Divisions : Buildings Infrastructure Rail

4 Mars 2014 Consolis Corporate

CONSOLIS GROUP Leader in precast concrete solutions with over 1000 diversified products

Now offering ONSITE PRODUCTION from mobile factories to reach out overseas customers EPC/IPP with large diameter CW & onshore / offshore turnkey projects.

WATER PIPELINE SOLUTIONS for COOLING WATER SYSTEMS in POWER PLANTS & WATER SUPPLY PIPELINES Since 1993 CONSOLIS supplies its customers across South East Asia from partner subsidiary PT BONNA INDONESIA.

CONSOLIS - Bonna Indonesia REFERENCES & PROJECTS LOCATION

Since 1993, CONSOLIS supplies its customers across South East Asia from subsidiary PT BONNA INDONESIA

NATURAL MARKET

BONNA RCCP pressure pipes in POWER PLANTS

Solutions for Cooling systems

CONSOLIS pressure pipeline in ENERGY & WATER SUPPLY Bonna RCCP pipes for power plants

Prestressed PCP pipes for water supply

EPC design choices DRIVE overall performance of POWER PLANT Key impact of COOLING WATER (CW) pipeline material choice.

POWER PLANT CONSTRUCTION & COMMERCIAL CONDITIONS : EFFICIENCY and RELIABILITY OF A PLANT are MAJOR FACTORS for COMMERCIAL SUCCESS of their OWNERS (including IPPs).

typically, for the FIRST 4 YEARS, the EPC CONTRACTOR is RESPONSIBLE for CONSTRUCTION and WARRANTY

for the NEXT 25 YEARS, the OWNER becomes RESPONSIBLE for O&M, RELIABILITY and EFFICIENCY which WILL BE the MAIN DETERMINANT for the COMPANY FINANCIAL RESULTS.

CONDENSER efficiency will depend on GOOD CW DESIGN and will indirectly IMPACT TURBINE performance

ADEQUATE SELECTION of RELIABLE CW MATERIAL / EQUIPMENT at EPC STAGE will contribute to CONTROL of POWER PLANTs future overall O&M and EFFICIENCY

Bonna RCCP pipes : concrete-based solution to optimize cost of ownership

NEW POWER PLANT : COOLING SYSTEM is only a minor CAPEX component yet its performance will impact OPEX & OVERALL EFFICIENCY

Boiler Turbine

Generator

CW pumps Intake head Discharge outfall

CIVIL WORKS 10%

CW pipes = usually 0.2% to 1.5% of total CAPEX depending of diameter & length

condenser

POWER ISLAND 85%

Important : choose the right PIPELINE MATERIAL with proven performance.

SEAWATER COOLING SYSTEMS CRITICAL TARGET : EFFICIENCY by REDUCING MAINTENANCE

In a context of rising CW diameters the MAIN ISSUES are linked to SURFACE & DESIGN Proliferation of marine life will affect flow rates

If corrosion prone high-maintenance, impaired durability

All linings (rubber, epoxy) will eventually peel off

Important : choose the right PIPELINE MATERIAL with proven performance.

Plants capacity MW

CW diameters

BONNA pipes - CUSTOM-MADE integrated SOLUTIONS

for ENERGY POWER PLANTS owners & EPC contractors

BONNA offers complete SERVICES for the BENEFITS of its customers

( ENGINEERING, DESIGN, STUDIES, INSTALLATION & TECHNICAL FIELD ASSISTANCE )

COMPLETE INNOVATIVE SOLUTIONS for COOLING WATER SYSTEMS 1. ONSHORE inlet/outlet pipelines from pumping station to condenser

2. OFFSHORE intake pressure pipeline & discharge outfall

3. Modular precast concrete intake headers/risers & diffusers

BONNA RCCP PIPES in POWER PLANTS

header intake inshore pipeline

PRESSURE (typical

COOLING WATER SYSTEM - OFFSHORE PIPELINE Discharge OUTFALL in RCCP and DIFFUSER in precast concrete

Custom-made diffusers (= RCCP tees)

Discharge OUTFALL in RCCP and DIFFUSER in precast concrete

Custom-made diffusers (= RCCP tees)

Custom-made intake head in precast concrete

Underwater jacking tightening system of pre-welded RCCP piping sections.

COOLING WATER SYSTEM - OFFSHORE PIPELINE Pressurized INTAKE PIPE in RCCP and aspiration HEADER / RISER in precast concrete

CONSOLIS - COOLING WATER SOLUTIONS for POWER PLANTS EXPANDING SCOPE of OFFER to MEET NEW DEMAND

TRENDS in BOP Bonna RCCP new benefits Innovative + cost effective requirements for owners / IPP / EPC integrated SOLUTIONS

Increased customer support across ASIA :

Expanded CW scope beyond ONSHORE into OFFSHORE

advantageously replace traditional carbon steel / GRP / HDPE

BONNA RCCP pipes

3500 4000

Future 5000

COOLING WATER SYSTEMS for POWER PLANTS Trend : demand for LARGE DIAMETER PIPES > ND4000 mm

So BONNA RCCP pipes even more attractive cost-wise, compared to CARBO STEEL PIPE

Bonna RCCP pipes response to MARKET DEMAND (internal in mm)

Current catalog : from 400 to 3500

Transport limit from our Indonesian factory (bridge height) : 3800

Current demand up to 4000 now offering onsite production (mobile factory)

Near future already testing 4800

BONNA RCCP pipes made onsite in MOBILE FACTORY

Offshore launching

Inland fabrication & long sections pre-

assembly

Onshore launching

Custom-Made precast concrete Intake header/risers

OFFSHORE CASE STUDY

Intake / Discharge Pipelines Intake Header/Riser

OFFSHORE COOLING WATER SOLUTIONS in PRECAST REINFORCED CONCRETE Modular intake / outfall PIPELINES + HEADER + DIFFUSERS

DESIGN of the CW will determine its own performance and directly impact the operating EFFICIENCY of the power plant CONDENSER.

minimize CAPEX to fit offshore contractor equipment at construction stage

optimize OPEX to site-specific constraints (depth, water flow, speed)

Modular construction to fit marine contractors equipment, facilitate handling and avoid underwater welding. Intake head assembled under or above water.

Chlorination kit and access manhole included, pre-assembled in factory

Maintenance-free (no apparent steel, no need for cathodic protection)

Environmental-friendly structural concrete design : typical height 2.0m to limit maximum water flow to 0.2-0.3m/s and organic intake.

Custom-made aspiration header / risers for power plants up to 1000 MW

Example above : 5.5m velocity cap,

4 components, total weight

conceptual drawing

OFFSHORE INTAKE PIPELINE

Intake Heads x3

Pump station

A

B

C

Typical

Bonna RCCP ND2800 x2 lines ?

SAVINGS in dredging+ backfill reduction ?

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Typical

OFFSHORE INTAKE PIPELINE in BONNA pipes Proposed installation method 1/2

1. Pre-assembly: Bonna pipe type S-L welded in sections of 5-6 spools (~100 tons) on shore on barge

E and R ends are generally fitted with anchoring boxes for underwater jointing purpose..

2. Sections are then floated with temporary inflatable plugs Launching from on shore Sunk from barge/platform with crane (typical

250 tons capacity)

3. Towed sections by tugboat to sink on place with crane on barge.

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4. Divers guide sinking, alignement and positioning

of sections, until ready to connect by jack fitting.

5. Underwater assembly :

Fitting of flexible joints by tightening of hydraulic jacks.

Divers to check compressed PU foam seals on inner/outer pipe circumference.

6. Once joined together, the sections are secured before backfilling, with tied rods, using the same anchor boxes.

No underwater use of welding or mortar for jointing is necessary.

OFFSHORE INTAKE PIPELINE in BONNA pipes Proposed installation method 2/2

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OFFSHORE INTAKE PIPELINE Bonna RCCP pipe instead of HDPE

CONSOLIS PROPOSAL : Since RCCP self-reinforced internal structure allow very large pipe diameter,

replacie the 3 lines of HDPE ND2400 (13.6m2 combined section) by 2 lines of RCCP ND2800 (12.3m2)

RCCP ND2800 typical pipe characteristics : external diameter OD3280mm, length 3.50 meters, weight

5.50 tons/linear meter

1. DREDGING Reduced trench pathway (width x depth) if only 2 lines are used instead of 3 lines. Reduces dredging volume proportionately. Dimensional savings : m3 x dredging cost at $/m3

2. FOUNDATION / BEDDING

Rough trench surface is acceptable for Bonna reinforced concrete pipes. Specially graded bedding material not required as with HDPE. Savings : m3 x crushed aggregates at $/m3

3. COST OF PIPELINE MATERIAL (including installation ingredients)

Assumption : same order of magnitude between RCCP and HDPE. Difference = $ ?

4. INSTALLATION METHOD (without underwater welding) Field manual & technical assistance by BONNA specialist

5. BACKFILLING

Bonna ND2800 pipes are heavier and also have an inherent resistance under load and higher density (2.45 versus HDPE 0.95), offer the possibility of natural backfilling (as in Indonesia) then savings in crushed stones or controlled

Backfill. Potential savings : m3 x graded aggregates at $/m3

Bonna pipes 2 lines ND2800 = 10 tons/ml

Estim. weight trenching material : 52m3 x1.8 = 95 tons/ml

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Intake Heads x3

Intake Head

conceptual drawing

OFFSHORE INTAKE HEADER/RISER

Replace by 2 precast RCCP INTAKE HEADS ?

Possibility to let (partial) natural backfilling fill in the RCCP trenched pipeline ?

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CONSOLIS PROPOSAL : precast concrete head with velocity cap in a 5.m. Factory-made modular structure of 4 full

reinforced components for a total weight

1. Dredge seabed for the intake platform imprint.

2. Prepare seabed for 2 identical heads Can be based on 100m2 or 150m2 Can be with rock or other base

3. Pre-assemble intake head T-shaped base Can be done on barge Can be done on pier. Only needs grouting (Connexions only by fitting, grouting or bolting with resin) Field manual & technical assistance by BONNA specialist

4. Mount Ring on the top of the T-shaped base Welding of SL type joints (10mm steel plate) Protect with grouting

5. Attach Ring+T-shaped base on 5 lifting cables and lower piece in position

6. Attach velocity cap to lifting cables Lower piece in position Bolt the 5 screws Protect with grouting

7. Protect all metallic parts with grouting Fill area between seabed and intake head if relevant

8. Lower manhole into position Close manhole Tighten 8 bolts

OFFSHORE INTAKE HEADER/RISER 8 easy steps to install the modular precast structure

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OFFSHORE INTAKE HEADER/RISER 8 easy assembly steps - summary

MATERIAL COSTS 2 heads versus 3 heads Less dredging for intake head location.

INSTALLATION COST & METHOD (without underwater welding)

Time to install 2 versus 3 heads Lifting equipment and barges only for 60T max Assemble head components above surface or directly underwater Connexions only by fitting, grouting or bolting

BACKFILLING COSTS

Self supporting pipes can sustain higher weight and loads No risk of ovalization No need for special backfilling materials No need for anchoring as pipes are self anchoring

MAINTENANCE COSTS

No need for cathodic protection (no steel is in contact with water) Chlorination pipe facilitates protection against marine life incursion

(mussels and algae)

OFFSHORE INTAKE HEADER/RISER Savings compared to Cast-in-place ?

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BONNA RCCP pipes & SPECIAL FITTINGS

Manufacturing Process

SMOOTH PERMANENT LINING :

Protection against chemical corrosion of the steel thanks to passivation effect

Anti-abrasion Low hydraulic head loss

Watertightness Self-anchoring (no thrust blocks)

REINFORCED OUTER CONCRETE:

Resistance to water pressure Protection against full vacuum conditions Structural protection against mobile + fixed loads (backfill & wall side charges)

RCCP pipes PRODUCTION in FACTORY & SHIPPING POSSIBILITIES

Bonna pipes RCCP solutions COMPLETE range of diameter & components

As per EN639-641 up to 10% more economical than AWWA C-300

BONNA RCCP pipes & SPECIAL FITTINGS

Field Installation

Bonna RCCP pipes installation welded/flexible joints A SIMPLE LEGO-LIKE FIELD ASSEMBLY

TYPICAL SEQUENCE of OPERATIONS 1. Ground support foundations & bedding preparation 2. Laying-out the pipe spools / special fittings (Tees, Elbows,

Reducers, Wall crossings, Manholes, Flanges, etc) 3. Fitting of pipe segments (or closing the pipeline with lap-joints) 4. Welding S-L end-rings or fitting E-R flexible joints 5. Joint filling with mortar 6. Backfilling with native material Installation may proceed simultaneously on several fronts. Full choice of starting point : at interface or anywhere else. STAFF & EQUIPMENT - Optional ingredients (proposed by Consolis / Bonna) Welders & non-specialist semi-skilled labor Crawler crane for spools lifting & placement Loader for backfilling

BONNA RCCP pipes DESIGN ENGINEERING Typical trench design - as per NT 216

BONNA RCCP pipes DESIGN ENGINEERING Typical trench design - as per NT 216

Massive anchor / thrust blocks at every change of direction are NOT required. Backfilling can be done with the native material and single layer compaction

SPECIAL WORKS PIPE JACKING & MICRO-TUNNELLING

AREAS of EXPERTISE Capability to design PIPES for JACKING

Bonna RCCP pipes - BENEFITS of SELF-ANCHORING absence of massive anchor/thrust blocks

GRP

Welded restrained joint

W

W

W

W

W

W

With RCCP, massive concrete thrust (anchor) blocks are NOT required

WW WWWWW

THRUST FORCE

Welded or Fitted / flexible joints

W/F

W/F

W/F

ONSHORE CASE STUDY

Large diameter pipes Total Owners Cost (TCO) analysis

Soil improvement

ONSHORE TCO ANALYSIS : SHALLOW FOUNDATIONS for large diam BONNA RCCP pipes Design must be validated with specialist geotechnical engineers

Calculated savings > 4m USD/km Ie over 20m USD over whole project

CARBON STEEL PIPES Cost of traditional DEEP FOUNDATIONS PC piles (50m deep x 6 piles x 3m spread) and/or concrete cradles Estimated cost 5.0 mUSD/km versus BONNA RCCP pipes with SHALLOW FOUNDATIONS combining : Geo-textile mattress Sand bedding Rock stone ballast Estimated cost 300-500k USD/km

+Soil improvement

ONSHORE TCO ANALYSIS : CW for 2x600MW power plant (weak soil conditions)

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FOUNDATION SUPPORT & GEOTECHNICAL DESIGN

with BONNA reinforced concrete cylinder pipes (RCCP) RIGIDITY & self-supporting BEAM capability

BONNA RCCP pipes DESIGN ENGINEERING CW foundations to be specified / verified by geotechnical specialists

BONNA RCCP pipes design engineering GEOTECHNICAL CONSIDERATIONS versus CARBON STEEL, GPR/FRP or HDPE pipes

backfill density 1.8

water density 1.0

PIPE MATERIAL density x thickness typical for ND3000

RCCP (rigid, heavier) 2.40 240 mm

Carbon steel (semi-rigid) 7.85 16-22 mm

GRP/FRP (flexible) 1.3-1.9 20-30 mm

HDPE plastic (flexible) 0.95 100-300 mm

The CW pipeline INTRINSIC MATERIAL CHARACTERISTICS (rigidity / flexibility) may be affected and/or determine the FOUNDATION REQUIREMENTS and NATURE and VOLUME of the BACKFILL MATERIAL particularly OFFSHORE.

CONSOLIS & geotechnical specialists should be consulted for suggestions of optimization

BONNA RCCP pipes can be designed to behave as a RIGID BEAM and offer more economical ground support solutions than SEMI-FLEXIBLE CARBON

PIPES, particularly with weak soils / risks of differential settlements

RCCP maximum allowable deflection : 1. Curvature depends of pipe diameter and can be dimensioned from internal design

2. Shallow foundations (graded aggregates in geotextile mattress) spread pipe load

3. shallow foundations allow wider span between deep piles compared to semi-rigid carbon steel pipes

RCCP are self-anchoring pipes : they DO NOT REQUIRE massive anchor/thrust blocks.

BONNA RCCP pipes are quite different in their principle compared to steel pipes or GRP/FRP :

Carbon steel pipes/GRP/FRP need sufficient thickness to avoid deformation under external loads (backfill, traffic live load).

RCCP resistance to pressure is provided by thin steel cylinder, resistance to external loads by the reinforced concrete.

RCCP pipe can therefore be economical in low and middle-range pressure such as in power plants usual conditions.

BONNA RCCP pipes - GEOTECHNICAL CONSIDERATIONS Allowable Pipeline Curvature & Bending Deflection

Thanks to their inherent rigidity and robustness, BONNA RCCP pipes

Are less sensitive to deformation than carbon steel pipes

Can tolerate full vacuum after an internal depression

Require less precautions during field installation

Bonna RCCP pipes & maximum allowable deflection

Can be designed to act as self-supporting beam

Can be bent to a radius of approx 1000 times the nominal pipe diameter

Curvature depends of pipe diameter - ie ND3800 : 1/400th ie +/-50mm every 20m of pipe section

Overall performance can be improved by combining with SMJ flexible joints & other special fittings

Minimum backfill up to the pipe low angle of support then native as dug material

BONNA RCCP pipes A superior solution compared to traditional products

BONNA reinforced concrete cylinder pipes (RCCP) Benefits vs OTHER PIPE MATERIALS for power plants cooling systems

Prestressed concrete PCCP Carbon Steel GRP/FRP HDPE Plastic

BONNA RCCP pipes are quite different in their principle compared to steel pipes or GRP/FRP : Steel pipes and GRP/FRP need sufficient thickness to avoid deformation under external loads (backfill, traffic live load).

With RCCP, the resistance to pressure is given by a thin steel cylinder and the resistance to external loads is provided by reinforced concrete.

RCCP pipe can therefore be economical in low and middle-range pressure such as in power plants usual conditions.

BONNA RCCP pipes versus CARBON STEEL pipes + LINING

COMPETITIVE ADVANTAGES Attractive economics / proven durability / maintenance-free / simple installation

Weld inspection by simple PT test

ADVANTAGES of BONNA PIPES SITE INSTALLATION

1. No surface treatments, linings or coatings with pinhole / peeling risk

2. Jointing : straight-forward filet welding assembly & PT inspection

3. Joint closing by simple mortar by mason or semi-skilled labor

4. Pipe closing by lapjoints (supplied as ingredient)

5. Trench reclamation : faster , more economic backfilling with native material, single-layer compaction

6. No cathodic protection maintenance-free passivation

Epoxy multi-coatings

Rubber / Epoxy lining

16-25mm steel thickness + arc

rings (depends of pipe diameter)

Expensive Non-Destructive Examination (NDE)

by Ultrasound or X-ray radiography

Outer self -flow grouting

External welding

for smaller pipes

CW pipeline construction: CARBON STEEL PIPES require delicate treatments during fabrication

Power plant CW pipeline construction - comparison Bonna Precast Concrete RCCP versus Carbon Steel pipes

TYPICAL SEQUENCE of OPERATIONS 1. Reception numbered pipes on site 2. Ground support foundations & bedding preparation 3. Laying-out the pipe spools / special fittings (Tees, Elbows,

Reducers, Wall crossings, Manholes, Flanges, etc) 4. Fitting of pipe segments with simple jack-pull 5. Two-pass filet weld S-L end-rings or fitting of E-R flexible joints 6. Joint filling inner/outer gap with mortar/self-flow grout 7. Close pipeline with lap-joints 8. Backfill with native material 9. Simple compaction 10. Field trench test with end caps Pre-checked factory QA data Pipeline installation may proceed simultaneously on several fronts. Choice of starting point : at interface or anywhere else. Possibility to modify/repair pipes onsite ABSENCE of costly anchor blocks at every change of direction REQUIRED STAFF & EQUIPMENT Optional ingredients (may be supplied by Bonna) Welders & non-specialist semi-skilled labor Crawler crane for spools lifting & placement Loader for backfilling

Bonna RCCP (typical length 2.00-6.15 ml)

SIMPLE LEGO-LIKE FIELD ASSEMBLY ensures PREDICTABLE planning & budgeting

Carbon steel pipes (typical length 6-12ml)

CHALLENGING onsite QA REQUIREMENTS affect PRODUCTIVITY & COSTS

TYPICAL SEQUENCE of OPERATIONS 1. Build massive concrete anchor / thrust blocks 2. Import source thick steel plates, bevel-cut, roll (onsite QA) 3. Weld plates together by multi-pass welding 4. Weld spur reinforcement rings every 1-2m (ovalisation) 5. Inspection of welds by radiography / ultrasound 6. Prepare surface by sand blasting 7. Apply Inner/External coatings (primer, middle, top layers) in

epoxy, rubber, coal tar 8. Dry curing conditions to be ensured 9. Alignment issues vs conformers 10. Pipe joints assembly by multipass butt-welding 11. Inspection of welds by radiography / ultrasonic testing 12. Close pipeline with lap-joints 13. Install & refill cathodic protection 14. Backfill only with graded material 15. Compacting requires several passes 16. Post-field test integrity (vacuum, ovalization) Cost of non-conformity ? Waste disposal ? REQUIRED STAFF & EQUIPMENT Highly qualified welders Crawler crane for spools lifting & placement Numerous smaller loaders for backfill compaction

GRP/FRP PIPES - typical characteristics

Available in lengthy sections

Maximum diameter size ND3000 mm ?

Lightweight material (density 1.3-1.9)

Corrosion resistant for chemical industries and tanks

Time degrading, UV-sensitive material

E Young modulus not constant in time : ovalization / elliptical deformation creates flow rate discrepancy

Quality depends on raw materials must verify grade (stiffness depends of fibers orientation)

Delicate joints assembling by hazardous resins with solvents

Geometrical irregularities of smooth internal surface in annular waves increase boundary layer thickness and head losses

Reduced repairs after installation (

BONNA RCCP pipes versus GRP/FRP pipes

1- Inherently robust, not a time-degrading material. 2- No internal lining or outer coating needed. No deterioration risk from UV exposure. 3- No need to protect the pipe against UV during transportation & storage. 4- Totally innocuous jointing material. No hazardous solvents used in lamination joints. 5- Absence of massive anchor blocks at every change of direction. Rigidity allows shallow foundations 6- Simple backfilling with native material. Without tedious multi-layer compaction of graded aggregates. No risk of pipe ovalisation. 7- Comparable roughness coefficient (k = 0.002 mm). Absence of wavy profile at boundary layer. 8- No risk of pipe bursting or collapse under excessive water pressure.

COMPETITIVE ADVANTAGES Attractive economics / proven durability / maintenance-free / simple installation

Available in lengthy sections

Maximum size ND2500 mm

Ultra lightweight material (density 0.95)

Time degrading material, UV-sensitive

Thermo-sensitive to temperature

Massive thrust blocks at each onshore directional change

Underwater laying requires concrete ballast inner grout or external collars or rings.

Butt-fused joints requires special equipment & cooling time

Hardly repairable after installation

HDPE plastic pipes - Main characteristics

REFERENCES

PROVEN DURABILITY

CONSOLIS Bonna RCCP PIPELINE KEY REFERENCES in ASIA - Energy & Power plants

BONNA Reinforced Concrete Cylinder pipes (RCCP) : over 4000 WORLDWIDE REFERENCES in ENERGY, INDUSTRY & WATER SUPPLY

JAPAN

NUCLEAR APPLICATIONS (17% worldwide market share)

SOUTH EAST ASIA

CHINA

EUROPE

AFRICA

FRANCE

AMERICAS EAST ASIA

Toyo

KOREA

POSCO ENGINEERING

PRICES

TYPICAL VALUE of BONNA RCCP pipes

BONNA PIPES TYPICAL MATERIAL VALUE in USD per linear meter Ex-Works basis

These are approximate figures only, subject to change according to each project specific site conditions (total pipeline length, pressure, backfill, live loads, elevations, interface connections) and owner specific design / engineering requirements. Excluded : transportation (maximum +30%), special fittings (elbows, tees, wyes, reducers, SMJ, wall crossings, manholes, flanges), soil improvement, ground bedding preparation, field assembly installation costs (onshore / offshore). Please consult CONSOLIS or PT Bonna Indonesia for a qualified estimate of your EPC / IPP specific project.

Subject to prior validation for each specific project