFICATIONANDAPPLICATION

ThepipemanufacturedbyISPhasonehelicalseamproducedbytheautomaticsubmergedarcweldingwhereonepass
isontheinside,andonepassisontheoutside.ThisprocessisknownasDSAW(DoubleSubmergedArcWelding)
resultinganexcellentweldqualitywhichmeetsmostofthemajorinternationalstandardsandacceptablecodes,e.g.:

OilandGaspipeline:
API5L/ISO3183PSL1/PSL2/H/J
SNI070537
BS3601

Forsubmarinepipeline:
DNVOSF101

Structural/PilingPipe:
DIN17120
DIN17123
JISA5525/G3444
ASTMA252

Watertransmissionanddistribution:
AWWAC200
ASTMA139
BS534
DIN2460

QUALITYCONTROL
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QUALITYCONTROL
Oneveryproductionstepsacloseanddiligentinspectionarecarriedoutusingpropertools,calibratedmeasurements,
documentedprocedures,andqualifiedpersonneltoensurethatanydeviationfromtherequirementswillbeidentifiedat
thefirsttimeofitsoccurrence,andavoidofitsreoccurrence.
ThequalitysystemofAPISpecificationQ1andISO9001areimplementedconsistentlyandprogressivelyimproved,
andsupportedwithastrongcommitmentofthetopmanagement.
AtypicalQCprocessofAPI5Lare:
1.Receivinginspection
2.U/Tonlineinspectionon:
Weldseamforlongitudinalandtransversedefects
Edgeslamination
Bodylamination
3.Dimensionalandvisualinspection
4.Xrayradiography
5.Hydrotest
6.MechanicalTest
7.Chemicalcompositiontest
8.CharpyTest
9.Offlineultrasonictest
10.FinalInspection

Forsourservice,additionalcorrosiontestarerequired,i.e.:
1.HICtestacc.toNACETM0284
2.SSCCtestacc.toNACETM0177

SIZESAVAILABILITY
ISPofferawiderangeofsizecombination,wallthicknessanddiameter,andvariousgradesofmaterialwhichmayfulfill
allofstandardsrequirementsoflinepipes,evenextendsintoaspecificrequirements.Linepipeswithstandard
dimensionaccordingtoAPI5L,AWWAC200,ASTMA134,orASTMA139canbemanufactured.
Theintermediatesizesarealsopossible.ISPcanmanufacturelinepiperangingfrom4inchesupto80inchesofoutside
diameterandwallthicknessfrom0.125inchupto1inch.ThesteelqualityfromAPI5LgradeAuptoX100which
complytothespecificrequirementsofAPI5LPSL1,PSL2,PSL2Annex.G,Sourservice(Annex.H),orOffshore
(Annex.J).

ANTICORROSIONCOATING
Externalcorrosionprotectionforpipelinesconsistofcoatingandcathodicprotection.Itssuccessgreatlydependsonthe
coatingsabilitytoprovideabarrieragainstoxygenandwaterandtoworkwithcathodicprotection.

Forinternalprotection,however,successmainlydependsonthecoatingsabilitytopreventthecorrosioncausingions
fromreachingthepipesurface.

Althoughcorrosionprotectionisthemajorfactorindeterminingthetypeofpipelinecoating,mechanicalproperties
(flexibility,impactresistance,adhesion,andabration)alsoinfluencethischoicebecausetheirroleincontrollingthe
economicofpiplinecontruction.
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PTINDALSTEELPIPEprovidesacompleteoptionforeitherinternalorexternalcorrosionprotectionsandalsotoinstall
sacrificialanode.

Theexternalcorrosionprotectionconsistof:

1.ThreelayerPolyethylenecoating
2.ThreelayerPolyprophylenecoating
3.Fusionbondedepoxycoating
4.Coaltarenamelcoating

Theinternalcorrosionprotectionconsistof:

Liquidepoxycoating
Cementmortarlining

ForsubmarinepipelinePTIndalSteelPipemayprovideconcreteweightcoating

ThreelayerPolyethyleneorPolyprophyleneand
FusionBondedEpixyCoating
Steelpipelinemustbeprotectedagainstcorrosion.Thelatestdevelopmentofthreelayersystemoffermany
advantageous:
excellentcorrosionprotection,
goodmechanicalprotection,
easytohandleandinstall,
durableandlongservicelife,
reasonablyeconomic.

Thethreelayersystemconsistoffusionbondedepoxy(+150micron)onthefirstlayer,adhesivecopolymer(+
150micron)onthesecondlayer,andPolyethyleneorPolypropylene(1.5mm4mm)onthetoplayer.Theservice
temperatureofthefieldconditionswilldictatetheselectionofPEorPP.PEwillworkwellbelow80oCwhilePP
mayworkover80oC.

usionbondedepoxyprovidesexcellentadhesiontosteelpipe,resistancetocathodicdisbondmentandchemical
resistance.ExtrudedintermediateadhesivelayerandtheextrudedPE/PPtoplayerproviding,inadditiontothe
corrosionprotection,astrongphysicalandmechanicalprotections.

FBEcoatingsarestandaloneonepartdrypowderthermosettingcoatingsthat,whenheatactivated,producea
chemicalreactiontothesteelpipesurfacewhilemaintainingtheperformanceofispropertiesasalongtermdurable
corrosionprotection.Materialsareappliedwithathermostaticsprayontothesurfaceofaninductionheatedblast
cleanedsteelpipeinacontrolledplantenvironment.

TheStandardThicknessis300400micronforonshorepipeline,an600750micronforoffshorepipelinewith
CWC.

Applicablestandards
CSAZ245.21:ExternalPolyethyleneCoatingforPipe
DIN30670:PolyethyleneSheathingofSteelTubes

DIN30678:PolypropyleneCoatingforSteelPipe
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DIN30678:PolypropyleneCoatingforSteelPipe
NFA49710:SteelTubesExternalThreeLayerPolyethyleneBaseCoating
NFA49711:SteelTubesExternalThreeLayerPolypropyleneBaseCoating
NACERP0394:RecommendedPracticeforApplication,PerformanceandQualityControlofPlantApplied,
FusionBondedEpoxyExternalPipeCoating
APIRP5L7:RecommendedPracticesforUnprimedInternalFusionBondedEpoxyCoatingofLinePipe
AWWAC213:FusionBondedEpoxyCoatingforTheInteriorandExteriorofSteelWaterPipelines

CTE(CoalTarEnamelProtectiveCoating)
Hotappliedcoaltarenamelhasbeenusedasacorrosionprotectionofsteelpipeasanexteriorcoating.Theyare
reinforcedwithglassfiberinnerandouterwraps.Thesewrapshavereplacedtheoriginalfibrousmaterial,suchas
asbestosfelt,whichwasastandardwrapformanyyearsuntilhealthconcernregardingasbestossurfaced.Theglass
fiberinnerandouterwrapsarenowbeingspecifiedasroutinereinforcementsforcoaltarenamelcoatings.

ThecoatingsystemcomplytoAWWAC203consistofonecoatofliquidadhesivefollowedbyahotappliedcoaltar
enamelonwhichasinglelayerofspecifiedouterwrapshallbeapplied.Thecoatingshallthenbefinishedwitheither
onecoatofwaterresistentwhitewashorwateremulsionlatexpaint,orasinglewrapofkaftpaper.Theresulting
constructionoftheexteriorcoatingsystemshallconsistofliquidadhesive(5010micron),coaltarenamel(2.4mm+
0.8mm),outerwrapandfinishcoat.Thickercoatingconstructionisalsoacceptable.

Whenadditionalexternalcoaltarenamelcorrosionprotectionisrequiredbeyondtheabovementionedcontruction,the
coatingcontructionshallconsistof(1)liquidadhesive,(2)coaltarenamel(2.4mm+0.8mm)thick,(3)glassfiber
innerwrap,(4)coaltarenamel(minimum0.8mm)thick,(5)glassfibreouterwrap,(6)coaltarenamel(minimum0.8mm)
(7)glassfiberouterwrap,and(8)whitewash,wateremulsionlatexpaint,orkraftpaperfinishgood.

INTERNALCENTRIFUGALLYAPPLIEDCEMENT
LININGACC.AWWAC205
Cementmortarlinedsteelpipecombinesthephysicalstrengthofsteelwiththe
protectivequalitiesofcementmortar.Theliningappliedcentrifugally,createa
smooth,densefinishthatprotectthepipefromtuberculationandprovideameasure
ofcorroosionprotection.Thesmoothinteriorsurfacewillprovideahighflow
coefficientforthedesignlifeofthepipelineundernormaloperatingconditions.

CementmortarliningThickness

NominalPipeSize(mm)LiningThickness(mm)Tolerance(mm)

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1002506(1.6/+3.2)

2755758(1.6/+3.2)

60090010(1.6/+3.2)

Over90013(1.6/+4.8)

Spinningspeedshallbesuchthatproduceacentrifugalaccelerationbetween75upto150g,wherebygis9.81m/s 2

CONCRETEWEIGHTCOATING
Concrete Weight Coating (CWC) is a plant applied coating developed to provide negative buoyancy, mechanical
protection,andonbottomstabilityforsubmarinepipelines.CWCalsoapplicableforrivercrossingorswampyarea.

The concrete is made of a mixture of cement, sand, and heavy aggregate. The mixture is designed and controlled
strictlytofulfilltherequirementsofdensity,compressionstrength,dimension,waterabsorbtion,andnegativeboyancy.
The concrete formulation can be tailored to any specified density specification. Typical product formulations are 140,
165,190,and200poundspercubicfoot(nominal),but,greaterdensitiesarealsoavailable.Thicknessescanbeapplied
fromonetoeightinches.Concretecompressivestrengthsrangefrom3000psiandgreaterreinforcinggalvanizedwireis
availableinseveralmeshandgaugevalues,withsingleormultiplefeeds.

CWCcanbeappliedoveranticorrosionandinsulationcoatingsystems.Thisenablesprojectteamstochoosethemost
appropriateweightcoatingsystemwithoutcompromisingthelongtermcorrosionprotectionofthepipeline.

Thepipediametercanbeprocessedis4upto60.

POLYURETHANECOATING

Insomeapplicationsitissometimerequiredtomaintainthefluidtemperatureatcertainminimumvalue.Acalor
dissipationduringthetransmissionpipelineshallbereducedtominimum.Forthispurposepolyurethane(PU)insulation
coatingisthebestsolution.

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ThetypicalonshoreapplicationsofthePUcoatingare:

Transmissionlineforparrafinicoil.
Distributionlineforhotwatercityheatingsystem
Steampipelineforsteamfloodoilrecoverysystem.

Foroffshoreapplication,itmaybecoatedwithaheavyconcrete.

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Plant Facilities
WrittenbyIndalSteelPipe

ISPhassixcompletelinesofSAWHpipemillstoproducesteelpipefrom4inchesupto80inches.Allofthem
arededicatedmainlyforproducingsteelpipeforoilandgastransportationsystemcomplytoAPI5LandISO3183.For
smallerpipediameters,ISPhasoneslitinglinetogetaproperstripwidth.Toreduceresidualstresseswithinthe
weldmentofsubmergedarcweldingahighfrequencyseamanneallerisinstalled.Thepipemovementswithinthefactory
arecarriedouteitherbydiaboloconveyororoverheadcrane.Combinedwithpropermachinelayout,theflowofprocessis
excellentwithoutanypotentialofbottlenecking.Onecompletelineofthreelayerpolyethylenecoatingmachinecan
produce250jointsdaily.Allofthosemachineriesarelocatedon10hectarespace.

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Specification and Application

WrittenbyPTINDALSTEELPIPE

ThepipemanufacturedbyISPhasonehelicalseamproducedbyuseofautomaticsubmergedarcweldingsystem
whereonepassisontheinside,andonepassisontheoutside.ThisprocessisknowasDSAW(DoubleSubmergedArc
Welding)resultinganexcellentweldqualitywhichmeetsmostofthemajorinternationalstandardsandacceptable
codes,e.g.:

Oil and Gas pipeline:

-API 5L/ISO 3183 PSL1/PSL2/H/J

SNI070537
BS3601
For Submarine pipeline:

-DNV OS-F-101

Structural/Piling Pipe:

-DIN 17120

-DIN 17123

-JIS A 5525/G 3444

-ASTMA252

Water transmission and distribution:

-AWWA C200

-ASTMA 139

-BS 534

-DIN 2460

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