GENERAL

ERECTION & INSTALLATION OF WATER

TREATMENT PACKAGE SYSTEM 4

DOCUMENT TITLE : ERECTION & INSTALLATION PROCEDURE

EQUIPMENT NAME : WATER TREATMENT PACKAGE SYSTEM 4

EQUIPMENT TAG NO :

PA/PO NUMBER : TP.01.03/U.DEP.IP.P3FH.1534/VIII/2017

VENDOR NAME : PT MEMIONTEC INDONESIA

VDRL CODE : P3FH-MS-4000-PRC-1006-R0

0 9-May-2018 Issued for Information AC IKA GPS

C 3-May-2018 Issued for Internal Review AC IKA GPS

B 11-Apr-2018 Issued for Internal Review AC IKA GPS

A 3-Apr-2018 Issued for Internal Review AC IKA GPS

PRE CHK APP

REV DATE DESCRIPTION
PT.MEMIONTEC INDONESIA
TOTAL OR PARTIAL REPRODUCTION AND/OR UTILIZATION OF THIS DOCUMENT ARE FORBIDDEN WITHOUT PRIOR WRITTEN
AUTHORIZATION OF PT. WIJAYA KARYA PERSERO Tbk.

PROYEK PEMBANGUNAN PABRIK FERONIKEL HALMAHERA TIMUR (P3FH)

Contract Number :
TP.01.03/U.DEP.IP.P3FH.1534/VIII/2017
Wika Document No :
P3FH-MS-4000-PRC-1006-R0
Vendor Document No. :
P3FH-MS-4000-PRC-1006-R0

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TABULATION OF REVISION SHEET

REVISION REVISION
SHEET REMARKS SHEET REMARKS
A B C D E F A B C D E F
1 21
2 22
3 23
4 24
5 25
6 26
7 27
8 28
9 29
10 30
11 31
12 32
13 33
14
ATTACHMENT
15
16 1
17 2
18 3
19 4
20 5

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REVISION SHEET DESCRIPTION

NO PAGE SUBJECT DESCRIPTION OF CHANGE REV

1 5 Tools Added tools detail C
Working
2 7 & 17 Working floor area will use clarifier foundation C
Floor Area
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

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Table of Contents

I. SCOPE 5

II. PREPARATION 5

III. TANK & VESSEL ERECTION 6

IV. CLARIFIER 6

V. PIPING INSTALATION 13

VI. VALVES 14

VII. INSTRUMENT 15

VIII. PIPE SUPPORT 15

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I. SCOPE

This procedure covers the methods to be followed for the installation and erection at site for
this project.

II. PREPARATION

 All drawing & document has been approved and will be reference for erection & installation
at site.
 Equipment and tools for installation work tank construction should be prepared before
starting work as follows:

No. Tools Remarks

1 Chain Block 3 ton 2 Pcs

2 Drilling Machine

3 Welding Machine, 5 Unit

250 A, 3 phase

4 Welding Machine, 1 Unit

200 A, 1 phase

5 Spotlights *if required

6 Crane 50 Ton .

7 Grinding

8 Lever Block ¾ Ton 2 pcs

9 Cutting Well Machine 4 Inch & 7 Inch

10 Supporting Material Finger Pin, Strong Back, Horse

Shoe

11 Safety Tools

12 Water Pass

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 Make sure all sizes of Dimensions Foundation and the tank to be installed in accordance
with the approved drawings.
 Make sure the flatness of the foundation .
 Prepare Lifting Plan

III. TANK & VESSEL ERECTION (Buffer Tank, Dosing Tank, Sand Filter & Softener)

 Make sure the tank placement location is at the appointment of the crane maneuver.
 Check the condition Lifting Lug of the tank and make sure that is safe enough to be
appointed.
 Marking orientation 0 °, 90 °, 180 ° and 270 ° of foundation.
 Verification elevation and surface flatness of the foundation.
 Mark all points of the anchor hole from the tank to the surface of the foundation.
 Lift the tank slowly approximately one meter, check the condition of Lifting Lug tank and
make sure the tank is safe enough to be lifted over it.
 Lift the tank and then place the tank/container in accordance with the orientation and
position the anchor holes into the anchors appropriately.
 Tighten the nut of anchors after it was confirmed the position is correct.

IV. CLARIFIER.

Material/Parts
All material / parts shall be submitted to site as prefabricated.

Jig and Welding rod for field fabrication

The necessaries jig and welding rod shall be supplied by PT Memiontec Indonesia. The
quantity of jig and welding rod supplied has been calculation based on extensive fieldwork
techniques, experience and past achievements. Heavy equipment use for installation for this
tank is Crane 50 ton (will be prepared in filed).

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1. CHECKING AND ACCEPTANCE OF FOUNDATION

Before erection works of Clarifier, the center of foundation, the radius of the pad, slope,
Anchor position and level of tank foundation marking of the center point and the orientation
marks shall be checked.

2. INSTALLATION OF LEG SUPPORT (H-300) (refer to fig.1)

After inspection of foundation was completed. The leg support will install as per drawing and
move leg support by using crane and adjust it with anchor bolt. after leg support position
straight up, tighten bolt of anchor.

3. ASSEMBLY OF SHELL PLATE (Shell plate I, II & III, Stifener, Top Ring & Bottom Ring)
- Preparation
The shell plates shall be install/setup at the bottom.
Prior to the assembly, horse shoes for straight and curved strong back shall be welded
temporality on the shell plates

- Assembly
 Shell Plate 3 (Please see fig. 3)
a. The shell plates shall be assembled at the bottom (ground level), Starting point on
shell plate 1.
b. After completion Shell Plate 1 assembly, checking shall be executed to ensure that
level at top edge, plumpness, joint alignment and root opening are correct. For
working floor area will use clarifier foundation.
c. Stiffener, Bottom Ring assemble after shell plate 3 assembled
d. Lifting Plan Of Shell Plate 3 (See Fig.6)
- Assembly the lifting lug (4 Set) in outside Shell plate 3
- Marking the nozzle and orientation or refer to drawing
- Loading the shell using the crane to leg support
- And strengthen the bolt.

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 Shell Plate 2 (pease See Fig.4)

a. Scaffolding boards with hook and bracket shall be arranged on both side Shell Plate
2.
b. The vertical joint between Shell plate 3 and shell plate 2 shall be match accurately in
position with jig.

c. The horizontal joint between Shell plate 1 and shell plate 2 shall be match to each
plate retained in position with jig.
d. Traveling, scaffolding if used shall be installed on outside of the shell
 Shell Plate 1
a. The Shell plate 1 shall be assembled in the same manner as the Shell plate 2.

 Top Ring
Top ring assembled after all shell plate are complete install.

- Welding
 Welding for vertical joint for Shell Plate 1
a. The vertical joint shall be tack-welded from inside and curve strong back, spacer with
finger pin shall be removed out.
b. The continuous welding shall be executed from the outside first.
c. Prior to application of first bead to inside welding, the welded joint shall be cleaned
thoroughly in the manner that will leave expose surface satisfactory for fusion of the
weld metal to be added.
d. After than, the inside of vertical joint shall be welded.

 Welding joint for Shell Plate 2

a. Welding of vertical joint for Shell plate 2 shall be executed in the same manner the
Shell plate 1.
b. Welding Horizontal joint between Shell plate 1 and Shell plate 2
c. The horizontal joint shall be tack welded from inside and straight strong back, spacer
with finger pin shall be removed out.

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d. The continuous welding shall be executed from outside first. After than, the inside of
horizontal joint shall be welded.

 Welding joint of Shell Plate 3

a. The vertical joint of Shell plate 3 shall be welded before welding of horizontal joint
between shell plate 2 and shell plate 3
b. Regarding to the all shell plates, the welding of horizontal joint shall not be welded
before the welding of vertical joint.

 Welding joint Bottom Ring & Top Ring

The Bottom Ring and Top Ring setup and welding after all Shell plate already assembled.

4. ASSEMBLY OF CONE PLATE (Bottom Plate, Cone Plate 2, Cone Plate 3, Cone Plate 4, Cone
Plate 5)
- Preparation
The Cone plates shall be install/setup at the bottom (ground level)
Prior to the assembly, horse shoes for straight and curved strong back shall be welded
temporality on the Cone plates .

- Assembly
 Bottom Plate & Cone Plate 1
a. The Bottom plates shall be assembled at the bottom (ground level), Starting point on
Bottom Plate & Cone Plate 1.
b. After completion Bottom plate and Cone Plate 1 assembly, checking shall be executed
to ensure that level at top edge, plumpness, joint alignment and root opening are
correct.

 Cone Plate 2
a. Scaffolding boards with hook and bracket shall be arranged on both side Cone Plate
2.

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b. The vertical joint between Cone plate 1 and Cone plate 2 shall be match accurately
in position with jig.
c. The horizontal joint between Cone Plate 1 and Cone plate 2 shall be match to each
plate retained in position with jig.
d. Traveling, scaffolding if used shall be installed on outside of the cone shell.
 IWF, Leg Support (Leg support at cone Plate)
a. Install IWF and adjust it with the cone slope to facilitate the installation of the next
cone
b. After finish IWF assembled, setting the leg support and Welding leg support to IWF
and then setting bracing to outside leg support.

 Cone Plate 3
a. Scaffolding boards with hook and bracket shall be arranged on both side Cone Plate
3.
b. The Cone plate 3 shall be assembled in the same manner as the Cone plate 2.

 Cone Plate 4
a. Scaffolding boards with hook and bracket shall be arranged on both side Cone Plate
4
b. The Cone plate 3 shall be assembled in the same manner as the Cone plate 2.

 Cone Plate 5
a. Scaffolding boards with hook and bracket shall be arranged on both side Cone
Plate 5
b. The Cone plate 3 shall be assembled in the same manner as the Cone plate 2.

 Stiffener & Riser

Stiffener Cone plate & Riser and Leg Support assembled after all Cone plate are complete
install and welded.

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- Welding
 Welding joint for Cone Plate 2
a. The vertical joint shall be tack-welded from inside and curve strong back, spacer with
finger pin shall be removed out
b. The continuous welding shall be executed from the outside first.
c. Prior to application of first bead to inside welding, the welded joint shall be cleaned
thoroughly in the manner that will leave expose surface satisfactory for fusion of the
weld metal to be added.
d. Welding of vertical joint for Cone plate 2.
e. Welding Horizontal joint between Cone plate 1 and Cone plate 2
f. The continuous welding shall be executed from outside first. After than, the inside of
horizontal joint shall be welded.

 Welding joint of Cone Plate 3

a. The vertical joint of Cone plate 3 shall be welded before welding of horizontal joint
between Cone plate 2 and Cone plate 3
b. Regarding to the all Cone plates, the welding of horizontal joint shall not be welded
before the welding of vertical joint.

 Welding joint of Cone Plate 4

a. The vertical joint of Cone plate 4 shall be welded before welding of horizontal joint
between Cone plate 3 and Cone plate 4

 Welding joint of Cone Plate 5

a. The vertical joint of Cone plate 4 shall be welded before welding of horizontal joint
between Cone plate 4 and Cone plate 5.

 Welding Stiffener & Riser

The Stiffener & Riser setup and welding after all Shell plate already assembled.

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5. ACCESSORIES (Nozzle, manhole, Inside / outside ladder and Earth lug etc)
The hole of nozzle and manhole shall be marked and made in accordance with drawing and
reinforcing plates/ pad plates shall be welded.
The clip bracket for piping support, ladder, and stage shall be marked in accordance with
drawing. All accessories shall be assembled and welded in principle, full water test in
accordance with drawing.

6. INSPECTION AND TEST

Inspection and test item to be witnessed by client during field erection shall be in accordance
with inspection and test procedure. The record of inspection and testing shall be submitted
to client for review and approval in accordance with inspection and test procedure. Shell
welding should be PT (Penetran Test)

7. LEAK TEST
a) To ensure there is no water leakage, leak test is required
b) Prior to leak test all welding has been properly cleaned and repainted
c) Leak test should be done by filling the water until all welding spot is covered or equal
to half of the top shell plate
d) Check points before leak test :
 All welding works shall be finished and painted
 PT is required shall be completed
 Temporary piping for filling water test shall be completed
 Inside tank all clean
 All shell opening or vent or nozzle shall be closed during the test
e) Inspection of during leak test
 Settlement of tank foundation . When it is anticipated that an extraordinary
settlement will occur and case bad effect to the tank, subcontractor shall be report
it to inspector as soon as possible
 Leakage of weld seam

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V. PIPING INSTALATION

Pipe, pipe fittings, flanges, valves, gaskets, studs bolts etc. used in a given piping system shall
be as per the "Piping Material Specification" for the "Pipe Class" specified for that system.

a. CARBON PIPE

 Before erection all pre-fabricated spool pieces, pipes, fittings etc. shall be cleaned inside and
outside by suitable means. The cleaning process shall include removal of all foreign matter
such as scale, sand, weld spatter chips etc. by wire brushes, cleaning tools etc. and blowing
with compressed air/or flushing out with water. Special cleaning requirements for some
services, if any shall be as specified in the piping material specification or isometric or line
list.
 Galvanised carbon steel piping shall be handled properly, so as not to damage galvanised
surfaces. This piping involves only threaded joints and additional external threading on
pipes may be required to be done as per requirement.
 Components like pipes, elbows, couplings, half-couplings etc. shall be cut / trimmed / edge
prepared wherever required to meet fabrication and erection requirements, as per
drawings and instructions of Company Site Representative. Nipples as required shall be
prepared from straight length piping.
 All flange facings shall be true and perpendicular to the axis of pipe to which they are
attached. Flanged bolt holes shall straddle the normal centrelines unless different
orientation is shown in the drawing.
 Spacers shall be used while tack welding pipe and fittings in position to insure proper gap
and full penetration in welding. The tack welds complying with the requirements of ASME
B31.3, 328.5.1(C) may be allowed to become a part of the finished weld, whereas those not
complying are not acceptable and must be chipped out before completing the weld.
 Where tack welding is carried out, Tack welds shall be removed so that they do not form
part of the finished weld unless they are produced fully qualified and tested welders to the
same procedure as the finished weld, in which case they may be absorbed into the finished
weld.

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 Dimensional control of prefabricated piping spools shall be performed in a systematic

manner, assuring that the final installation will be correct.

b. PVC PIPE

 cut the pvc pipe with a hacksaw, but abrasive disks are made for miter saws that work
better to get a straight edge. A joint that is skewed due to pipe not being cut straight can
throw off the entire run of pipe.
 After cutting, clean all shavings out of the pipe inside edges. When the pipe is cut to the
proper length, lay it out on the floor with fittings in place to determine if the length is
correct.
 pipe must be cleaned with all-purpose pipe cleaner, called primer. Swab the primer around
the end of the pipe and the inside of the fitting to ensure there are no contaminants that can
get in the way of adhesion.
 PVC is joined with a special type of cement. The cement sets up very quickly, so you must
be ready to go as soon as it is applied. Coat the inner surface of the joint with the cement,
insert the PVC pipe, and turn the pipe in the fitting a full turn if you can, and then turn it
back to ensure that the glue has covered the entire joint. Be certain that the pipe is seated
correctly in the joint.
 Let the first few moments to ensure the connection is really strong.
 Place the pipe support while in the middle of the last pipe and the area which is likely to
occur latency to leak.
 If it is the proper for length & ensure the connection is really strong, proceed to installation.

VI. VALVES

Valves shall be installed with spindle / actuator orientation / position as shown in the layout
drawings. In case of any difficulty in doing this or if the spindle orientation / position is not
shown in the drawings, the Company Site Representative shall be consulted and work done
as per his instructions. Care shall be exercised to ensure that uni-directional valves bearing
"Flow direction arrow "on the valve body are installed with the arrow pointing in the correct

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direction. If the direction of the arrow is not marked on such valves, this shall be done in the
presence of Company Site Representative before installation.

VII. INSTRUMENTS

Fabrication and erection of piping up to first block valve / nozzle / flange for installation of
offline Instruments for measurement of level, pressure, temperature, flow etc. shall also form
part of piping construction work. The limits of piping and instrumentation work will be shown
in drawings / standards / specifications. Orientations / locations of take-offs for temperature,
pressure, flow, level connections etc. shown in drawings shall be maintained.

VIII. PIPE SUPPORT

Pipe supports are designed and located to effectively sustain the weight and thermal effects
of the piping system and to prevent its vibrations. Location and design of pipe supports will
be shown in drawings.

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Fig. 1 Installation of Leg Support

Fig. 2 Assembly of Shell Plate 3 thk 10mm

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Clarifier foundation

Fig. 3 Assembly of Shell Plate to Plate (Shell Plate 1 - Vertical)

Fig. 4 Assembly of Bottom Ring UNP 250 for Shell Plate 3

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Fig. 5 Assembly of Stiffener Swing

Fig. 6 Loading Shell Plate 3 to Leg Support

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Fig. 7 Assembly of Shell Plate 2 thk 8mm

Fig. 8 Assembly of Shell Plate to Plate (Horizontal)

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Fig. 9 Assembly of Shell Plate 1 thk 6mm

Fig. 10 Assembly of Shell Plate

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Fig. 11 Assembly of Bottom Plate & Cone Plate 1

Fig. 12 Assembly of IWF & Leg support

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Fig.13 Assembly of Cone Plate 1-5

Fig. 14 Assembly of Riser & Stiffener

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Fig. 15 Assembly of Center Well

Fig. 16 Assembly of Walkway

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