DOCUMENT No.

WP - QC - 001

NOTE: THIS DOCUMENT IS CONTROLLED WITHIN THE PENTA INDONESIA BATAM DOCUMENT CONTROL SYSTEM.

Project Title:

GO GREEN TERMINAL OIL TANK

DOCUMENT TITLE:

DIMENSIONAL CONTROL PROCEDURE

REVIEW AND APPROVAL

A 18/09/04 Issued for Approval GT BN MN

ORIGINATED CHECKED APPROVED BY APPROVED BY

REV
DATE DESCRIPTION PROJECT
No. BY BY CORD ENG.
MANAGER

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CONTENTS
1 PURPOSE 3

2 REFERENCES 3

3 DEFINITIONS 4

4 RESPONSIBILITIES 4

5 METHODOLOGY OF DIMENSIONAL CONTROL

4

6 FABRICATED INDIVIDUAl MEMBER

5

7 DECK PANEL AND SUB-ASSEMBLIES

6

8 MODULE ASSEMBLIES 6

9 PRESENTATION AND REPORTING

7

10 DIMENSIONAL TOLERANCES 7

11 ATTACHMENTS 8

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1 PURPOSE
This procedure describes the organisation and methodology of dimensional control for the
fabrication of steel structures for _______________Project. The dimensional control shall be
performed throughout the fabrication process of the topside steel structures as per contract. The
purpose is to verify dimensions of the fabricated assembly before and after welding and to provide
documentary evidence of the successful implementation of dimensional control activity and
compliance with specified tolerance as required by project specifications including codes and
standards mentioned in section 2.

2 REFERENCES
2.1 The following listed specifications and codes are reference documents for dimensional
requirements and tolerances.

SPECIFICATIONS & DESCRIPTION

CODES
AWS D1.1/D1.1M:2002 Steel Structural Welding Code
API RP 2A 1993 Recommended Practice for Planning, Designing and Constructing
Fixed Offshore Platforms.
API RP 2B 2001 Specification for Fabricated Structural Steel Pipe
ASTM A6 Standard Specification for General Requirements for Rolled Steel
Plates, Shapes, Sheet Piling, and Bars for Structural Use

3 DEFINITIONS

3.1 The following terminologies and abbreviations apply to this procedure:

c) CA - Certifying Authority
d) QA/QC - Quality Assurance / Quality Control.
e) DC - Dimensional Control
f) DCR - Dimensional Control Report
g) PMT - Project Management Team
h) NCR - Non Conformance Report

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4 RESPONSIBILITIES

4.1 PMT Project Manager shall be responsible for controlling dimensional tolerance as per
contract.

4.2 PMT Construction Manager or Fabrication Manager shall be responsible for taking
corrective action in cases of dimensional non-conformances.

4.3 QA/QC Dimensional controllers shall execute dimensional inspections and surveys at
various stages of fabrication to verify dimensions of the fabricated members and
assemblies.

4.4 Senior QA/QC Manager shall be responsible for monitoring the system.

5 METHODOLOGY OF DIMENSIONAL CONTROL

5.1 Dimensional control will be implemented at various stages of fabrication. Dimensional
control activities shall be as per Appendix 1.
5.2 Electronic total stations of survey equipments are to be used for dimensional control for the
duration of fabrication. Optical level instrument can be used for levelling and elevation
check. Appendix 2 is a survey equipment list. The number of equipment used and surveyors
involved depends on the workload during fabriction.
5.3 Measuring instrument shall be calibrated prior to use. The calibration frequency shall be
once every six months. Self-check will be done monthly or any time during use when the
function of the equipment is in doubt. Calibration of Electronic Total Stations will be
carried out by qualified service company. Calibration of optical level instrument will be
carried out by QA/QC dimensional controller as per manufacturer’s procedure. Calibration
documentation will be filed in QA/QC for review.
5.4 All measurements shall be corrected for temperature variation. Air temperature and air
pressure at time of survey will be taken and input in the electronic total stations so that
such corrections can be applied to all field survey data. Steel thermal effects shall be
considered when performing major dimensional surveys. Such measurements should be
made as much as possible at the same time of a day under similar weather conditions.
5.5 All reference points, work points, centre line or grid line intersection points shall be clearly
and permanently marked on structures by punching. Measurements shall be related to these
markings during fabrication.

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5.6 A coordinated survey control shall be established around the fabrication area. The
coordinate system shall relate to the grid system of platform structures. See Appendix 3 for
a sample module control network.
5.7 Client’s shall be informed and advised in advance prior to critical dimensional surveys.
Dimensional surveys of assemblies and sub-assemblies shall demonstrate that specification
tolerances are being met or welding shall not proceed without written approval by Client’s

6 FABRICATED INDIVIDUAL MEMBER

6.1 For members fabricated from plates, dimensions are checked as per the latest revised shop
drawings.
6.2 The fabrication of individual tubular members is to be checked for length, ovality and
circumference. When individual tubulars joint together, proper alignment shall be checked
and misalignment corrected. Appendix 4 is a sample DC report for fabricated tubulars.
6.3 The fabrication of individual primary plate girder is to be checked for proper alignment and
geometry. Appendix 5 is a sample DC report for fabricated plate girders.

7 DECK PANEL AND SUB-ASSEMBLIES

7.1 Assembly of the structural steel shall proceed on a level and stable surface. Before assembling
each deck, the temporary supports are levelled to within ±5mm.
7.2 The initial dimensional control shall use a centre line of one of the main plate girders as the
reference line for the layout of the subsequent members. The girder beam centre line shall be
defined as the centre line of the web. As the assembly increases in size, it may be necessary to
establish a control network.
7.3 Geometry dimensions and levelling checks are carried out and recorded during fit-up of assembly
and prior to welding.
7.4 Subsequent interim levelling checks will be performed when required during welding to ensure
control of possible distortion.

7.5 On completion of welding, a post-weld survey shall be carried out. The surveys shall indicate
best-fit locations of column legs, stabbing points, assembly interface points, grid line or centre
line intersection points, and, when required, other critical locations as well. See Appendix 6 for a
sample deck panel DCR.
7.6 Secondary structures, such as equipment skids, shall be checked for proper locations and levels.

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8 MODULE ASSEMBLY

8.1 Where each deck is assembled as a separate entity, dimensional surveys shall be carried out on
each completed deck before assembly. When columns are erected, dimensions and vertical
alignment are to be checked and misalignment corrected before lifting. See Appendix 7 for a
sample DCR for deck column installation.
8.2 Before deck panel erection, a theoretical trial fit will be carried out for connection interfaces
between assemblies and components through best fit analysis. Refer Appendix 8 for a sample
theoretical trial fit of deck panel column legs before upper deck panel erection.
8.3 Levels of each deck panel, when erected, shall be checked and corrections shall be made for out-
of-levels before welding deck legs and secondary supports.
8.4 Where a row, side or other portion of the module is assembled as a separate entity, for example, a
flare boom, dimensional surveys shall be carried out of each completed potion, particularly at
interface points and a best-fit analysis done.
8.5 Monitoring for possible settlement of temporary supports shall be conducted during construction
of the module at regular intervals of once a month or period proved necessary by previous
monitoring results.

9 PRESENTATION AND REPORTING

9.1 All dimensions shall be measured and reported in metric and all angles in degrees unless otherwise
noted.
9.2 Horizontal fabrication deviations from theoretical positions will be given, based on best fit
calculations, in the form of vectors in two perpendicular directions in the theoretical grid system
specified in the drawings. Vertical fabrication deviations from true plane or best-fit plane will be
shown in circles (plan view), using "+" or "-" to indicate rise or fall, or in the form of vectors
(isometric view). Refer Appendix 6 for a sample deck panel DCR.

9.3 Post-weld surveys or as-built surveys shall be submitted to the SAIPEM and as each work item
is completed. Fit-up or interim in-house dimensional survey results will be submitted on request
and for information only. Dimensional results will be reported on a weekly basis.

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9.4 Project Manager is responsible for official transmission of DCR to SAIPEM either electronically
or through hardcopy.

10 DIMENSIONAL TOLERANCES

0
10.1 General fabrication tolerances are given in CLIENT REQUIREMENT. Tolerance not covered
inCLIENT SPEC or on the design drawings shall be obtained from relevant codes and standards
mentioned in section 2 of this procedure.

10.2 For out-of-tolerance dimensions, PMT shall take corrective actions. 0

10.3 Principal dimensional tolerances are tabulated as in appendix 10 for quick reference.

11.0 ATTACHMENTS

Appendix 1 – Dimensional Control Process Flow Chart

Appendix 2 – Surveying Equipment List
Appendix 3 – A Sample Module Control Survey Network
Appendix 4 – A Sample DCR for Fabricated Tubulars
Appendix 5 – A Sample DCR for Fabricated Plate Girder
Appendix 6 – A Sample DCR for Deck Panel Framing
Appendix 7 – A Sample DCR for Deck Column Installation
Appendix 8 – A Sample DCR for Module Column Alignment
Appendix 9 – A Sample DCR for Deck Column Trial Fit
Appendix 10 – Dimensional Tolerance Table
Appendix 10 – Dimensional Tolerance Table ( Continued )
Appendix 10 – Dimensional Tolerance Table ( Continued )

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Appendix 1 – Dimension Control Process Flow Chart

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Production Team
to request dimensional check

Dimensional Controller
to execute dimensional check

for pre-weld for post-weld

Dimensional Controller Dimensional Controller

to perform Pre-weld dimension to perform Post-weld dimension
check check

Dimensional Controller
To Prepare DCR for Review
and approval by PTT

To start welding of Within Tolerance?

Yes Within Tolerance?
fabricated item Shrinkage Considered.

No Yes
To inform Production Team to
carry out further adjustment No
or rectification

Rectification can be Report signed and filed.

Yes
done?

Engineering
to raise proposed
method for rectification No

Dimensional Controller
to raise NCR

Non-Conformance
Control Procedure
to be followed

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0
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Appendix 2 – SURVEYING EQUIPMENT LIST

ITEM MODE SERIAL NO ACCURACY REMARKS

(ASSET NO)

NET2100 27730  (0.8+1ppmD)mm

SOKKI
Total Station
SET330 27185  (3+2ppmD)mm

PENTAX PTS-V2 520636  (2+2ppmD)mm

Total Station (28500101147)

NIKON NPL-820 210047  (3+3ppmD)mm

Total Station (28500101173)

Standard
C41 41249  2.5 mm Deviation
for 1 km
double run
SOKKI
Auto Level
B20 10323  1.0 mm

Stainless Tape
(master tap) TOUGH H101555

Appendix 3 – A Sample Module Survey Control Network

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Appendix 4 – A Sample DCR for Fabricated Tubulars

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Appendix 5 – A Sample DCR for Fabricated Plate Girders

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Appendix 6 – A Sample DCR for a Deck Panel Framing

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Appendix 7 – A Sample DCR for a Deck Panel Column Installation

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Appendix 8 – A Sample DCR for a Theoretical Trial Fit of Deck Legs before Erection

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Appendix 9 – A Sample DCR for Module Column Alignment

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APPENDIX 10 – DIMENSIONAL TOLERANCE TABLE

COMPONENT MEASUREMENT TOLERANCE REFERENCE COMMENTS

Fabricated Straightness 1 mm per meter AWS D1.1 No camber

Plate Girder / Sweep specified
Camber ±20 mm for spans≥30 m
±10 mm for spans<30 m
Flatness of Webs D/150 D: depth.
No intermediate
stiffeners
Overall Length  10 mm SP-S-
0404.04-
0 5020-205
Variation between  5 mm ASTM A6
Web and Flange Table 16.
Centrelines
 8 mm for size 12 in.
Flange tilt above
 6 mm for size 12 in.
below and incl.
Depth variation at  3 mm
the centreline
Flange width 6 mm
5 mm
Rolled Out of Roundness t  50mm API 2B t: wall thickness
Tubular 1% of nominal or 6 mm
maximum difference
between major and
minor outside diameters
t  50 mm
out of roundness to wall
thickness ratio  1/8
OD  1220 mm
12 mm max. if the
circumference tolerance
within  6 mm

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Appendix 10 – Dimensional Tolerance Table ( Continued )

COMPONENT MEASUREMENT TOLERANCE REFERENCE COMMENTS

Rolled Circumference  1% of nominal value, API 2B

Tubular or 13 mm, whichever is
less
3 mm for L ≤ 3 m, and L=Total length
Straightness 3mm x L÷ 3
for L > 3 m, L in meter,
10 mm max. in any 12m
Primary Centreline to SP-S-
Structure – Centreline of the  6 mm 0404.04-
Deck Panel Deck Legs or 5020-205
and Column Columns
Legs
Squaring Check of  16 mm
0 corner Columns -
Difference
Between Diagonal
Measurements
Alignment of 6 mm
columns
3 mm, for L ≤ 3 m L=Total length
Verticality 10mm, for 3m< L ≤12 m
12 mm, for L > 12 m
Top Elevation of  6 mm
columns
Deck Panel  6 mm
Levelness
Centerline of Plate  10 mm horizontally
Girder  6 mm vertically
Distance between  10 mm
centreline of
adjacent skid
beams

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Appendix 10 – Dimensional Tolerance Table ( Continued )

COMPONENT MEASUREMENT TOLERANCE REFERENCE COMMENTS

Grating and Elevation  1.6 mm SP-S-

Deck Plating Difference in 0404.04-
grating at edges 5020-205
Elevation  1.6 mm
Difference in Deck
0 Plate at seams
Flatness of deck  6 mm
plate panel

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