FABRICATION PROCEDURE FOR PRESSURE VESSEL, BOILER,

HYDRANT PILLAR & PRESSURE CONTAINING PIPING

NO. COIN/FPS/001/V/2018

Approval and Authorization

Originated Name Title Signature Date

Prepared Eva Sofiana Administration 06/05/19

Reviewed Agung Prasetyo Engineering 07/05/19

Authorized Agung Haryono Manager Eng Pro 09/05/19

Approved

Jl. Pulogadung 1 No. 11A, Kawasan Industri Pulogadung, Jakarta Timur

Phone : (021) 468 34480, Fax : (021) 468 34904
E-mail : composites39a@gmail.com
Website : composites-indonesia.com
 FABRICATION PROCEDURE FOR PRESSURE VESSEL, BOILER, PAGE
HYDRANT PILLAR & PRESSURE CONTAINING PIPING 1 of 19

DOCUMENT NUMBER : REVISION : DATE OF ISSUED :

1
COIN/FPS/001/V/18 REVISION DATE : EFFECTIVE DATE :

NO. CONTENT PAGE APPROVED BY

1.0 SCOPE 2 OF 19

2.0 CODES & REFERENCE 2 OF 19

3.0 PROJECT SPECIFICATION 2 OF 19

4.0 MATERIAL & MATERIAL INSPECTION 4 OF 19

5.0 MATERIAL IDENTIFICATION 5 OF 19

6.0 CUTTING & EDGE PREPARATION 5 OF 19

7.0 GENERAL WELDING CONTROL 6 OF 19

8.0 INSPECTION & TESTING 10 OF 19

9.0 DIMENSIONAL CHECK 13 OF 19

10.0 HYDROTEST 13 OF 19

11.0 FINISHING & PACKAGING 15 OF 19

REVISION STATUS
REV. NO. DATE DECRIPTION DISTRIBUTION

Jl. Pulogadung 1 No. 11A, Kawasan Industri Pulogadung, Jakarta Timur

Phone : (021) 468 34480, Fax : (021) 468 34904
E-mail : composites39a@gmail.com
Website : composites-indonesia.com
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1. SCOPE
1.1 GENERAL SCOPE ALL PROCESS
The scope of this procedure is to explain / describe the minimum fabrication requirements of tank
components to meet specifications and drawings and according to ASME Standards.

2. CODES & REFERENCE

2.1 ASME Section II “Materials”
2.2 ASME Section V “Non Destructive Examination”
2.3 ASME Section VIII Div. (1) “Rules of Construction of Pressure Vessel”
2.4 ASME Section VIII Div. (2) “Alternative rules for construction of Unfired Pressure Vessels”
2.5 ASME Section IX “Welding and Brazing Qualification”

3. PROJECT SPECIFICATION
3.1 PROPOSAL INSTRUCTION
Each Vendor shall submit a base proposal for equipment complying strictly with this specification
and the reference documents listed. Conflicting requirements in these documents shall be referred to
PURCHASER for resolution prior to submission of the proposals.
Vendors may submit alternative proposals that deviate from PURCHASER’s requirements if
significant savings can be demonstrated. Such proposals will receive full consideration, provided
each deviation is fully described and the corresponding documents are provided.
The PURCHASER reserves the right to accept any alternative proposal without further consideration
of the Vendor. An alternative design shall not be used unless it is approved in writing by the
PURCHASER. No subletting of any fabrication or welding will be permitted after the award of
contract, unless prior approval has been taken from PURCHASER.
3.2 GENERAL
Mechanical Data Sheet which includes material specifications, principal dimensions, general
requirements codes etc. will be furnished by PURCHASER.
3.3 PROCESS DESIGN
Where process design by the VENDOR is required it shall be so indicated on the vessel data sheet.
The VENDOR shall size the vessel when so required within limitations stated on the vessel data
sheet. It will be the VENDOR’s responsibility to design all internals. Vessel size and internal design
shall permit internal access to all welds for inspection and non-destructive examination proposed
during fabrication and for in-service inspection/ maintenance.
3.4 GUARANTEES
The Vendor shall guarantee the equipment and their components against defect in design, materials
and workmanship. Approval by PURCHASER of design calculations and detail fabrication drawing
will not anyway absolve the VENDOR from his responsibilities to supply equipment in accordance
with order specifications. Where process design of the equipment is provided by the VENDOR, the
performance of the equipment shall be guaranteed to satisfy the specified process requirements.
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3.5 MECHANICAL DESIGN

3.5.1 Design Pressure
The design pressure at the top of the vessel shall be as stated on the Mechanical Data Sheets.
The static head due to contents (min. S.G.=1) shall be added in all cases. Vessels shall be
designed and protected against vacuum only when the vessels are to be actually subjected to
external pressure during operation. Vacuum caused by emptying water after hydrostatic tests
or condensing steam after steaming out the vessel, should not be considered as a design
condition. Vessel shall be designed for Steam out condition if specified on Mechanical Data
Sheet.
3.5.2 Design Temperature
Design temperature shall be as specified on Mechanical Data Sheets. Two kinds of design
temperature, one for the maximum design temperature (called as “Design Temperature”) and
other for minimum design temperature(called as “Minimum design metal temperature” =
MDMT) are specified. If several pressure-temperature combinations are specified, the most
stringent shall apply.
3.5.3 Corrosion Allowance
The corrosion allowance stated on the vessel data sheet shall be added to all exposed internal
surfaces of pressure parts, non-removable internals. Internal components welded to shell shall
include corrosion allowance on all exposed sides. Half the minimum corrosion allowance shall
be added to the exposed surfaces for removable parts. Internal fillet welds shall be sized to
include the specified corrosion allowance on the throat thickness.
3.5.4 Minimum Thickness
3.5.4.1 Shells and Heads
The thickness of shells and heads excluding allowances for forming and corrosion
shall be the greater of that required for loadings given in 4.7.6 or the following :
5 mm for austenitic steel
5 mm for C, C.Mn and low-alloy steel vessels up to and including 1200 mm
inside diameter
7 mm for C, C.Mn and low-alloy steel vessels above 1200 mm inside
diameter
10 mm plus cladding for clad vessels. (Minimum Clad thickness shall be
3mm. It shall not be considered while doing stress calculation)
3.5.4.2 Nozzles
The nozzle size, number of nozzles and flange rating shall be in accordance with
Mechanical Data Sheet.
3.5.4.3 Skirts and Leg Supports
Skirt or leg supports shall be designed for specified loads, but shall not be less than 6
mm thick.
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3.5.5 Calculation
The VENDOR shall provide detailed calculations to justify the design. Calculations shall be
fully detailed showing all working and references used and shall be presented in such a manner
that they can be easily checked. All calculations, except those for weights and Centre of
Gravity, shall represent the vessel in the fully-corroded condition. The VENDOR shall
establish weights (shipping, empty, operating and test) and the locations of the centre of
gravity (empty and operating). Vessels and their supports shall be designed for the most severe
condition of coincident loading, as defined below and in paragraph 4.7.7 :
The effects of external primary mechanical loads plus design pressure and the effects of
secondary stresses due to differential thermal expansion shall be investigated, and the resulting
combined stresses and deflections shall be evaluated, if specifically asked in Mechanical Data
Sheet. Material tolerances shall be applied to give the most conservative design, e.g. pipe
thickness shall be minimum for mechanical design, plate thickness shall be maximum for
weight calculations. Design calculations for metal clad vessels shall be based on nominal
thickness of the base material. Where the vessel is in cyclic service, fatigue shall be considered.
3.5.5.1 Units
Calculations may be made in the units of choice. When calculations are made in units
other than SI, the result of all principal steps and the final results shall additionally be
expressed in SI units:
Calculations shall use metric units as follows:
Dimensions mm
Pressure barg
Stress Kg/mm2

4. MATERIAL & MATERIAL INSPECTION

The quality of materials should be according to Customer specifications and drawings. The Grade of
structural steel shall conform to European Standard EN 10025 as noted on the drawings with
minimum yield strength as specified below :
The steel shall be free from loose mill scale, surface defects, flaky rust, slag inclusions, laminations,
pitting and be of full weight or thickness within tolerances specified in standard. Approved Steel
suppliers will be used. As a normal practice mill certificates will be made available for steel ordered.
Substitution if any, on sizes or quality shall be implemented only after obtaining approval from the
Owner / Engineer.
All steel supplied shall be stored in a safe condition with proper care taken during storage to ensure
that no damage occurs, which renders the materials unserviceable. All steel material shall be stored
at the shop/yard above the ground on the platforms, skids or concrete blocks.
Materials for this project shall be marked differently from the other project material. The identifying
and marking system shall be established. All steel material procured shall be properly documented
to ensure conformity to specifications and it shall be the responsibility of the control foreman or staff
to ensure conformity of steel to the specifications.
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5. MATERIAL IDENTIFICATION
After receipt of raw material warehouse responsible shall verify the material and forward the Raw
material inspection report to quality acceptance. Project Engineer will inspect the raw material and
verify the heat number correlation and material specification. On acceptance, Quality staff will give
a Material Code number for punching as per Identification and Traceability Procedure. Refer Project
Quality Plan. The Fabrication Engineers / Foreman shall be responsible to arrange to mark the Item
number and punch the material code number on each member.

6. CUTTING & EDGE PREPARATION

6.1 CUTTING PLANS
The cutting plan shall be prepared for all material before commencement of fabrication work.
Material mark number shall be provided for easy identification.
6.2 MARKING
Marking shall be carried out as per approved cutting plan under the guide lines of fabrication
foremen, and subsequently verified by the Fabrication engineer prior to cutting. Prior to marking the
material shall be checked for its identification and the defects. Necessary items shall be carefully and
accurately marked in accordance with approved shop drawings or templates.
6.3 CUTTING
Material cutting shall be carried out either by shear, plasma, CNC Profile cutting and drilling
machine, pug cutting machine. The edges of all plates shall be perfectly straight and uniform
throughout. Cut edges shall be visually examined for laminations and inclusions. All corners shall
be shaped so as to be notch free, sheared or cropped edges shall be dressed so that they are free from
distortion and burrs. Edge preparations for field welding shall be done in the shop.
6.4 CUTTING OF HEAVY SECTION
The relevant standard rolled shapes or plate’s thickness exceeding 50 mm before cutting preheating
(Min 660C) shall be used. All cut edges shall be free of sharp notches and gauges.
6.5 EDGE PREPARATION
The edges or surfaces of parts to be joined by welding shall be uniform, smooth and cleaned from all
foreign materials such as moisture, slag, oil, grease, paint, scale or rust. Edge preparation shall be
verified for proper groove angle and root face dimensions. Welding groove dimensions shall be
inspected as per shop drawings under tack-welded condition prior to welding. The allowable
misalignment of adjoining plates to be butt-welded shall be in accordance with AWS D1.1or BS-
ENISO.
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7. GENERAL WELDING CONTROL

7.1 GENERAL FABRICATION REQUIREMENTS
Fabrication welding includes the inspection of material, equipment's, workmanship, testing, and
other items required to weld and inspect steel structures. Each fabrication technique shall be in
accordance with accepted current good engineering practice and shall be in accordance with
requirement of applicable specifications. Material shall be kept free from dirt, grease and other
foreign matter, and shall be protected from corrosion. Fabrication shall take place at shop location to
the greatest extent possible.
All Code welding shall be accordance with ASME Section IX and related Construction Code and
Specification and to qualified welding procedures. Unless otherwise specified, all welds shall be full
penetration welds except where noted on drawings. All welds shall be continuous. But welds between
materials of different thickness shall be tapered by grinding the thicker parent material at a taper of
1 in 3 and not by the use of additional weld outside the width of joint. When the different of thickness
is less than 3/8" (10) the transition may be formed by adding addition weld metal and MPI upon
adequate surface dressing of the weld.
7.2 PRODUCTION WELDING
7.2.1 Welding Material
Unless otherwise approved by Authorized Inspector, welding electrodes For SMAW shall
conform to low hydrogen E-70XX classification of SFA 5.1,5.4 & 5.5 spec.
For SAW shall conform to SFA 5.17 & 5.23
For FCAW shall conform to SFA 5.20 ,5.22 & 5.29
For GMAW shall conform to SFA 5.9,5.18 & 5.28
For GTAW shall conform to SFA 5.9,5.18 & 5.28
7.2.2 Backing, Backing Gas, or Inserts
CJP groove welds may be made with or without the use backing gas, backing or consumable
inserts, or may have the root of the initial weld gouged, chipped, or otherwise removed to
sound metal before welding is started on the second side.
7.2.2.1 Backing
Roots of groove or fillet welds may be backed by cooper flux, glass tape, ceramic,
Iron powder, or similar materials to prevent melting through. They may also be sealed
by means of root passes deposited with low-hydrogen electrodes if SMAW is used, or
by other arc welding processes. Steel backing shall conform to the following
requirements:
• Fusion. Groove welds made with the use of steel backing shall have the weld metal
thoroughly fused with the backing.
• Full length Backing. Steel backing shall be made continuous for the full length of
the weld. All joint in the steel backing shall be CJP groove weld butt joints being
all the requirements of paragraph 5 of this procedure.
• Backing Thickness. The recommended minimum nominal thickness of backing
bars, provided that the backing shall be of sufficient thickness to prevent melt-
through, is shown in the following table :
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Process Thickness, min

In mm
GTAW 1/8 3
SMAW 3/16 5
GMAW ¼ 6
FCAW-S ¼ 6
FCAW-G 3/8 10
SAW 3/8 10
Note: Commercially available steel backing for pipe and tubing is acceptable,
provided there is no evidence of melting on exposed interior surface.
7.2.3 Welding Equipment
To ensure the production of sound welds, welding machines, line-up clamps, bevelling
machines, cutting torches, tools, supplies and other equipment used in conjunction with the
welding work shall be keep in good mechanical condition. Equipment shall be inspected at
regular intervals. Equipment, tools, or supplies that are not satisfactory shall be rejected and
replaced with satisfactory and supplies. Welding shall have adequate controls for making the
current adjustment as necessary for all welding requirement. Suffient metres, portable or
permanent shall be provided to calibrate machines and to regulate voltage and amperage on
regular basis.
7.2.4 Preheat and Interpass Temperature
Welding preheat and interpass temperatures shall be as specified in the Company's qualified
welding procedure specification. Preheat shall be performed by using oxy-fuel / fuel gas (other
than acetylene) blowtorches, induction, or electric resistance heat. For preheating of material
greater than 2,5 inches and over where continuous preheating by using flame torch is
impracticable, then electric heating element may be used as an alternative.
Preheat must be performed before any welding commences, including tack welding. When
specified in procedure qualification. Preheat shall be established for distance of at least 3
inches on either side of the weld line and throughout the wall thickness. Preheat temperature
shall have be measured by thermocouples, temperature indicating crayons or pyrometers. In
all cases, regardless of thickness, interpass temperature shall not exceed 600° F (315° C) unless
a greater temperature is recorded in the procedure qualification.
7.2.5 Preheat and Interpass Temperature
Shearing, flame cutting, bevelling, and chipping shall be done carefully and accurately with
and automated or mechanically guided tool, where possible. Any bevelled edge that has been
damaged shall be restored prior to welding. The cutting line shall be marginated to allow the
back dressing of 0.5 mm (minimum), except the case where PG-76.2 is applicable.
Beveled edge of carbon steel material prepared for field assembly or store more than two
weeks may be protected by lead free primer coat, such as deoxialuminate of about 25 um to
50 um.
Surfaces of metal to be welded and 2 inches to either side of the weld, shall be free of fins,
tears, cracks, mill scale, slag, rust, oil, paint, and other defects of contaminants which might
adversely affect the quality or strength of the weld.
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Run On-Run Off Tabs, used in welding of longitudinal seams and plate splices, shall be of the
same thickness, specification, grade and edge preparations the plate being welded. Tabs shall
be of a minimum as required to permit complete freezing of the puddle on the tab before
exnguishing the arc. Material for the Run On-Run Off tabs shall be furnished from original.
The welding shall proceed in a manner that minimizes residual stresses or distortion.
The arc welding shall only be struck through strike plate into the weld preparation or onto
previous deposited weld metal. Should arc strikes occur outside the joint, they shall be
removed grinded and / or repaired in accordance with an approved procedures. Should are
strikes occur outside the joint, they shall be removed, flushed to smooth contour and checked
to ensure soundness.
When more than one weld pass is deposited on a joint, each pass shall be thoroughly cleaned
by wire brushing, grinding and chipping before the next pass is applied. For Welding at
material in excess at 1% inch (38.1 mm) thick, welding shall not be discontinued until half
weld is completed. If interruption occurs after this stage, such as inspection etc., then the
minimum preheat shall be ensured before restarting. Should the weld deposit is less than the
half thickness and the weld should be terminated for more than six (6) hours than a suitable
means at NDT, eg. MT or PT to be applied.
Weld shall be protected from rapid cooling caused by rain, wind, or inclement weather.
Suitable wind breaks / shields shall be provided, when necessary.
Completed weld shall be cleaned of any slag dirt, and debris to permit inspections.
Completed welds shall be clearly marked with welder’s stamps as effective for each weld run
of max. 3 ft. (1 M) or fraction there as enable proper documentation of weld.
The weld joint, length, welder stamp shall be entered in the “Weld Map” displayed at work
floor.
7.2.6 Weld Profile
Where shown on the Specification Drawing or required by the Code Requirement, weld profile
control shall be carried out to improve the fatigue life of the vessel. The surface reinforcement
profile shall be in accordance with ASME Construction Code acceptance criteria. See
Appendix 1 for "Acceptable and Unacceptable Welds Profiles"
7.2.7 Tack Welding
Tack welding, seal welding, and welding of temporary attachment (including scaffolding
support and tie-downs) shall be performed in accordance with the welding parameters covered
by an approved welding procedures. Tack weld shall have minimum length of four times the
plate thickness, or 2 inches, whichever is less, be ground to feather edge, and completely fuse
with the root run whenever they will be form part of the completed weld. Further only qualified
welder shall making tack weld.
7.2.8 Fit-Up and Alignment
When required stiffeners shall be fitted accurately, neatly, and tightly to transmit bearing loads,
Stiffener end shall be milled or ground smooth to conform to the geometry of the stiffer
member to assure 100 percent fusion in the root of the weld.
In the event that joint fit-up tolerance for production weld exceed permitted values, build-up
of the joint surfaces is permissible, using a qualified, approved, welding procedure Build-up
at no time to exceed 3/8” (10 mm) in the thick.
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Excess root opening at welds may be repaired by depositing weld metal from one side only,
by applying welds build-up to their side the joint (i.e. through member). The maximum weld
build-up deposit thickness shall be limited to 3/8 inch (10 mm) total for any weld joint. The
corrected root opening shall be capable of closure with a single pass of an approved electrode.
Weaving techniques shall not be employed to close excessively wide root openings.
7.2.9 Temporary Weld
Temporary welds on items such as handling attachments and lugs, shall be minimized. When
temporary welding is necessary the welding shall be performed with the same care, materials,
process, minimum preheat and welding procedures as permanent welds. The temporary weld
shall subsequently be removed with an oxy-acetylene torch or arc gouging, by severing the
attachment no closer than 1/8 inch (3.2 mm) from the surface of the vessel part and grinding
the remainder of the weld deposit flush with the vessel part. Temporary weld shall not be
removed by hammering. After grinding, the surface shall be inspected by MT or PT
examination and repaired as specified herein, if defects are discovered.
Temporary welds are prohibited on elements of the vessel part, which have been post weld or
relief heat-treated.
7.2.10 Weld Repair
A weld repair specification, including the method for removal of defects, preparation of weld
area, subsequent non-destructive testing, and the minimum and maximum repair length / depth
shall be prepared by Production Department and submitted to QC Head for approval. The AI
concurrence for major repair is mandatory and shall be documented in ITP The weld repair
(major) specification shall be approved by Welding Engineer before any welding is performed.
The production Department shall repair the defect in accordance with approved welding
specification.
The Production Dept. shall notify QC inspector and Authorized Inspector (major repair only)
about any repair welds performed to correct weld defects, weld bevel imperfection and / or
base material defect or imperfections. The repair of defects in weld deposits or base metal shall
be approved by QC and AI prior to executing, the repair and AI shall have right to witness
such repair by request.
Removal of the defect may be any method, which produces a clean surface for the installation
of the repair weld deposit. Details of all defects and their subsequent repair shall be
documented, for insertion in the inspection reports and weld map.
Cracks, plus approximately 2 (two) inches (50 mm) of sound metal at each end, shall be
removed (by grinding) to sound metal. Dye penetrant test or magnetic, is required to verify
complete removal of the crack. The entire weld joint shall be removed if, in the opinion of QC
Inspector or AI, the vessel part cannot be properly inspected or repaired or if the weld is
rejected.
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8. INSPECTION & TESTING

8.1 GENERAL TESTING
• Magnetic particle inspection is applicable to the carbon steel weld surfaces of all type joint. For
Austenitic Stainless Steel, other means of NDT methods should be applied.
• Radiographic testing (RT) is applicable to butt welds only.
• Ultrasonic Testing (UT) is applicable to all weld types. All UT shall be followed by MPI on
Carbon Steel weld surface reinforcement.
• The shop shall furnish all necessary personnel and equipment required for the transportation and
preparation materials component for testing.
• The qualification and competence off all NDT personnel shall as a minimum meet SNT-TC-1A
level II qualification, and certification requirements shall be subjected to AI review and
acceptance.
• The AI reserves the right to retest and rejected any or all NDT personnel at any time if he is doubt
the performance of the NDT personnel.
• The AI reserves the right to request testing of any welding samples at any time as necessary to
maintain verification of the quality of the welding work.
8.2 QUALITY CONFORMANCE INSPECTION
8.2.1 General
This section defines the minimum technical requirement for the inspection of the Boiler, Boiler
External Piping & Pressure Vessel Structural. The QC Department shall inspect and
documented all work during fabrication and assembly through the utilization of qualified
quality control inspectors and NDT personnel's.
The QC Department shall provide AI access to fabrication facility at all times of work at any
stage and to reject any part not complying with this specification. When, in the opinion of AI,
any section requires inspection, the Production Department shall thoroughly clean the section
of all excess and waste materials (such as sand, slag, or welding electrodes) and shall provide
for the section to be properly inspected by AI.
The latest edition of the specification and codes referred to in this specification shall be
available. The production shall furnish, install, and maintain in a safe operating condition, all
scaffolding, ladders, walkways and lighting as necessary for the safe and through inspection
of work by AI and provide adequate office space during surveillance visits.
8.2.2 Stage of Inspection
As a minimum, the inspection stages employed by the QC Inspector for welded joints shall be
as follows :
• Fit-up to first pass and where required during the root pass.
• Following any back grinding operation
• Following completion of weld.
Inspection at fit-up prior to first pass shall be visual and dimensional, checking tack welds and
pre-heat applied. Inspection following root pass or back grinding shall be visual only, unless
one more of the other technique describes in Para.8.2.3 are require to explore the extent of
visually observed flaws, or unless previous production performance indicates that
unacceptable flaws may be presented.
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Inspection at weld completion shall be carried out, as instructed in this specification, by one
of the methods listed in 8.2.3.
Welds in High Strength Material (50 ksi yield and over), a carbon steel and / or carbon alloy
steel with carbon contents 0.35% and over, due to the possibility of delayed hydrogen
cracking, shall be non-destructive examined not sooner than 48 hours after welding. If hand
placement of radiographic film cassette is prevent, then ultrasonic test may be as an alternative
means, subject to Al acceptance.
8.2.3 Methods of Non-destructive Inspection of Weld
8.2.3.1 Visual Inspection
Visual Inspection of the stages listed 8.2.2., shall include,but not limited to the
following:
• Each weld appurtenance shall be in accordance with requirement of the related
Code Contraction.
• Each weld surface profile shall be in accordance with Section 4.6.
• Each weld attaching saddles, skirt etc.
• Each weld attaching internal ring stiffener.
• Other weld in addition to the above, as specified by QC Inspector or AI.
8.2.3.2 Radiographic Examination
The QC Department shall submit the radiographic examination procedures and Weld
NDE Map to AI for reviewed and acceptance. AI reserves the right to test the shop's
radiographic procedure to ensure that the procedure meets the requirements Code of
Construction.
The shop's radiographic examination procedure shall be capable of detecting the welds
flaws permitted by the acceptance criteria of the ASME Contraction Code. X-Ray or
Gamma ray technique may be used.
Film exposure techniques and processing shall provide a film free from defects, which
will show require sensitivity based on the nominal wall thickness.
The shop's / sub-contractor shall comply with the safety requirements of current
Indonesia National Safety Regulation for atomic Energy (BATAN). In particular, the
shop's shall record the quantity of radiation received by radiographers, their helper and
any others personnel near sources of radiation.
Upon completion of the work, or earlier, the shop / sub- contractor shall return all
radioactive material to the place(s) of origin and shall not otherwise dispose of such
material by any method, time and place.
Radiographers shall be qualified as a minimum in accordance with SNT TC-1A Level
II. All films shall be identified by job number, mark number and / or weld number,
thickness, diameter and welder stamp as a minimum to allow full treacebility. Film
shall be helded for storage in a film safe box, as part of inspection records, and retain
for at least 5 (five) years.
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8.2.3.3 Ultrasonic Examination

The shop's / sub-contractor ultrasonic examination procedure shall be submitted to QC
Department and AI for review and acceptance.
As minimum, the shop / sub-contractor procedure shall be capable of detecting any
weld flaw permitted by acceptance criteria stated in the related ASME Construction
Code. QC Inspector and AI reserve the right to test the shop sub- contractor ultrasonic
examination procedure, to ensure that the procedure meets the Code's requirement. If
the shop sub-contractor procedure proves in adequate, QC/AI reserves the right to
change the procedure to one that gives the required weld flaw sensitivity. Ultrasonic
operator shall be qualified in accordance with SNT-TC-1A Level II .
8.2.3.4 Magnetic Particle Inspection & Dye Penetrant Test
The shop / sub-contractor shall submit the MPI/DPT procedure to QC and AI for
review and acceptance. The MPI / DPT procedure shall be in accordance with shop's
Standard Procedures. Acceptance level shall be in accordance with related ASME
Contraction Code.
QC and AI reserves the right to test the shop / sub- contractor's Procedure to ensure
that the procedure meets Code's requirements. Inspector using MPI / DPT shall be
qualified as a minimum in accordance with SNT-TC-1A Level II.
8.2.4 Acceptable and Unacceptable Weld Profile
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9. DIMENSIONAL CHECK
The fabricated steel structure shall be inspected in accordance with respective approved fabrication
drawings and specification. Overall length, orientation, diagonal measurement and all other
dimensions shall be verified and recorded. If dimensions are not with required tolerance the member
shall be corrected prior to further process. All dimensions shall be recorded in approved format.
100% visual inspection shall be carried out for external defects. Composites Quality staffs shall
conduct the final inspection and review all inspection reports and prepared as inspection and test plan
(ITP).

10. HYDROSTATIC TEST

10.1 RESPONSIBILITY
The Construction Engineer is responsible for ensuring that Hydrostatic test is conducted in
accordance with relevant job instructions which have been reviewed and accepted by the AI.
The personnel authorized by the Construction Engineer shall ensure that the equipment to be used
are suitable calibrated and that range is suitable for use in conjunction with the Hydrostatic Test to
be performed. OC Section will be responsible for ensuring that calibration is undertaken. Records
will be maintained as detailed in Calibration Procedure.
The OC Inspector shall issue completed “Hydrostatic Test Instruction” Sheets to Construction
Engineer / Foreman. The instruction will include, as a minimum:
• Job Number and Identification of the components or assembly to be tested.
• Pressure Gauge/Recorder Range
• Test Media
• Test Position, Test Pressure & Holding Time
The OC Inspector shall be responsible for compilation of reports and records for timely submission
to the Al for his review and client's Representative for approval and signature.
10.2 PROCEDURE SYSTEM
10.2.1 A Hydrostatic test shall be conducted on all pressure parts after :
10.2.1.1 All fabrication has been completed, except for operation which could not be
performed prior to the test, such as weld end preparation, cosmetic grinding on the
base material which does not attach the required thickness.
10.2.1.2 All examination have been performed, except those required after the test.
10.2.2 Pressure parts shall be subjected to a Hydrostatic Test pressure which at every point is :
For Section I : not less than 1.5 times the MAWP
For Section VIII Div 1 : at least to 1.3 times the MAWP
For Section VIII Div 2 : the greater of 1.43 times the MAWP or 1.25 x MAWP x SUS
For ASME B31.1 : not less than 1.5 times Design Pressure
(the MAWP may be assumed to be the same as the design pressure when calculations are not
made to determine the maximum allowable working pressure) to be marked on the vessel
multiplied by the lowest ratio (for the materials of which the vessel is constructed) of the
stress value S (Maximum allowable stress) for the test temperature on the vessel to the stress
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value S for the design temperature. All loading that may exist during this test shall be given
consideration.
10.2.3 The maximum Chlorine contents of the water used for Hydrostatic Test of Austenite
Stainless Steel Construction are 50 ppm.
10.2.4 Hydrostatic test inspection of all joints and connections shall be made at a pressure not less
than design pressure.
10.2.5 The visual Examination of joints and connections for leaks at the test pressure divided by
1.3 may be waived provided:
10.2.5.1 A suitable gas leak test is applied.
10.2.5.2 Substitution of the gas leak test is by agreement reached with Authorized Inspector.
10.2.5.3 All Welded structures which will be hidden by assembly be given a visual
examination by OC Inspector and Al for workmanship prior to assembly.
10.2.5.4 The vessel does not contain a “lethal” substance.
10.2.6 Vent shall be provided at all high points of the pressure vessel in the position in which it is
to be tested purge possible air pockets while the pressure envelope is being filled.
10.2.7 Before applying pressure, the equipment being tested shall be examined to see that it is
tight, clean, free from any debris, scale, grease, etc. and that all low pressure filling lines
and other appurtenances that should not be subjected to the test pressure have been
disconnected or blanked.
10.2.8 Pressure gauge to be used in the above testing shall be checked against a Master Gauge or
Death Weight Tester. For testing at field site, the gauges will be rechecked upon arrival at
shop after completion test.
10.2.9 For Pressure Vessel (sect. VIII Div. 1 and Div. 2 Vessel) in where pressure chamber
designed to operate independently, shall be tested separately: cach chamber shall be tested
without any pressure in adjacent chamber.
10.2.9.1 Any leaks that occurred shall be corrected in accordance with the rules after which
the test assembly shall be retest in accordance with the code section requirements.
10.2.9.2 Any pressure test shall be witnessed by Construction Engineer, OC Inspector,
Client Representative and AI.
10.2.10 Painting and Coating (UG — 99 (k))
10.2.10.1 Unless permitted by the user or his designated agent, pressure- retaining welds of
vessels shall not be painted or otherwise coated either internally or externally prior
to the pressure test. (See UCI- 99(b) and UCD-99(b))
10.2.10.2 When painting or coating prior to the hydrostatic test is permitted, or when internal
linings are to be applied, the pressure-retaining welds shall first be leak tested in
accordance with ASME Section V, Article 10. Such a test may be waived with the
approval of the user or his designated agent.
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10.2.10.3 Vessels for lethal service Isee UW-2(a)) shall not be painted or otherwise coated
or lined either internally or externally prior to the hydrostatic pressure test.
10.2.11 Additional reguirements for Section VIII Div. 1 Vessel
10.2.11.1 Vessel designed for vacuum
Vessel designed for vacuum or partial vacuum only and chamber of multi chamber
vessel designated for a vacuum or partial vacuum only shall be subjected to an
internal hydrostatic test or when this test is not practicable to a pneumatic test in
accordance with the provision of UG 100. Either type of test shall be made at
pressure not less than 1.3 times the difference between normal atmosphere pressure
and the minimum design internal absolute pressure.
10.2.12 Additional reguirement for Section VIII Div. 2 Vessel
10.2.12.1 Vessel designed for vacuum
All will be the same as Para 3.10.1. above except the test shall not be less than 1.43
times the different between normal atmosphere pressure and the minimum design
internal absolute pressure.

11. FINISHING & PACKAGING

11.1 PREPARATION OF MATERIALS BEFORE PACKING
11.1.1 All Materials should be dry, clean, and free from all defects prior to packing protection
against environmental corrosion caused by extremes of humidity, condensation, rain, dust,
sand, salted air, and sea spray.
11.1.2 The following requirements shall be considered as minimum essential protective measure
for :
1) All threaded areas shall be adequately greased and covered with adequate protective
shield to protect mechanical damage.
2) Materials shall be protected against corrosion during transit as necessary.
3) All equipment and materials including bright and machined parts shall be coated with a
recognized rust preventative suited to the particular application concerned.
4) All internal parts of machinery shall be treated with lubricant containing rust and
oxidation inhibitors to protect equipment from any possible damage. Such lubricants
shall be compatible with those that will subsequently be used in service and shall be
identified by appropriate tagging.
5) Packaged equipment shall have attached to its external carton a list of the specific rust
preventatives employed. The list shall include internal as well as external rust
preventatives used shall give the manufacturer, type number, and the locations where
each product has been applied.
6) The Vendor shall also include in the package any special instructions deemed necessary
for the removal or replacement of any rust preventative, together with any special
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7) precautions to be taken in the care of the protected equipment during the period of
storage.
8) Small loose parts, tools, etc. shall be packed with identical Tag in separate boxes inside
the main package. Flexible connections shall be disconnected, and either tied to the main
body or packed in separate boxes within the main package.
9) Small or sophisticated parts of instruments and Electric equipment shall be packed in
waterproof wooden box and precautions shall be made 10 prevent damage from
moisture as well vibration during the transportation.
10) Reactors and heat exchangers items, if required, including those supplied as parts of
rotating equipment or packaged units shall be purged and filled with an inert gas (e.g.,
Nitrogen). A warning show shall be applied with the text “CAUTUION, NITROGEN
FILLED, DO NOT ENTER’
11) Unless otherwise specified, after hydro test, operation, and/or performance test, all
fluids, lubricating oil, fuel oil water, etc. shall be completely drained from all tanks,
vessels, jacketing, piping, etc. and wiped or blown dry.
12) Rust Prevention
a) Unless specified otherwise on the Requisition, all unpainted machined metal surfaces
as gasket contact face of equipment, flanges, or other surfaces which are normally not
painted, bolt external and internal, shall be cleaned, dried and amply coaled with
acceptable rust preventatives which will maintain a protective coaling for minimum 12
months so long as the coaling is not burned, dissolved or mechanically rubbed off.
The vendor shall also include with the above list any special instructions deemed
necessary for the removal or replacement of any rust preventive, together with any
special precautions to be taken in the care of the protected equipment during the period
of storage. A separate copy of the rust preventive list and special instructions shall be
submitted to the Purchaser.
For Bulk materials (Pipe, Tube, Flange, Fitting, Valve and etc.). VENDOR shall
propose the rust preventative which will maintain a protective coating for minimum 6
months as VENDOR standard and submit its data sheet included manufacturer, type,
physical & chemical property, etc. for reference.
In addition, VENDOR shall be fully liable for and guarantee proper, sufficient and
adequate rust preventative.
All costs whatever resulting from inadequate or insufficient rust preventative shall be
fully charged to VENDOR.
The use of machine oils is strictly prohibited.
b) For external surfaces, the rust preventative should be a heavy application of grease or
liquid film which dries to a tough coating and which conforms with the performance
requirements of U.S. Defense Department Specification for Preservatives as listed
below :
(1) Spec. Designation : Mil-C-11796 Class 1
(2) Application Method: Hot (95°C 200°F max.) brush or dip
(3) Description and Use: Thick, hard drying, greasy film.
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For protection of highly finished parts of simple design for long periods.
(4) Acceptable preservatives are available from the major oil companies and their
dealers, for example:
i. Gulf: Gulf No-Rust #1
ii. Exxon (Enjay Chem): Rust-ban 385
iii. Shell: Ensis 264 iV. Mobil: Mobilcoat 601
iv. Texaco: Texaco Rust-Proof Compound L
v. Valvoline: Tectyle 506
vi. Other brands are available and acceptable, providing they conform to the
performance requirements above.
c) For internal machined surfaces of an assembled unit, the rust preventative should be of
a type which does not require before operation of the equipment and: which conforms
with the performance requirement of U.S Defense Department Specifications for
Preservatives as listed below :
(1) Spec. Designatio : Navy Mil-L021260, Grade 1, 2 or 3
(2) Application method : brush, dip, or spray, 15 to 50C (60 to 120F)
(3) Description : engine lube oil with corrosion inhibitors including hydrobromic acid
neutralizers
(4) Acceptable preservatives are available from the major oil companies and their
dealers, for example :
i. Gulf : Gulf no-rust Engine oil
ii. Grade 2 or Nox : Rust 310AC
iii. Shell : Ensis Engine Oil Grade 20
iv. Mobil : Mobilcoat — 501 or 503
v. Texaco : Preservative Oil 10W f) Exxon : Rust-ban #623
(5) Other brand are available and acceptable providing they conform to the
performance requirements above :
(6) Acceptable methods of applying rust preventative are spraying, brushing, filling,
etc. through all available openings disassembly if necessary, to completely coat
and protect all unpainted internal surfaces.
d) Particular attention should be paid to journal surfaces of sleeve bearings and complete
anti-friction bearings, so they are completely coated. VENDOR shall wire a large red
tag to the machine that states: “Caution-These Materials have been treated with a rust
preventative and no parts should be disturbed until ready to place in service. If protective
film is broken, it should be restored for continued storage.”
e) All internal surfaces of any piping materials disassembled from Materials for ease of
shipment shall be free of scale and all other foreign matters. Pickling and cleaning per
VENDOR’s standard is acceptable.
13) Protection of Openings
a) Flanged openings for pressure vessels, reactors, heat exchangers, etc. shall be protected
with bolted-on steel plate (minimum 6mm thick, 4 bolts) or outdoor plywood (minimum
12—0.5 mm thick, 4 bolts) with mastic sealer or rubber gaskets between the flange and
the steel plate. All flanged openings shall be wrapped with plastic waterproof tape.
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b) Butt weld connections shall be sealed with heavy plastic cap.

c) All valve ends shall be protected with plastic caps.
d) Porous bags filled with desiccant shall be hung on the inside of the wooden or metal
e) Covers on all major connections of rotating Materials unless size is restrictive
physically. Covers on all major connections of rotating Materials unless size is
restrictive physically.
f) Unconnected pipe threads to be used in normal operation shall be closed with threaded
metal plugs or caps. They shall be identified with metal tags explaining the purpose
and/or providing connection number used on CONTRACTOR's and VENDOR's
drawings.
g) All closures that are parts of original Materials shall fit tightly.
h) Plastic closures and thread protectors are prohibited unless they are approved By
CONTRACTOR
14) Flexible Connection & Small Loose Parts
All flexible connections subject to possible damage during shipment shall be
disconnected, nd either tied 10 the main body or packed in separate boxes within the
main package.
15) Shaft Couplings
Flexible coupling shall be taken off and adequately supported and protected 10 prevent
amage. Rigid coupling shall be in accordance with Vendor's recommendation to provide
full rotection and safely in transit and storage.
16) Dehydration
The use of desiccant crystals within an enclosed piece of materials is of particular
mportance in high humidity areas subject to wide variation in temperature over a 24
hours period. Desiccant should be located al suitable intervals 10 provide uniform
distribution.
17) N2 Gas Sealed Materials or VCI
Unless specified otherwise on the Requisition, Vendor who supplies stationary items
such as column, Vessel, Drum, shell & lube type heat exchangers, air cooled heat
exchangers Etc. and pipe spool of fired heaters, shall fill this equipment with N2 gas
(Concentration: min. 98%, pressure: 0.2 kg/cm2g) or VCI If vendor uses VCI, vendor
shall guarantee protection from corrosion for 2 years and shall submit proper procedure
for using VC! with technical data. VCI materials shall be such as below, or alternative
materials approved by purchaser.
a) VpCl 307, VpCI 309 (Manufactured in USA)
b) Dosage amount : 300-500 (g / m3 /2years)
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11.2 PACKING METHODS

11.2.1 Pipes
Pipes, which are sensitive because of their nature type of material, wall. thickness, machine
beveled ends, surface treatment, etc, must be bundled and packed in wooden framed crates
mentioned in the category 10 of para.5.6 Packing Style Criteria. All pipes shall be capped unless
otherwise specified on P/O.
1) All pipes 2" and below shall be packed in cases and be capped.
2) Carbon steel pipes 6" and below shall be bundled and banded in bundles of uniform length,
the weight of each bundle must be well within the breaking strain of the strapping. Bundle
weight shall not exceed 2,000kgs.
3) Carbon steel pipes between 8" and over shall be bare or loose type of package.
4) Pipes thread to be protected from corrosion and damage.
5) Coated Pipe (6” & Over) shall be follow as attachment #15.
11.2.2 Pipe Fitting
All piping fittings and flanges 4" and below are to be packed in cases in accordance with
Paragraph 3.1. Items above 4" shall be fixed securely and enclosed with an open boarded crate
for protection.
1) All Pipe Fittings shall be capped unless otherwise specified on P/O.
2) Serration of Flange surface shall be protected with bolted-on plastic plate (minimum 2 mm
thick, 4 bolts) or outdoor plywood (minimum 6 mm thick, 4 bolts) with mastic sealer or rubber
gaskets between the flange and the plywood plate.
3) Welding area of Weld neck flange shall be capped with protection rubber ring.
11.2.3 Valve
Valves above 4” shall be fixed securely and enclosed with an open boarded crate for protection.
Where valves have actuators attached rigidity must be ensured for valve and attached actuators.
The vulnerable parts of the-actuator are to be completely protected with a wooden box.
1) Thread type / Socket type / Flange type edge of Valves shall be protected with same method
of pipe fittings.
2) Butt welding area of valve shall be capped with protection rubber ring.
11.2.4 Pressure Vessel, Storage Tank
Pressure vessels shall be mounted on saddles, where not provided by their design, constructed of
steel or wood, to enable proper stowage on board ship, barge or road transport. If saddles are
constructed of wood, it is absolutely essential that layered timber is used and is shaped to provide
a 120 fit around vessel and that these layers are through bolted using substantial long bolts.
Saddles should be attached to vessels using strong steel straps, one end being firmly fixed to the
saddles, the other having a screw tensioner to provide adequate holding of vessel during shipment.
Vessel should be kept dry with Nitrogen (N2) through whole transportation and temporary storage
unless it's not physically available. If this method is not proper, bagged desiccants, such as VCI
corrosion inhibitor, will be put inside to protect against corrosion.